BMW 3 Series 325i 1984-1990 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Generation Chassis Code: E30 Generation Name: First Generation Codes Engine Code Series: M20 👋 Introduction Market Position Segment: Compact Executive Sports Sedan/Coupe Reputation: Renowned for its sporty handling, driver-focused cockpit, and build quality, establishing BMW's 'Ultimate Driving Machine' reputation. Competitive Analysis Key Competitors: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Ford Sierra XR4i, Volvo 240. Key Features Driving Dynamics: Excellent balance, precise steering, responsive suspension, rear-wheel drive platform. Engine Characteristics: Smooth and potent M20 inline-six engine, known for its character and linear power delivery. Manual Value Target Audience: BMW enthusiasts, DIY mechanics, independent repair shops specializing in classic European vehicles. 📋 Manual Details Coverage Areas Model Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990 Page Count Page Count: 225 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, maintenance, timing belt replacement, cooling system, lubrication system, fuel system (including Bosch LE-Jetronic/Motronic injection), ignition system, exhaust system. Transmission: Manual transmission (Getrag 260), Automatic transmission (ZF 4HP22), clutch system, driveshafts, differential, axle shafts. Chassis: Suspension (front McPherson strut, rear semi-trailing arm), steering system (power steering), brakes (front vented discs, rear discs, ABS system details for later models), wheel bearings, alignment specifications. Electrical: Wiring diagrams, starter system, charging system (alternator, battery), lighting system, instruments and controls, body electronics, fuses and relays, engine control unit (ECU) diagnostics. Body: Body panel removal and installation, doors, windows, sunroof, interior trim, bumpers, paint and corrosion protection. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, belt replacement, lubrication points. Repair: Engine rebuild, head gasket replacement, fuel injector service, transmission rebuild, brake caliper overhaul, suspension component replacement, electrical component repair. Troubleshooting: Diagnostic procedures for common engine, transmission, brake, and electrical faults; specific symptom-based troubleshooting guides. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Includes detailed torque specifications, diagnostic charts, and electrical schematics. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF for quick information retrieval. Print Quality Printability: Printable pages for workshop use. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Name: M20B27 (de-stroked variant, often referred to as the 'eta' engine, though the 325i typically used the higher-revving variant) Engine Type: Inline 6-cylinder, SOHC, 12-valve Displacement: 2.5 liters (2494 cc) Performance Horsepower Hp: 168 hp @ 5800 rpm (approx. for Euro-spec/later US models) Torque Lb Ft: 164 lb-ft @ 4300 rpm (approx. for Euro-spec/later US models) Fuel System Fuel Delivery: Bosch Motronic (later models) or Bosch LE-Jetronic fuel injection Fuel Type: Unleaded Gasoline Ignition System Ignition Type: Distributor-based electronic ignition Cooling System Coolant Type: BMW Blue Coolant (ethylene glycol based) or equivalent Lubrication System Oil Type: SAE 15W-40 or 20W-50 (refer to specific manual for optimal viscosity based on climate) Oil Capacity Quarts: 6.2 quarts (with filter) 🔧 Transmission Standard Transmission Type: Getrag 260 5-speed manual transmission Optional Transmission Type: ZF 4HP22 4-speed automatic transmission Features Clutch Type: Hydraulically operated single dry plate clutch Gear Ratios Manual: Typically 3.72, 2.02, 1.32, 1.00, 0.85 (subject to specific model year) Transmission Fluid Manual: GL-4 SAE 75W-90 or 80W-90 gear oil Transmission Fluid Automatic: ATF Dexron III or equivalent 📐 Dimensions Exterior Length Inches: 170.5 (Coupe/Sedan) Width Inches: 65.4 Height Inches: 54.7 (Coupe), 55.0 (Sedan) Weights Curb Weight Lbs: 2700-2900 lbs (approx., depending on body style and options) Gross Vehicle Weight Rating Gvwr Lbs: 3850 lbs (approx.) 🛡️ Safety Features Ratings NHTSA Rollover Rating: Not rated under modern standards (vehicle predates current testing methodologies) Active Features ABS: Optional (standard on later models, typically 1987+) Passive Features Seatbelts: 3-point front and rear seatbelts Crumple Zones: Designed with front and rear crumple zones for energy absorption 💡 Technology Features Infotainment Radio: Factory AM/FM cassette player (often Blaupunkt or Grundig), optional CD player on later models. Speakers: Typically 4 or 6 speakers Driver Assistance ABS: Optional Anti-lock Braking System (ABS) for improved braking control. Connectivity Connectivity Features: Basic analogue systems, no modern Bluetooth or USB connectivity. 🔧 Maintenance Service Intervals Oil Change Interval Miles: Every 5,000 - 7,500 miles or 12 months Timing Belt Replacement Miles: Every 40,000 - 60,000 miles or 4-5 years (critical replacement item for M20) Spark Plug Replacement Miles: Every 20,000 - 30,000 miles Brake Fluid Flush Miles: Every 2 years Fluid Specifications Coolant Capacity Liters: 9.5 liters Brake Fluid Type: DOT 3 or DOT 4 Known Issues Engine Common: Head gasket failures, coolant leaks (especially around thermostat housing and water pump), fuel distributor leaks (LE-Jetronic), idle control valve issues, occasional injector seal leaks. Suspension Common: Worn control arm bushings, worn ball joints, rear trailing arm bushings (RTABs), worn shock absorbers. Electrical Common:...
