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BMW 3 Series 320 320i 323i 325i (E21) Service & Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E21 Engine Variants Covered: 320, 320i, 323i, 325i Codes Internal Codes: E21 Generation 👋 Introduction Market Position Target Audience: BMW dealership mechanics and skilled DIY enthusiasts seeking professional-grade repair information. Competitive Analysis Manual Quality: Considered one of the most comprehensive and authoritative resources for the E21 generation, directly from BMW's technical documentation. Key Features Instruction Style: Step-by-step instructions facilitate complex repairs. Visual Aid Quality: Clear pictures and exploded views enhance understanding of component relationships and assembly. Scope: Encompasses all major mechanical, electrical, and body systems for the specified E21 models. 📋 Manual Details Coverage Areas Vehicle Coverage: BMW 3 Series E21 chassis variants: 320, 320i, 323i, 325i Page Count Total Pages: 600+ Manual Type Type: Service & Repair Manual (Dealership Level) Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, rebuilding, timing, valve adjustments, piston and rod installation, crankshaft and bearing service, cylinder head service, oil pump and system. Engine Fuel System: Carburetor (e.g., Zenith, Solex) overhaul and adjustment, fuel injection (K-Jetronic for later models) system diagnosis and repair, fuel pump and filter replacement, fuel lines. Engine Cooling System: Radiator, water pump, thermostat, hoses, fan clutch, coolant specifications and flushing procedures. Engine Ignition System: Distributor service, spark plug selection and gap, ignition timing, coil and lead testing, electronic ignition components (where applicable). Transmission Manual: Clutch service, gear selection mechanism, transmission disassembly and reassembly, gear oil specifications and capacities, driveshaft and CV joint service. Transmission Automatic: Automatic transmission diagnosis, fluid type and level checks, torque converter service, linkage adjustments (if applicable). Brakes: Disc brake service (front and rear), caliper overhaul, brake pad and rotor replacement, master cylinder, brake booster, parking brake adjustment, brake fluid specifications. Suspension: Front and rear suspension components, shock absorber replacement, ball joint and tie rod end service, wheel alignment specifications, bushings. Steering: Steering gear service, power steering system (if equipped), steering column, tie rods, and linkages. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses and relays, instrument cluster, starting and charging system troubleshooting. Body And Chassis: Body panel removal and installation, doors, hood, trunk, interior trim, glass replacement, chassis component identification, rust repair considerations. Heating Ventilation Air Conditioning: HVAC system components, blower motor, heater core, evaporator core, refrigerant types (R12 for this era), system leak testing, dash control panel. Procedures Included Maintenance: Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, cooling system problems, and brake system malfunctions. Repair: Step-by-step instructions for major component repairs and overhauls, including engine rebuilds, transmission repairs, and brake system overhauls. Diagnostics: Detailed diagnostic trees and fault code interpretation (if applicable for the era), using test equipment and visual inspection. Special Tools: Identification of specific tools and equipment required for various repair and maintenance procedures. Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic maintenance and adjustments to full engine and transmission rebuilds, including detailed diagnostic information. Illustrations: Clear pictures and exploded view illustrations for component identification and assembly/disassembly guidance. Schematics: Inclusion of electrical wiring diagrams and vacuum schematics for accurate troubleshooting and repair. Specifications: Detailed technical specifications for all covered systems, including torque values, clearances, fluid capacities, and performance data. 📊 Manual Specifications File Format Format: PDF Compatibility: Windows, Mac, Linux Print Quality Printability: Printable without restriction Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Searchability Text Search: Yes (typically for PDF manuals, allowing keyword searches) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 and Inline-6, SOHC, naturally aspirated 320/320I Engine Code: M10 series (e.g., M10B18, M10B20) 320/320I Displacement: 1.8L (1766 cc) and 2.0L (1990 cc) 323I Engine Code: M20 series (e.g., M20B23) 323I Displacement: 2.3L (2316 cc) 325I Engine Code: M20 series (e.g., M20B25) 325I Displacement: 2.5L (2494 cc) Performance 320I Hp Approx: ~100-105 hp (depending on market and specific version) 323I Hp Approx: ~140-143 hp 325I Hp Approx: ~170-171 hp Fuel System Induction Early Models: Carbureted (e.g., Zenith 35/40 INAT, Solex C32/32 DIDTA) Induction Later Models: Bosch K-Jetronic CIS (Continuous Injection System) for 320i (M10), 323i, and 325i Fuel Type: Unleaded gasoline (premium recommended) 🔧 Transmission Standard Type: 4-speed manual, 5-speed manual ( Getrag 245) Optional Type: 3-speed ZF automatic (e.g., 3HP22) Features Clutch Type: Single dry plate diaphragm spring clutch Rear Axle: Independent rear suspension with semi-trailing arms, limited-slip differential available on some models 📐 Dimensions Exterior Wheelbase: Approx. 2565 mm (101.0 in) Length: Approx. 4350 mm (171.3 in) Width: Approx. 1610 mm (63.4 in) Height: Approx. 1380 mm (54.3 in) Weights Curb Weight: ~1150 - 1250 kg (2535 - 2755 lbs) depending on engine and equipment 🛡️ Safety Features Ratings Era Specific Ratings: Limited official crash...
