BMW 325i 325is 1984-1990 Workshop Service Manual Repair
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๐ท๏ธ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i / 325is Codes Chassis Code: E30 ๐ Introduction Market Position Market Segment: Compact Executive Sedan/Coupe Competitive Analysis Key Competitors: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75 Key Features Driving Dynamics: Renowned for its excellent handling, rear-wheel-drive dynamics, and driver-focused cockpit. Build Quality: Typical BMW build quality and durability. Design Heritage: Iconic E30 design language, a cornerstone of BMW's sporty image. ๐ Manual Details Coverage Areas Model Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download Page Count Estimated Page Count: ~1000+ pages (typical for comprehensive workshop manuals) ๐ Manual Coverage Systems Covered Engine Mechanical: Complete overhaul and repair procedures for the M20 inline-six engine. Engine Management: Detailed diagnostics and repair of the Bosch Motronic fuel injection and ignition system. Transmission Manual: Repair and overhaul for Getrag 260 5-speed manual transmission. Transmission Automatic: Repair and overhaul for ZF 4HP22 4-speed automatic transmission. Suspension And Steering: Front MacPherson struts, rear semi-trailing arms, power steering system repair. Brake System: Front vented discs, rear solid discs, ABS system diagnostics and repair (if equipped). Electrical System: Wiring diagrams, component testing, fuse and relay identification. Body And Chassis: Body panel repair, door mechanisms, sunroof operation, alignment procedures. HVAC System: Heating, ventilation, and air conditioning system diagnosis and repair. Procedures Included Routine Maintenance: Oil change, filter replacement, spark plug service, fluid checks and top-offs. Engine Overhaul: Detailed steps for engine disassembly, inspection, reassembly, and break-in. Transmission Rebuild: Step-by-step instructions for manual and automatic transmission rebuilding. Brake Replacement: Pad and rotor replacement, caliper service, brake bleeding procedures. Suspension Repair: Strut replacement, bushing installation, alignment procedures. Diagnostics Troubleshooting: Fault code interpretation, symptom-based diagnostics, common problem solutions. Electrical Diagnosis: Troubleshooting shorts, open circuits, and component failures using wiring diagrams. Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to complete engine and transmission rebuilds. Diagnostic Capabilities: Detailed procedures for diagnosing electronic and mechanical systems. ๐ Manual Specifications File Format File Format: High-resolution, searchable PDF Print Quality Print Quality Suitability: Suitable for high-quality printing, with clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) โ๏ธ Engine Specifications Primary Engine Engine Code: M20B27 (early 'eta' variants), M20B25 Engine Type: SOHC Inline 6-cylinder Displacement: 2.7 Liters ('eta'), 2.5 Liters Performance Horsepower 325I: 168 hp @ 5800 rpm (US Spec M20B25) Torque 325I: 164 lb-ft @ 4750 rpm (US Spec M20B25) Fuel System Fuel Delivery: Bosch Motronic electronic fuel injection (EFI) Recommended Fuel: Premium Unleaded (91+ Octane) ๐ง Transmission Standard Transmission Type Standard: 5-speed Manual (Getrag 260) Optional Transmission Type Optional: 4-speed Automatic (ZF 4HP22) Features Clutch Type: Hydraulically actuated single dry plate clutch Rear Differential: Limited Slip Differential (LSD) often optional or standard on 'is' models ๐ Dimensions Exterior Wheelbase: 100.6 inches (2555 mm) Length: 170.5 inches (4331 mm) Width: 66.1 inches (1680 mm) Height: 54.2 inches (1377 mm) Weights Curb Weight: ~2900-3100 lbs (1315-1406 kg), varies by model and options Gross Vehicle Weight Rating: Approx. 3858 lbs (1750 kg) ๐ก๏ธ Safety Features Ratings Crash Test Performance: Generally considered robust for its era, but lacks modern airbag and crumple zone technology. Active Features ABS: Anti-lock Braking System (ABS) available as an option or standard on some models. Traction Control: Traction control (ASC) became available later in the E30 lifecycle, less common on these specific models. Passive Features Airbags: Driver-side airbag became available later in the E30's production, not standard on early models. Seatbelts: 3-point front seatbelts, rear lap belts. ๐ก Technology Features Infotainment Head Unit: Original BBMW Bavaria C or similar cassette-based radios, often upgraded by owners. Speakers: Factory speaker locations, often 4-6 speakers. Driver Assistance Cruise Control: Optional cruise control system. Connectivity Connectivity Features: Limited by era; primarily radio and optional power features. ๐ง Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions. Timing Belt Interval: Every 30,000-50,000 miles or 3-5 years (critical maintenance item for M20 engine). Fluid Specifications Engine Oil Specification: SAE 10W-40 or 15W-40, API SG or higher. Coolant Specification: BMW Blue Antifreeze/Coolant (ethylene glycol based) or equivalent. Transmission Fluid Manual: ATF Dexron III or equivalent for manual transmission synchronizers. Transmission Fluid Automatic: ZF TE-ML 11A or equivalent (e.g., Dexron II/III). Brake Fluid Specification: DOT 4 brake fluid. Known Issues Common Problems Engine: Cracked cylinder head (especially early M20s), fuel pump failure, vacuum leaks, oil pan gasket leaks. Common Problems Suspension: Worn control arm bushings, rear trailing arm bushings, shock absorber failure. Common Problems Electrical: Corroded wiring harnesses, faulty fuel pump relays, instrument cluster issues. Common Problems Body: Rust (especially around wheel arches, rocker panels, and battery tray), sunroof drain blockage. ๐ Vehicle History Brand Heritage Bmw Philosophy: BMW's commitment to 'The Ultimate...