BMW 325e 325es 325is 1984-1990 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variants: 325e, 325es, 325is Production Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990 Codes Chassis Code: E30 Engine Codes: M20B27 (325e/es), M20B25 (325is) 👋 Introduction Market Position Segment: Compact Executive Sports Sedan/Coupe Target Audience: Enthusiasts and owners seeking to maintain or repair their E30 3 Series vehicles. Competitive Analysis Competitors: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo Milano, Ford Sierra XR4i, Volvo 240 GLT. Key Features Driving Dynamics: Renowned for excellent handling, rear-wheel drive dynamics, and driver-focused cockpit. Engine Variants: The 'e' models featured a lower-revving, fuel-efficient M20B27 inline-six engine (eta engine), while the 'is' models received the higher-performance M20B25. Design Era: Classic BMW design language of the 1980s, characterized by clean lines and iconic kidney grilles. 📋 Manual Details Coverage Areas Maintenance: Scheduled maintenance, routine checks, fluid changes, filter replacements. Repair: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, transmission, drivetrain, brakes, steering, suspension, electrical system, bodywork, HVAC. Diagnostics: Troubleshooting guides, fault code interpretation, diagnostic procedures for various systems. Specifications: Torque specifications, clearances, fluid types and capacities, electrical diagrams, component dimensions. Page Count Estimated Pages: Over 1500 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, pistons, connecting rods, crankshaft, timing components, lubrication system, oil pump, oil cooler. Fuel System: Fuel injection (Bosch Motronic), fuel pump, fuel injectors, fuel filter, fuel pressure regulator, fuel tank, fuel lines. Ignition System: Ignition coils, spark plugs, distributor, ignition control module (ICM), troubleshooting ignition faults. Cooling System: Radiator, water pump, thermostat, cooling fan, coolant hoses, coolant reservoir, temperature sensor. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, exhaust pipes, oxygen sensors. Transmission Manual: Clutch assembly, gearbox overhaul, shift linkage, gears, bearings, seals. Transmission Automatic: Automatic transmission (e.g., ZF 4HP22), valve body, torque converter, transmission control module, fluid cooler. Drivetrain: Driveshaft, universal joints, differential, axle shafts, CV joints. Brakes: Brake discs, brake pads, calipers, master cylinder, brake booster, ABS system (if equipped), parking brake. Steering: Steering rack, power steering pump, steering column, tie rods, steering knuckle. Suspension: Front suspension (MacPherson struts, control arms, sway bar), rear suspension (semi-trailing arms, shock absorbers, springs), wheel bearings. Electrical System: Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting system, gauges, instrument cluster. Bodywork: Body panel removal and installation, doors, hood, trunk, bumpers, glass, trim. HVAC: Heating system, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant lines). Procedures Included Engine Overhaul: Complete engine rebuild procedures, including cylinder head gasket replacement, piston ring replacement, bearing replacement. Transmission Rebuild: Step-by-step instructions for rebuilding both manual and automatic transmissions. Brake System Service: Brake pad and disc replacement, caliper service, bleeding the brake system, ABS component replacement. Suspension And Steering Repair: Replacement of ball joints, tie rod ends, control arm bushings, strut replacement, power steering system repairs. Electrical Troubleshooting: Wiring diagram interpretation, diagnosis of electrical faults, component testing. Fuel Injection Diagnostics: Troubleshooting Motronic system faults, testing fuel injectors and sensors. Timing Belt Replacement: Correct procedure for replacing the timing belt and tensioners on M20 engines. Engine Mounts Replacement: Procedure for replacing engine and transmission mounts. Radiator And Coolant Service: Coolant flush and fill, radiator replacement, thermostat replacement. Body Panel Alignment: Instructions for adjusting doors, hood, and trunk for proper alignment. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic flowcharts and specifications for accurate repairs. 📊 Manual Specifications File Format PDF Quality: High-resolution scans of original factory documentation, generally clear and readable text and diagrams. Searchability: Likely text-searchable PDF, allowing for quick location of specific information. Print Quality Print Readability: Designed to be printable for workshop use, with clear diagrams and text. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Quality: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine 325E Es Engine Code: M20B27 Engine Type: SOHC Inline-6 Displacement: 2.7 Liters (2693 cc) Bore X Stroke: 84.0 mm x 81.0 mm Compression Ratio: 8.5:1 (US Spec) Horsepower: 121 hp @ 4800 rpm (US Spec) Torque: 170 lb-ft @ 3250 rpm (US Spec) Primary Engine 325Is Engine Code: M20B25 Engine Type: SOHC Inline-6 Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 8.8:1 (US Spec) Horsepower: 168 hp @ 5800 rpm (US Spec) Torque: 164 lb-ft @ 4300 rpm (US Spec) Fuel System Injection System: Bosch Motronic (various versions depending on year and model) Fuel Type: Unleaded Gasoline (Premium Recommended) General Engine Layout: Front-engine, Rear-wheel Drive 🔧 Transmission Standard 325E Es Type: 4-speed Automatic (ZF 4HP22) Optional 325E Es Type: 5-speed Manual Getrag 260/5 Standard 325Is Type: 5-speed Manual Getrag 260/5 Optional 325Is Type: 4-speed Automatic (ZF 4HP22) Features Clutch Type: Single dry plate diaphragm spring clutch (Manual) Final Drive Ratio 325E:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Model Variants:

