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BMW 325i 1987-1991 Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Generation: E30 Production Years Covered: 1987, 1988, 1989, 1990, 1991 Codes Chassis Code: E30 👋 Introduction Market Position Vehicle Segment: Compact Executive Sport Sedan Target Audience: Enthusiasts, DIY mechanics, professional technicians Competitive Analysis Competitors: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo Milano Key Features Driving Dynamics: Renowned for sharp handling, balanced chassis, and driver engagement Engine Performance: Smooth and potent inline-six engine Build Quality: Typical BMW solid construction for its era Purpose Of Manual Benefit: Empowers owners and technicians with the knowledge to maintain and repair the vehicle effectively 📋 Manual Details Coverage Areas General Repair: Complete Maintenance: Comprehensive Diagnostics: In-depth Troubleshooting: Extensive Page Count Estimated Pages: Approx. 2000+ (typical for this era comprehensive manuals) Manual Type Type: Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: M20B25 (inline-six cylinder) Fuel System: Bosch Motronic (EFI) Ignition System: Electronic ignition, distributors Cooling System: Radiator, fan, water pump, thermostat Exhaust System: Catalytic converter, mufflers, pipework Transmission Manual: Getrag 260 (5-speed) Transmission Automatic: ZF 4HP22 (4-speed) Drivetrain: Rear-wheel drive (RWD), differential, driveshafts Suspension Front: MacPherson struts, control arms, sway bar Suspension Rear: Semi-trailing arms, shock absorbers, springs Steering System: Recirculating ball, power steering Braking System: Front discs, rear discs, ABS (optional/standard) Electrical System: 12V system, battery, alternator, starter, wiring diagrams Lighting System: Headlights, taillights, interior lighting Body And Chassis: Frame, body panels, doors, hood, trunk HVAC System: Heating, Ventilation, Air Conditioning Interior Trim: Seats, dashboard, door panels Safety Systems: Seat belts, airbags (driver-side, later models/optional) Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement Engine Overhaul: Complete rebuild procedures, piston/ring replacement, cylinder head work Transmission Repair: Internal component replacement, clutch service (manual), valve body service (auto) Brake System Repair: Pad/rotor replacement, caliper service, bleeding, ABS diagnostics Suspension Repair: Component replacement (shocks, struts, bushings, ball joints, tie rods) Steering System Repair: Rack and pinion service, pump replacement, hose replacement Electrical Diagnostics: Component testing, wiring harness repair, fuse/relay troubleshooting Fuel Injection Service: Injector cleaning/replacement, fuel pump testing, pressure regulator service Cooling System Service: Thermostat replacement, radiator flush, coolant leak diagnosis HVAC Service: Refrigerant recharge, compressor service, blower motor replacement Bodywork Repair: Panel replacement, dent repair, rust remediation Interior Component Installation: Seat removal/installation, dashboard disassembly Troubleshooting Guides: Systematic fault finding for common issues Technical Depth Depth: Professional Technician Level Diagnostics Detail: Detailed diagnostic trouble codes (DTCs), sensor data interpretation Torque Specifications: Complete list for all critical fasteners Clearances And Tolerances: Engine component clearances, bearing tolerances, etc. Wiring Diagrams: Comprehensive, system-specific diagrams 📊 Manual Specifications File Format Type: Searchable PDF Quality: High-resolution scans, legible text and diagrams Print Quality Scanned Vs Native: Likely scanned from original manuals, designed for digital use Binding Type Digital Format: N/A (digital download) Paper Type Digital Format: N/A (digital download) ⚙️ Engine Specifications Primary Engine Engine Code: M20B25 Configuration: Inline 6-cylinder, SOHC Displacement: 2.5 Liters (2494 cc) Performance Horsepower: 168 hp @ 5800 rpm Torque: 164 lb-ft @ 4300 rpm Fuel System Type: Electronic Fuel Injection (EFI) Management System: Bosch Motronic (typically Motronic ML or ML-3) Cooling System Type: Water-cooled Oil System Oil Capacity: Approx. 4.5 Liters (with filter) Recommended Oil Viscosity: 10W-30 or 10W-40 (refer to manual for specific BMW approvals) 🔧 Transmission Standard Type: 5-speed Manual (Getrag 260) Optional Type: 4-speed Automatic (ZF 4HP22) Features Clutch Type: Hydraulic single-plate dry clutch Fluid Specification Manual Fluid Type: MTF LT-2 or equivalent (BMW recommended manual transmission fluid) Fluid Specification Automatic Fluid Type: ATF Dexron II or III (BMW approved) 📐 Dimensions Exterior Length: Approx. 4340 mm (170.9 in) Width: Approx. 1675 mm (65.9 in) Height: Approx. 1380 mm (54.3 in) Wheelbase: Approx. 