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BMW 3 Series 320 320i 323i 325i (E21) Service & Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E21
Engine Variants Covered:
320, 320i, 323i, 325i
Codes
Internal Codes:
E21 Generation
👋 Introduction
Market Position
Target Audience:
BMW dealership mechanics and skilled DIY enthusiasts seeking professional-grade repair information.
Competitive Analysis
Manual Quality:
Considered one of the most comprehensive and authoritative resources for the E21 generation, directly from BMW's technical documentation.
Key Features
Instruction Style:
Step-by-step instructions facilitate complex repairs.
Visual Aid Quality:
Clear pictures and exploded views enhance understanding of component relationships and assembly.
Scope:
Encompasses all major mechanical, electrical, and body systems for the specified E21 models.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
BMW 3 Series E21 chassis variants: 320, 320i, 323i, 325i
Page Count
Total Pages:
600+
Manual Type
Type:
Service & Repair Manual (Dealership Level)
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, rebuilding, timing, valve adjustments, piston and rod installation, crankshaft and bearing service, cylinder head service, oil pump and system.
Engine Fuel System:
Carburetor (e.g., Zenith, Solex) overhaul and adjustment, fuel injection (K-Jetronic for later models) system diagnosis and repair, fuel pump and filter replacement, fuel lines.
Engine Cooling System:
Radiator, water pump, thermostat, hoses, fan clutch, coolant specifications and flushing procedures.
Engine Ignition System:
Distributor service, spark plug selection and gap, ignition timing, coil and lead testing, electronic ignition components (where applicable).
Transmission Manual:
Clutch service, gear selection mechanism, transmission disassembly and reassembly, gear oil specifications and capacities, driveshaft and CV joint service.
Transmission Automatic:
Automatic transmission diagnosis, fluid type and level checks, torque converter service, linkage adjustments (if applicable).
Brakes:
Disc brake service (front and rear), caliper overhaul, brake pad and rotor replacement, master cylinder, brake booster, parking brake adjustment, brake fluid specifications.
Suspension:
Front and rear suspension components, shock absorber replacement, ball joint and tie rod end service, wheel alignment specifications, bushings.
Steering:
Steering gear service, power steering system (if equipped), steering column, tie rods, and linkages.
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses and relays, instrument cluster, starting and charging system troubleshooting.
Body And Chassis:
Body panel removal and installation, doors, hood, trunk, interior trim, glass replacement, chassis component identification, rust repair considerations.
Heating Ventilation Air Conditioning:
HVAC system components, blower motor, heater core, evaporator core, refrigerant types (R12 for this era), system leak testing, dash control panel.
Procedures Included
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, cooling system problems, and brake system malfunctions.
Repair:
Step-by-step instructions for major component repairs and overhauls, including engine rebuilds, transmission repairs, and brake system overhauls.
Diagnostics:
Detailed diagnostic trees and fault code interpretation (if applicable for the era), using test equipment and visual inspection.
Special Tools:
Identification of specific tools and equipment required for various repair and maintenance procedures.
Technical Depth
Depth Of Coverage:
Comprehensive: Covers everything from basic maintenance and adjustments to full engine and transmission rebuilds, including detailed diagnostic information.
Illustrations:
Clear pictures and exploded view illustrations for component identification and assembly/disassembly guidance.
Schematics:
Inclusion of electrical wiring diagrams and vacuum schematics for accurate troubleshooting and repair.