325e, 325es, 325is

Production Years Covered:

1984, 1985, 1986, 1987, 1988, 1989, 1990

Codes

Chassis Code:

Engine Codes:

M20B27 (325e/es), M20B25 (325is)

👋 Introduction

Market Position

Segment:

Compact Executive Sports Sedan/Coupe

Target Audience:

Enthusiasts and owners seeking to maintain or repair their E30 3 Series vehicles.

Competitive Analysis

Competitors:

Mercedes-Benz 190E, Audi 80/90, Alfa Romeo Milano, Ford Sierra XR4i, Volvo 240 GLT.

Key Features

Driving Dynamics:

Renowned for excellent handling, rear-wheel drive dynamics, and driver-focused cockpit.

Engine Variants:

The 'e' models featured a lower-revving, fuel-efficient M20B27 inline-six engine (eta engine), while the 'is' models received the higher-performance M20B25.

Design Era:

Classic BMW design language of the 1980s, characterized by clean lines and iconic kidney grilles.

📋 Manual Details

Coverage Areas

Maintenance:

Scheduled maintenance, routine checks, fluid changes, filter replacements.

Repair:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, transmission, drivetrain, brakes, steering, suspension, electrical system, bodywork, HVAC.

Diagnostics:

Troubleshooting guides, fault code interpretation, diagnostic procedures for various systems.

Specifications:

Torque specifications, clearances, fluid types and capacities, electrical diagrams, component dimensions.

Page Count

Estimated Pages:

Over 1500 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, connecting rods, crankshaft, timing components, lubrication system, oil pump, oil cooler.

Fuel System:

Fuel injection (Bosch Motronic), fuel pump, fuel injectors, fuel filter, fuel pressure regulator, fuel tank, fuel lines.

Ignition System:

Ignition coils, spark plugs, distributor, ignition control module (ICM), troubleshooting ignition faults.

Cooling System:

Radiator, water pump, thermostat, cooling fan, coolant hoses, coolant reservoir, temperature sensor.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, exhaust pipes, oxygen sensors.

Transmission Manual:

Clutch assembly, gearbox overhaul, shift linkage, gears, bearings, seals.

Transmission Automatic:

Automatic transmission (e.g., ZF 4HP22), valve body, torque converter, transmission control module, fluid cooler.

Drivetrain:

Driveshaft, universal joints, differential, axle shafts, CV joints.

