BMW 3 Series 325 1987-1991 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325 Model Years Covered: 1987, 1988, 1989, 1990, 1991 Codes Chassis Codes: E30 👋 Introduction Market Position Market Position: The BMW 3 Series (E30) of this era was a benchmark for sports sedans and coupes, prized for its driving dynamics and build quality. Competitive Analysis Competitive Analysis: Competed against vehicles like the Mercedes-Benz 190E, Audi 80/90, and various Japanese sports sedans, often lauded for superior handling. Key Features Key Features: Renowned for its rear-wheel-drive platform, balanced chassis, and the iconic 'M' division influence even on standard models. Target Audience Target Audience: Enthusiasts, DIY mechanics, and professional workshops working on the E30 325 models. 📋 Manual Details Coverage Areas Diagnostic Procedures: Full diagnostic procedures for all major systems. Electrical Systems: Comprehensive coverage of all electrical components and wiring diagrams. Engine Mechanical: Detailed mechanical repair procedures for the engine. Transmission And Drivetrain: Complete repair and maintenance for manual and automatic transmissions and driveshafts. Suspension And Steering: In-depth coverage of suspension components, steering systems, and alignment. Braking System: Detailed procedures for brake system maintenance, repair, and troubleshooting, including ABS if equipped. Body And Chassis: Procedures for body repair, panel replacement, and chassis diagnostics. HVAC System: Repair and maintenance of the heating, ventilation, and air conditioning system. Fuel And Exhaust Systems: Repair and diagnosis of fuel delivery, injection, and exhaust components. Cooling System: Maintenance and repair of the engine cooling system, including radiators and water pumps. Maintenance Schedules: Detailed preventative maintenance schedules for various mileages and time intervals. Page Count Page Count: 225 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Includes detailed information on the Bosch Motronic engine management system. Emission Control: Covers emission control systems, including catalytic converter operation and diagnosis. Instrumentation: Details on dashboard instruments, warning lights, and their functions. Lighting System: Complete wiring diagrams and troubleshooting for exterior and interior lighting. Interior Components: Removal and installation procedures for interior trim and components. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, fluid level checks. Major Repairs: Engine overhauls, transmission rebuilds, clutch replacement, suspension component replacement. Troubleshooting Diagnostics: Step-by-step troubleshooting guides for common and complex issues. Component Replacement: Detailed instructions for replacing major components like alternators, starters, fuel pumps. Adjustment Procedures: Idle speed, valve lash (where applicable), and other critical adjustments. Technical Depth Technical Depth: Comprehensive: covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed electrical troubleshooting. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, clear text and diagrams suitable for printing. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Searchability Searchability: Fully searchable text for quick information retrieval. Instant Download Instant Download: Yes ⚙️ Engine Specifications Primary Engine Engine Code: M20B25 Engine Type: Inline 6-cylinder, SOHC, 12-valve Displacement: 2.5 Liters (2494 cc) Performance Horsepower Gross Approx: 168 hp @ 5800 rpm Torque Gross Approx: 164 lb-ft @ 4300 rpm Fuel System Fuel System Type: Bosch Motronic Fuel Injection (e.g., Motronic ML-1.3) Recommended Fuel: Unleaded Premium (91 Octane or higher) Engine Management Ignition System: Distributorless ignition system (DIS) on later models, or distributor-based systems. 🔧 Transmission Standard Standard Transmission: 5-speed Manual (Getrag 260/5) Optional Optional Transmission: 4-speed Automatic (ZF 4HP22) Features Clutch Type: Single dry plate, hydraulic actuation. Rear Differential: Standard Limited Slip Differential (LSD) on many 325 models, with open differential as an option. 📐 Dimensions Exterior Wheelbase: approx. 101.2 inches (2570 mm) Length: approx. 170.5 inches (4330 mm) Width: approx. 67.3 inches (1709 mm) Height: approx. 55.1 inches (1400 mm) Weights Curb Weight Approx: 2,900 - 3,100 lbs (1315 - 1406 kg), depending on body style and options. Wheels Tires Wheel Bolt Pattern: 5 x 120 mm Standard Wheel Size: 14-inch or 15-inch alloy wheels. Standard Tire Size: 205/60VR14 or 205/55VR15 🛡️ Safety Features Ratings Safety Ratings Era: Vehicles of this era typically did not have standardized crash test ratings like NHTSA or Euro NCAP. Active Features Active Safety Features: ABS (Anti-lock Braking System) was optional on most 325 models, becoming more standard on later years. Passive Features Passive Safety Features: Impact-absorbing steering column, reinforced door beams, front and rear crumple zones. Restraints Seat Belts: Three-point inertia-reel seatbelts for front occupants, lap belts for rear. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio with cassette player was standard, with optional premium sound systems. Driver Assistance Driver Assistance Features: ABS was the primary electronic driver assistance feature available as an option. Connectivity Connectivity Features: None by modern standards; primarily analog systems. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 to 10,000 miles or 12 months, whichever comes first, depending on driving conditions. Spark Plug Replacement: Approximately every 30,000 miles, depending on spark plug type...