Suspension (front McPherson strut, rear semi-trailing arm), steering system (power steering), brakes (front vented discs, rear discs, ABS system details for later models), wheel bearings, alignment specifications.
Electrical:
Wiring diagrams, starter system, charging system (alternator, battery), lighting system, instruments and controls, body electronics, fuses and relays, engine control unit (ECU) diagnostics.
Body:
Body panel removal and installation, doors, windows, sunroof, interior trim, bumpers, paint and corrosion protection.
Diagnostic procedures for common engine, transmission, brake, and electrical faults; specific symptom-based troubleshooting guides.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Includes detailed torque specifications, diagnostic charts, and electrical schematics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Print Quality
Printability:
Printable pages for workshop use.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Name:
M20B27 (de-stroked variant, often referred to as the 'eta' engine, though the 325i typically used the higher-revving variant)
Engine Type:
Inline 6-cylinder, SOHC, 12-valve
Displacement:
2.5 liters (2494 cc)
Performance
Horsepower Hp:
168 hp @ 5800 rpm (approx. for Euro-spec/later US models)
Torque Lb Ft:
164 lb-ft @ 4300 rpm (approx. for Euro-spec/later US models)
Fuel System
Fuel Delivery:
Bosch Motronic (later models) or Bosch LE-Jetronic fuel injection
Fuel Type:
Unleaded Gasoline
Ignition System
Ignition Type:
Distributor-based electronic ignition
Cooling System
Coolant Type:
BMW Blue Coolant (ethylene glycol based) or equivalent
Lubrication System
Oil Type:
SAE 15W-40 or 20W-50 (refer to specific manual for optimal viscosity based on climate)
Oil Capacity Quarts:
6.2 quarts (with filter)
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-speed manual transmission
Optional
Transmission Type:
ZF 4HP22 4-speed automatic transmission
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Gear Ratios Manual:
Typically 3.72, 2.02, 1.32, 1.00, 0.85 (subject to specific model year)
Transmission Fluid Manual:
GL-4 SAE 75W-90 or 80W-90 gear oil
Transmission Fluid Automatic:
ATF Dexron III or equivalent
📐 Dimensions
Exterior
Length Inches:
170.5 (Coupe/Sedan)
Width Inches:
65.4
Height Inches:
54.7 (Coupe), 55.0 (Sedan)
Weights
Curb Weight Lbs:
2700-2900 lbs (approx., depending on body style and options)
Gross Vehicle Weight Rating Gvwr Lbs:
3850 lbs (approx.)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Not rated under modern standards (vehicle predates current testing methodologies)
Active Features
ABS:
Optional (standard on later models, typically 1987+)
Passive Features
Seatbelts:
3-point front and rear seatbelts
Crumple Zones:
Designed with front and rear crumple zones for energy absorption
💡 Technology Features
Infotainment
Radio:
Factory AM/FM cassette player (often Blaupunkt or Grundig), optional CD player on later models.
Speakers:
Typically 4 or 6 speakers
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) for improved braking control.
Connectivity
Connectivity Features:
Basic analogue systems, no modern Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
Every 5,000 - 7,500 miles or 12 months
Timing Belt Replacement Miles:
Every 40,000 - 60,000 miles or 4-5 years (critical replacement item for M20)
Spark Plug Replacement Miles:
Every 20,000 - 30,000 miles
Brake Fluid Flush Miles:
Every 2 years
Fluid Specifications
Coolant Capacity Liters:
9.5 liters
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Common:
Head gasket failures, coolant leaks (especially around thermostat housing and water pump), fuel distributor leaks (LE-Jetronic), idle control valve issues, occasional injector seal leaks.
Suspension Common:
Worn control arm bushings, worn ball joints, rear trailing arm bushings (RTABs), worn shock absorbers.
Electrical Common:
Wiring harness degradation (especially near heat sources), faulty door lock actuators, instrument cluster problems, AFM (Air Flow Meter) sensor issues.
Rust:
Susceptible to rust in common E30 areas: jacking points, rocker panels, fender lips, rear wheel arches, battery tray, sunroof drain channels.
Introduced in 1982 as the successor to the E21 3 Series. The 325i model became prominent in 1987 for the US market.
E30 Facelift:
Received a significant facelift in 1987, introducing revised bumpers (large 'diving boards'), updated interior, and revised M20 engine tuning for some models.
Production
Production Period:
1982-1994 (E30 generation)
Manufacturing Locations:
Germany, South Africa, USA (CKD kits)
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The E30 generation, including the 325i, was a frequent recipient of Car and Driver's '10Best' lists during its production run, acknowledging its superior driving dynamics and value.
Sales Success:
Highly successful model for BMW, contributing significantly to the brand's growth and establishing its performance credentials in the compact executive segment.
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