Brakes:

Brake discs, brake pads, calipers, master cylinder, brake booster, ABS system (if equipped), parking brake.

Steering:

Steering rack, power steering pump, steering column, tie rods, steering knuckle.

Suspension:

Front suspension (MacPherson struts, control arms, sway bar), rear suspension (semi-trailing arms, shock absorbers, springs), wheel bearings.

Electrical System:

Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting system, gauges, instrument cluster.

Bodywork:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, trim.

HVAC:

Heating system, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant lines).

Procedures Included

Engine Overhaul:

Complete engine rebuild procedures, including cylinder head gasket replacement, piston ring replacement, bearing replacement.

Transmission Rebuild:

Step-by-step instructions for rebuilding both manual and automatic transmissions.

Brake System Service:

Brake pad and disc replacement, caliper service, bleeding the brake system, ABS component replacement.

Suspension And Steering Repair:

Replacement of ball joints, tie rod ends, control arm bushings, strut replacement, power steering system repairs.

Electrical Troubleshooting:

Wiring diagram interpretation, diagnosis of electrical faults, component testing.

Fuel Injection Diagnostics:

Troubleshooting Motronic system faults, testing fuel injectors and sensors.

Timing Belt Replacement:

Correct procedure for replacing the timing belt and tensioners on M20 engines.

Engine Mounts Replacement:

Procedure for replacing engine and transmission mounts.

Radiator And Coolant Service:

Coolant flush and fill, radiator replacement, thermostat replacement.

Body Panel Alignment:

Instructions for adjusting doors, hood, and trunk for proper alignment.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic flowcharts and specifications for accurate repairs.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans of original factory documentation, generally clear and readable text and diagrams.

Searchability:

Likely text-searchable PDF, allowing for quick location of specific information.

Print Quality

Print Readability:

Designed to be printable for workshop use, with clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine 325E Es

Engine Code:

M20B27

Engine Type:

SOHC Inline-6

Displacement:

2.7 Liters (2693 cc)

Bore X Stroke:

84.0 mm x 81.0 mm

Compression Ratio:

8.5:1 (US Spec)

Horsepower:

121 hp @ 4800 rpm (US Spec)

Torque:

170 lb-ft @ 3250 rpm (US Spec)

Primary Engine 325Is

Engine Code:

M20B25

Engine Type:

SOHC Inline-6

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

8.8:1 (US Spec)

Horsepower:

168 hp @ 5800 rpm (US Spec)

Torque:

164 lb-ft @ 4300 rpm (US Spec)

Fuel System

Injection System:

Bosch Motronic (various versions depending on year and model)

Fuel Type:

Unleaded Gasoline (Premium Recommended)

General

Engine Layout:

Front-engine, Rear-wheel Drive

🔧 Transmission

Standard 325E Es

Type:

4-speed Automatic (ZF 4HP22)

Optional 325E Es

Type:

5-speed Manual Getrag 260/5

Standard 325Is

Type:

5-speed Manual Getrag 260/5

Optional 325Is

Type:

4-speed Automatic (ZF 4HP22)

Features

Clutch Type:

Single dry plate diaphragm spring clutch (Manual)

Final Drive Ratio 325E:

3.25:1 (often)

Final Drive Ratio 325Is:

3.73:1 (often)

Fluid Specifications

Automatic Transmission Fluid:

Dexron III (or equivalent, consult manual for exact spec and quantity)

Manual Transmission Fluid:

GL-4 SAE 75W-90 (or equivalent, consult manual for exact spec and quantity)

📐 Dimensions

Exterior Coupe

Length:

4,330 mm (170.5 in)

Width:

1,674 mm (65.9 in)

Height:

1,380 mm (54.3 in)

Wheelbase:

2,565 mm (101.0 in)

Exterior Sedan

Length:

4,330 mm (170.5 in)

Width:

1,674 mm (65.9 in)

Height:

1,380 mm (54.3 in)

Wheelbase:

2,565 mm (101.0 in)

Weights

Curb Weight Coupe:

Approx. 1,300 kg (2,866 lbs)

Curb Weight Sedan:

Approx. 1,350 kg (2,976 lbs)

Cargo

Trunk Capacity:

Approx. 0.43 m³ (15.2 cu ft)

Wheels And Tires

Wheelbase:

2,565 mm (101.0 in)

Bolt Pattern:

5x120 mm

Tire Size Common:

205/55VR14, 205/50VR15 (depending on trim and options)

🛡️ Safety Features

Ratings

Historical Safety Standards:

Vehicles of this era were tested to different standards than modern vehicles. Specific NHTSA/IIHS ratings may vary or be unavailable.

Active Features

Available as an option on some models, standard on later 325is.

Limited Slip Differential:

Available as an option, particularly on 325is models.

Passive Features

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Radio:

Factory-installed AM/FM cassette players were common, often with upgraded speaker systems.

Speakers:

Door, dash, and rear deck speakers were typical configurations.

Driver Assistance

Cruise Control:

Available as an option on many models.

Connectivity

Diagnostics Port:

Proprietary BMW diagnostic connector, requiring specific tools for advanced diagnostics. This manual will cover manual diagnostic procedures.

🔧 Maintenance

Service Intervals General

Oil Change Interval:

Typically every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions and oil type. Consult manual for specific year/model.

Air Filter Replacement:

Every 15,000 - 30,000 miles or annually.

Fuel Filter Replacement:

Every 30,000 - 50,000 miles.

Spark Plug Replacement:

Every 30,000 - 60,000 miles depending on plug type.

Timing Belt Replacement:

Crucial! Every 60,000 miles or 5 years (critical due to interference engine design).

Fluid Specifications

Engine Oil Type:

SAE 20W-50 or 15W-40 (check manual for specific climate/year recommendations, often synthetic recommended)

Coolant Type:

Ethylene glycol based antifreeze (BMW recommends blue/green coolant or equivalent, typically a 50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 (DOT 4 preferred for better performance)

Power Steering Fluid:

ATF Dexron II/III or specific BMW hydraulic fluid (consult manual).

Known Issues

Engine Oil Leaks:

Common leaks from valve cover gasket, oil pan gasket, oil filter housing, and rear main seal.

Cooling System:

Radiator leaks, thermostat housing cracks, heater core leaks, water pump failure.

Suspension Wear:

Worn control arm bushings, worn ball joints, sagging springs, leaking shock absorbers.

Rear Wheel Arches:

Prone to rust due to design and road salt exposure.

Fuel Pump Reliability:

Can be a wear item, especially on higher mileage vehicles.

Idle Control Valve Icv:

Can become dirty or fail, leading to rough idle or stalling.

📚 Vehicle History

Brand Heritage

Bmw Heritage:

BMW's reputation for building sporty, driver-oriented cars with excellent engineering and build quality.

Model Evolution

E30 Generation:

The E30 chassis succeeded the E21 and preceded the E36. It is highly regarded for its handling and iconic status.

325E Introduction:

Introduced as a more fuel-efficient option with the 'eta' engine, prioritizing torque and economy over outright power.

325Is Introduction:

Represented the sportier variant, featuring the more powerful M20B25 engine, stiffer suspension, and often sport seats and limited-slip differential.

Production

Production Period:

1982-1994 (E30 chassis globally), with 325e/es/is models primarily from 1984-1992.

Manufacturing Locations:

Germany (primarily Munich, Dingolfing)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E30 3 Series, including the 325is, was a frequent recipient of Car and Driver's '10Best' list for its handling and performance.

Automotive Journalism Acclaim:

Consistently praised by automotive journalists for its driving pleasure, build quality, and engineering.

Certifications

Manual Type Certification:

Professional workshop manual, often sourced from or based on official BMW factory service information.