BMW 325i 325is 1984-1990 Full Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i, 325is Generation: E30 Codes Chassis Code: E30 Engine Codes: M20B25 (2.5L) 👋 Introduction Market Position Segment: Compact Executive Sports Sedan/Coupe Target Audience: Enthusiasts, DIY mechanics, owners seeking to maintain and repair their classic BMW. Competitive Analysis Key Competitors: Mercedes-Benz 190E, Audi 80/90, Ford Sierra XR4i, Alfa Romeo 75. Key Features Vehicle Reputation: Renowned for its sporty handling, balanced chassis, and driver engagement, defining the modern BMW driving experience. Manual Value Proposition: Essential resource for preserving and maintaining the performance and longevity of the E30 325i/325is. 📋 Manual Details Coverage Areas Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990 Page Count Estimated Page Count: Approximately 1000+ Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF, Printable) 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of the M20B25 inline-six engine, including diagnostics, repair, and overhaul. Fuel System: Detailed information on Bosch Motronic fuel injection system, fuel pump, injectors, fuel lines, and pressure regulation. Ignition System: Coverage of the electronic ignition system, coil, distributor, spark plugs, and timing. Cooling System: Radiator, water pump, thermostat, coolant hoses, and fan assembly maintenance and repair. Exhaust System: Catalytic converter, muffler, exhaust manifold, and pipes diagnosis and replacement. Transmission Manual: Repair and overhaul procedures for the Getrag 260 5-speed manual transmission. Clutch system diagnosis and replacement. Transmission Automatic: Information on the ZF 4HP22 4-speed automatic transmission, including fluid changes and basic troubleshooting. Drivetrain: Driveshaft, CV joints, differential, and axle shaft service and repair. Suspension Front: MacPherson struts, control arms, ball joints, bushings, and anti-roll bar service. Suspension Rear: Trailing arms, shock absorbers, bushings, and spring replacement. Steering System: Power steering pump, rack and pinion, steering linkage, and wheel alignment procedures. Brakes Front: Disc brake rotor, caliper, pads, and brake line service. ABS system components if applicable. Brakes Rear: Drum brake (on some models) or disc brake caliper, pads, and parking brake mechanism. Electrical System: Wiring diagrams, fuse box layout, battery, alternator, starter, lighting, and accessories. Body And Frame: Panel removal and installation, body repair, door mechanisms, and interior trim. HVAC: Heater core, blower motor, A/C system components, and climate control adjustments. Troubleshooting: Diagnostic charts and procedures for common problems. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks, belt inspections. Engine Repair: Cylinder head removal/installation, piston and connecting rod service, crankshaft bearing replacement, timing chain/belt replacement. Fuel System Service: Fuel injector cleaning, fuel pump replacement, fuel pressure testing. Transmission Overhaul: Detailed steps for disassembling, inspecting, and reassembling manual and automatic transmissions. Brake System Repair: Brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake line bleeding, ABS component replacement. Suspension Replacement: Strut, shock absorber, control arm, bushing, and ball joint replacement. Electrical Diagnostics: Using multimeters and oscilloscopes to diagnose electrical faults, starter/alternator testing. Body Panel Replacement: Procedures for replacing fenders, doors, hoods, and trunk lids. Climate Control Repair: Recharging A/C systems (with proper certification), replacing heater cores and blower motors. Technical Depth Depth: Extremely high. Covers everything from basic fluid changes to complete engine and transmission rebuilds. Diagnostic Level: Advanced diagnostics for mechanical, electrical, and fuel injection systems. Special Tools: Lists required special tools for specific repair procedures. 📊 Manual Specifications File Format File Type: Likely PDF Searchable Text: High likelihood of being text-searchable for quick information retrieval. Print Quality Print Readability: Designed for clarity and readability when printed. Binding Type Binding: Not applicable for digital format, but implies robust content for physical binding. Paper Type Paper Quality: Not applicable for digital format, but implies professional layout and illustration quality. ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-Six Cylinder Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 8.8:1 or 9.1:1 (depending on year/market) Valve Train: SOHC (Single Overhead Camshaft), 12 Valves (2 per cylinder) Performance Horsepower Est: 168-171 hp @ 5800-6000 rpm Torque Est: 164-167 lb-ft @ 4300-4500 rpm Fuel System Fuel Delivery: Bosch Motronic ML-Jetronic (later L-Jetronic or LE-Jetronic on early models) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Cooling System Coolant Capacity: Approximately 9.5 Liters (10 Quarts) 🔧 Transmission Standard Type: Getrag 260 5-Speed Manual Optional Type: ZF 4HP22 4-Speed Automatic Features Clutch Type: Hydraulically Actuated Single Dry Plate Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 or equivalent GL-4 rated gear oil (e.g., Red Line MTL) Automatic Transmission Fluid: Dexron III or equivalent ATF 📐 Dimensions Exterior Length: Approx. 170.5 inches (4331 mm) Width: Approx. 67.3 inches (1709 mm) Height: Approx. 54.9 inches (1395 mm) Weights Curb Weight Est: 2,700 - 2,900 lbs (1225 - 1315 kg) Wheelbase: Approx. 101.2 inches (2570 mm) 🛡️ Safety Features Ratings Crash Test Results: Older vehicle, no standardized NHTSA/IIHS ratings comparable to modern vehicles. Known for robust safety cage construction. Active Features ABS: Available on most models, standard on...