Specifications:
Detailed technical specifications for all covered systems, including torque values, clearances, fluid capacities, and performance data.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows, Mac, Linux
Print Quality
Printability:
Printable without restriction
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Searchability
Text Search:
Yes (typically for PDF manuals, allowing keyword searches)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 and Inline-6, SOHC, naturally aspirated
320/320I Engine Code:
M10 series (e.g., M10B18, M10B20)
320/320I Displacement:
1.8L (1766 cc) and 2.0L (1990 cc)
323I Engine Code:
M20 series (e.g., M20B23)
323I Displacement:
2.3L (2316 cc)
325I Engine Code:
M20 series (e.g., M20B25)
325I Displacement:
2.5L (2494 cc)
Performance
320I Hp Approx:
~100-105 hp (depending on market and specific version)
323I Hp Approx:
~140-143 hp
325I Hp Approx:
~170-171 hp
Fuel System
Induction Early Models:
Carbureted (e.g., Zenith 35/40 INAT, Solex C32/32 DIDTA)
Induction Later Models:
Bosch K-Jetronic CIS (Continuous Injection System) for 320i (M10), 323i, and 325i
Fuel Type:
Unleaded gasoline (premium recommended)
🔧 Transmission
Standard
Type:
4-speed manual, 5-speed manual ( Getrag 245)
Optional
Type:
3-speed ZF automatic (e.g., 3HP22)
Features
Clutch Type:
Single dry plate diaphragm spring clutch
Rear Axle:
Independent rear suspension with semi-trailing arms, limited-slip differential available on some models
📐 Dimensions
Exterior
Wheelbase:
Approx. 2565 mm (101.0 in)
Length:
Approx. 4350 mm (171.3 in)
Width:
Approx. 1610 mm (63.4 in)
Height:
Approx. 1380 mm (54.3 in)
Weights
Curb Weight:
~1150 - 1250 kg (2535 - 2755 lbs) depending on engine and equipment
🛡️ Safety Features
Ratings
Era Specific Ratings:
Limited official crash test data available from modern standards; designed to meet 1970s/1980s safety regulations.
Active Features
Brakes:
Front ventilated discs, rear discs (or drums on some early 320 models)
Steering:
Recirculating ball steering (power steering optional)
Passive Features
Seat Belts:
3-point seat belts (front), 2-point seat belts (rear, often optional or lap belts)
Body Structure:
Reinforced passenger cell, crumple zones (typical for the era)
💡 Technology Features
Infotainment
Radio:
Factory AM/FM radio, often with cassette player for later models. Aftermarket head units common.
Speakers:
Typically 2-4 speaker configuration.
Driver Assistance
ABS:
Optional on some later models, particularly 6-cylinder variants.
Connectivity
Power Windows:
Optional on many models, standard on higher trims.
Air Conditioning:
Optional, often a dealer-installed or factory option.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, depending on driving conditions (refer to manual for precise intervals).
Coolant Flush Interval:
Every 2 years or 30,000 miles (48,000 km)
Spark Plug Replacement:
Approximately every 15,000 - 30,000 miles (24,000 - 48,000 km), depending on plug type and wear.
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-40 or 15W-50 (check manual for specific recommendations based on climate)
Coolant:
BMW Antifreeze/Coolant (blue or green type, typically a 50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4
Transmission Fluid Manual:
GL-4 gear oil, SAE 75W-90 or 80W-90 (specific BMW part numbers recommended in manual)
Transmission Fluid Automatic:
Dexron-III or equivalent (check manual for exact specification)
Known Issues
Rust Prone Areas:
Wheel wells, rocker panels, rear shock towers, door bottoms, battery tray area.
Cooling System:
Cracked radiator end tanks, leaking water pump seals, failed thermostat, worn fan clutch.
Fuel System Cis:
Leaking fuel distributor seals, faulty frequency valve, clogged injectors, vacuum leaks affecting mixture.
Electrical Components:
Degraded wiring insulation (especially around engine bay), faulty grounds, unreliable dashboard illumination, starter solenoid issues.
Suspension Bushings:
Worn control arm bushings, trailing arm bushings, and sway bar bushings leading to imprecise handling and knocking sounds.
📚 Vehicle History
Brand Heritage
Bmw Motorsport Legacy:
The E21 built upon BMW's reputation for sporty sedans and coupe-like styling, continuing the lineage of the highly successful 02 Series.
Model Evolution
Introduction:
Introduced in 1975 as a replacement for the BMW 02 Series, establishing the iconic 3 Series identity.
Design Philosophy:
Featured BMW's signature Hofmeister kink, kidney grille, and a driver-oriented cockpit.
Engine Lineup Expansion:
Initially offered with M10 4-cylinder engines (320i), later expanded to include the M20 6-cylinder engines (320/6, 323i, 325i) for increased performance.
Production
Production Years:
1975-1983
Manufacturing Locations:
Germany (e.g., Munich, Dingolfing)
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