2570 mm (101.2 in) Weights Curb Weight: Approx. 1300-1400 kg (2866-3086 lbs) depending on options Gross Vehicle Weight Rating: Refer to vehicle VIN plate 🛡️ Safety Features Ratings NHTSA Ratings: N/A for this era of testing, but known for robust construction Active Features ABS: Anti-lock Braking System (standard on later models/optional) Passive Features Airbags: Driver-side airbag (optional in early years, standard on later 1991 models) Seatbelts: 3-point front seat belts with pre-tensioners (later models) 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo cassette player, optional CD player Driver Assistance Cruise Control: Standard on most 325i models Connectivity Not Applicable In Modern Sense: No Bluetooth, USB, or smartphone integration from factory 🔧 Maintenance Service Intervals Oil Oil Change: Every 5,000-7,500 miles or 6-12 months (depending on driving conditions and oil used; check manual for specific recommendations) Service Intervals Filters Air Filter Replacement: Every 15,000-30,000 miles or as needed Fuel Filter Replacement: Every 30,000 miles Spark Plug Replacement: Every 30,000 miles (typically Bosch W7DC or similar) Fluid Specifications Coolant Type: BMW Blue Antifreeze or equivalent (50/50 mix with distilled water) Brake Fluid Type: DOT 3 or DOT 4 (high-quality synthetic) Power Steering Fluid:...
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BMW 325i 1987-1991 Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Generation:
E30
Production Years Covered:
1987, 1988, 1989, 1990, 1991
Codes
Chassis Code:
E30
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Sport Sedan
Target Audience:
Enthusiasts, DIY mechanics, professional technicians
Competitive Analysis
Competitors:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo Milano
Key Features
Driving Dynamics:
Renowned for sharp handling, balanced chassis, and driver engagement
Engine Performance:
Smooth and potent inline-six engine
Build Quality:
Typical BMW solid construction for its era
Purpose Of Manual
Benefit:
Empowers owners and technicians with the knowledge to maintain and repair the vehicle effectively
📋 Manual Details
Coverage Areas
General Repair:
Complete
Maintenance:
Comprehensive
Diagnostics:
In-depth
Troubleshooting:
Extensive
Page Count
Estimated Pages:
Approx. 2000+ (typical for this era comprehensive manuals)
Manual Type
Type:
Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
M20B25 (inline-six cylinder)
Fuel System:
Bosch Motronic (EFI)
Ignition System:
Electronic ignition, distributors
Cooling System:
Radiator, fan, water pump, thermostat
Exhaust System:
Catalytic converter, mufflers, pipework
Transmission Manual:
Getrag 260 (5-speed)
Transmission Automatic:
ZF 4HP22 (4-speed)
Drivetrain:
Rear-wheel drive (RWD), differential, driveshafts
Suspension Front:
MacPherson struts, control arms, sway bar
Suspension Rear:
Semi-trailing arms, shock absorbers, springs
Steering System:
Recirculating ball, power steering
Braking System:
Front discs, rear discs, ABS (optional/standard)
Electrical System:
12V system, battery, alternator, starter, wiring diagrams
Lighting System:
Headlights, taillights, interior lighting
Body And Chassis:
Frame, body panels, doors, hood, trunk
HVAC System:
Heating, Ventilation, Air Conditioning
Interior Trim:
Seats, dashboard, door panels
Safety Systems:
Seat belts, airbags (driver-side, later models/optional)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement
Engine Overhaul:
Complete rebuild procedures, piston/ring replacement, cylinder head work
Transmission Repair:
Internal component replacement, clutch service (manual), valve body service (auto)
Brake System Repair:
Pad/rotor replacement, caliper service, bleeding, ABS diagnostics
Suspension Repair:
Component replacement (shocks, struts, bushings, ball joints, tie rods)
Steering System Repair:
Rack and pinion service, pump replacement, hose replacement
Electrical Diagnostics:
Component testing, wiring harness repair, fuse/relay troubleshooting
Fuel Injection Service:
Injector cleaning/replacement, fuel pump testing, pressure regulator service
Cooling System Service:
Thermostat replacement, radiator flush, coolant leak diagnosis
HVAC Service:
Refrigerant recharge, compressor service, blower motor replacement
Bodywork Repair:
Panel replacement, dent repair, rust remediation
Interior Component Installation:
Seat removal/installation, dashboard disassembly
Troubleshooting Guides:
Systematic fault finding for common issues
Technical Depth
Depth:
Professional Technician Level
Diagnostics Detail:
Detailed diagnostic trouble codes (DTCs), sensor data interpretation
Torque Specifications:
Complete list for all critical fasteners
Clearances And Tolerances:
Engine component clearances, bearing tolerances, etc.