Strut, shock absorber, control arm, bushing, and ball joint replacement.
Electrical Diagnostics:
Using multimeters and oscilloscopes to diagnose electrical faults, starter/alternator testing.
Body Panel Replacement:
Procedures for replacing fenders, doors, hoods, and trunk lids.
Climate Control Repair:
Recharging A/C systems (with proper certification), replacing heater cores and blower motors.
Technical Depth
Depth:
Extremely high. Covers everything from basic fluid changes to complete engine and transmission rebuilds.
Diagnostic Level:
Advanced diagnostics for mechanical, electrical, and fuel injection systems.
Special Tools:
Lists required special tools for specific repair procedures.
📊 Manual Specifications
File Format
File Type:
Likely PDF
Searchable Text:
High likelihood of being text-searchable for quick information retrieval.
Print Quality
Print Readability:
Designed for clarity and readability when printed.
Binding Type
Binding:
Not applicable for digital format, but implies robust content for physical binding.
Paper Type
Paper Quality:
Not applicable for digital format, but implies professional layout and illustration quality.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-Six Cylinder
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
8.8:1 or 9.1:1 (depending on year/market)
Valve Train:
SOHC (Single Overhead Camshaft), 12 Valves (2 per cylinder)
Performance
Horsepower Est:
168-171 hp @ 5800-6000 rpm
Torque Est:
164-167 lb-ft @ 4300-4500 rpm
Fuel System
Fuel Delivery:
Bosch Motronic ML-Jetronic (later L-Jetronic or LE-Jetronic on early models)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Cooling System
Coolant Capacity:
Approximately 9.5 Liters (10 Quarts)
🔧 Transmission
Standard
Type:
Getrag 260 5-Speed Manual
Optional
Type:
ZF 4HP22 4-Speed Automatic
Features
Clutch Type:
Hydraulically Actuated Single Dry Plate
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent GL-4 rated gear oil (e.g., Red Line MTL)
Automatic Transmission Fluid:
Dexron III or equivalent ATF
📐 Dimensions
Exterior
Length:
Approx. 170.5 inches (4331 mm)
Width:
Approx. 67.3 inches (1709 mm)
Height:
Approx. 54.9 inches (1395 mm)
Weights
Curb Weight Est:
2,700 - 2,900 lbs (1225 - 1315 kg)
Wheelbase:
Approx. 101.2 inches (2570 mm)
🛡️ Safety Features
Ratings
Crash Test Results:
Older vehicle, no standardized NHTSA/IIHS ratings comparable to modern vehicles. Known for robust safety cage construction.
Active Features
ABS:
Available on most models, standard on later E30s.
Passive Features
Airbags:
Driver-side airbag became optional later in the production run, not standard across all models.
Seat Belts:
3-point front and rear seatbelts.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player. Optional premium sound systems available.
Driver Assistance
Cruise Control:
Optional on most models.
Connectivity
Bluetooth:
Not applicable for this era. Aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles or 6-12 months, whichever comes first, depending on driving conditions.
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plug Replacement:
Typically every 30,000 - 60,000 miles with platinum or iridium plugs (copper plugs require more frequent replacement).
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Timing Belt Replacement:
Crucial! M20 engines use a timing belt. Replace every 50,000-60,000 miles or 5 years to prevent catastrophic engine damage due to interference design.
Fluid Specifications
Engine Oil:
10W-40 or 20W-50 synthetic or semi-synthetic oil recommended. Check owner's manual for precise specifications.
Engine Oil Capacity:
Approx. 4.5 Liters (4.7 Quarts) with filter.
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific recommendation).
Known Issues
Engine Mounts:
Commonly degrade over time, leading to vibration.
Coolant Leaks:
Plastic coolant expansion tanks can crack; check hoses and thermostat housing for leaks.
Window Regulators:
Manual and electric window regulators can fail.
Fuel Pump Reliability:
In-tank fuel pumps can become noisy or fail over time.
Rust:
Common E30 issue, particularly around wheel arches, rocker panels, and jacking points. Regular inspection is crucial.
Dashboard Cracks:
The vinyl dashboards are prone to cracking from sun exposure.
Idle Control Valve:
Can become clogged, leading to rough idling or stalling.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Continued BMW's legacy of producing driver-focused, performance-oriented luxury vehicles.
Model Evolution
E30 Introduction:
The E30 generation succeeded the E21 3 Series and introduced significant advancements in chassis design and engineering.
325I Introduction:
The 325i, powered by the M20B25 engine, replaced the 323i and 325e, offering a significant performance upgrade.
325Is Distinction:
The 'is' designation often referred to sportier variants, potentially with specific suspension tuning or aerodynamic enhancements (depending on market).
Production
Production Years:
1982-1994 (E30 generation globally), 1984-1990 (for 325i/325is models covered by this manual).
Manufacturing Locations:
Germany, South Africa, USA (CKD assembly)
🏆 Awards & Recognition
Recognitions
Critical Acclaim:
The E30 3 Series, including the 325i/is, received widespread critical acclaim for its driving dynamics and build quality, frequently appearing on 'best driver's cars' lists.