Wiring Diagrams:
Comprehensive, system-specific diagrams
📊 Manual Specifications
File Format
Type:
Searchable PDF
Quality:
High-resolution scans, legible text and diagrams
Print Quality
Scanned Vs Native:
Likely scanned from original manuals, designed for digital use
Binding Type
Digital Format:
N/A (digital download)
Paper Type
Digital Format:
N/A (digital download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B25
Configuration:
Inline 6-cylinder, SOHC
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
168 hp @ 5800 rpm
Torque:
164 lb-ft @ 4300 rpm
Fuel System
Type:
Electronic Fuel Injection (EFI)
Management System:
Bosch Motronic (typically Motronic ML or ML-3)
Cooling System
Type:
Water-cooled
Oil System
Oil Capacity:
Approx. 4.5 Liters (with filter)
Recommended Oil Viscosity:
10W-30 or 10W-40 (refer to manual for specific BMW approvals)
🔧 Transmission
Standard
Type:
5-speed Manual (Getrag 260)
Optional
Type:
4-speed Automatic (ZF 4HP22)
Features
Clutch Type:
Hydraulic single-plate dry clutch
Fluid Specification Manual
Fluid Type:
MTF LT-2 or equivalent (BMW recommended manual transmission fluid)
Fluid Specification Automatic
Fluid Type:
ATF Dexron II or III (BMW approved)
📐 Dimensions
Exterior
Length:
Approx. 4340 mm (170.9 in)
Width:
Approx. 1675 mm (65.9 in)
Height:
Approx. 1380 mm (54.3 in)
Wheelbase:
Approx. 2570 mm (101.2 in)
Weights
Curb Weight:
Approx. 1300-1400 kg (2866-3086 lbs) depending on options
Gross Vehicle Weight Rating:
Refer to vehicle VIN plate
🛡️ Safety Features
Ratings
NHTSA Ratings:
N/A for this era of testing, but known for robust construction
Active Features
ABS:
Anti-lock Braking System (standard on later models/optional)
Passive Features
Airbags:
Driver-side airbag (optional in early years, standard on later 1991 models)
Seatbelts:
3-point front seat belts with pre-tensioners (later models)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo cassette player, optional CD player
Driver Assistance
Cruise Control:
Standard on most 325i models
Connectivity
Not Applicable In Modern Sense:
No Bluetooth, USB, or smartphone integration from factory
🔧 Maintenance
Service Intervals Oil
Oil Change:
Every 5,000-7,500 miles or 6-12 months (depending on driving conditions and oil used; check manual for specific recommendations)
Service Intervals Filters
Air Filter Replacement:
Every 15,000-30,000 miles or as needed
Fuel Filter Replacement:
Every 30,000 miles
Spark Plug Replacement:
Every 30,000 miles (typically Bosch W7DC or similar)
Fluid Specifications
Coolant Type:
BMW Blue Antifreeze or equivalent (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 (high-quality synthetic)
Power Steering Fluid:
ATF Dexron II or III (as per manual)
Known Issues
Engine Oil Leaks:
Valve cover gasket, oil pan gasket, rear main seal
Cooling System:
Cracked plastic radiator end tanks, hose failures, water pump leaks
Suspension:
Wear in control arm bushings, trailing arm bushings, ball joints
Electrical:
Wiring harness degradation (engine bay), fuse box issues, fuel pump relay failure
Body:
Rust (wheel arches, rocker panels, battery tray)
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
'The Ultimate Driving Machine', emphasis on performance and engineering
Model Evolution
E30 Lineage:
Successor to the E21 3 Series, predecessor to the E36 3 Series. E30 defined the modern BMW sedan/coupe formula.
Production
Manufacturing Locations:
Germany (Dingolfing, Munich)
Production Period E30:
1982-1994 (global, specific to 325i body style and engine variants vary)
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver's 10Best lists multiple times during its production run
Enthusiast Following:
Strong aftermarket support and dedicated enthusiast community
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