Distributorless ignition system (DIS) on later models, or distributor-based systems.
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual (Getrag 260/5)
Optional
Optional Transmission:
4-speed Automatic (ZF 4HP22)
Features
Clutch Type:
Single dry plate, hydraulic actuation.
Rear Differential:
Standard Limited Slip Differential (LSD) on many 325 models, with open differential as an option.
📐 Dimensions
Exterior
Wheelbase:
approx. 101.2 inches (2570 mm)
Length:
approx. 170.5 inches (4330 mm)
Width:
approx. 67.3 inches (1709 mm)
Height:
approx. 55.1 inches (1400 mm)
Weights
Curb Weight Approx:
2,900 - 3,100 lbs (1315 - 1406 kg), depending on body style and options.
Wheels Tires
Wheel Bolt Pattern:
5 x 120 mm
Standard Wheel Size:
14-inch or 15-inch alloy wheels.
Standard Tire Size:
205/60VR14 or 205/55VR15
🛡️ Safety Features
Ratings
Safety Ratings Era:
Vehicles of this era typically did not have standardized crash test ratings like NHTSA or Euro NCAP.
Active Features
Active Safety Features:
ABS (Anti-lock Braking System) was optional on most 325 models, becoming more standard on later years.
Passive Features
Passive Safety Features:
Impact-absorbing steering column, reinforced door beams, front and rear crumple zones.
Restraints
Seat Belts:
Three-point inertia-reel seatbelts for front occupants, lap belts for rear.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio with cassette player was standard, with optional premium sound systems.
Driver Assistance
Driver Assistance Features:
ABS was the primary electronic driver assistance feature available as an option.
Connectivity
Connectivity Features:
None by modern standards; primarily analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles or 12 months, whichever comes first, depending on driving conditions.
Spark Plug Replacement:
Approximately every 30,000 miles, depending on spark plug type (e.g., copper vs. platinum).
Timing Belt Replacement:
The M20 engine uses a timing belt, typically recommended for replacement every 60,000 miles or 4 years.
Fluid Specifications
Engine Oil Specification:
BMW High Performance Synthetic 5W-30 or 5W-40, or equivalent API SG/SH rated oil.
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors. BMW recommends a 50/50 mix with distilled water.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron III (or equivalent) automatic transmission fluid.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Known Issues Engine:
Cooling system component failure (radiator, hoses, water pump), idle control valve issues, head gasket leaks (less common than on 4-cyl), starter motor failure.
Worn control arm bushings, shock absorber degradation, trailing arm bushings (common E30 wear item).
Known Issues Body:
Rust in common areas like rocker panels, fender wells, battery tray, and sunroof drains.
📚 Vehicle History
Brand Heritage
Brand Heritage:
BMW has a long-standing reputation for building driver-focused, high-performance vehicles with excellent engineering.
Model Evolution
E30 Generation Introduction:
The E30 generation was introduced in 1982, succeeding the E21. The 325 model variant, featuring the larger M20 engine, arrived later in the E30's lifecycle.
325 Introduction Year:
The 325 badge typically referred to the 2.5-liter engine, introduced in Europe around 1985 and available in North America for the 1987 model year.
Production
Production Period:
1987-1991 for the 325 variant in North America.
Production Locations
Production Locations:
Primarily manufactured in Germany.
🏆 Awards & Recognition
Recognitions
Recognitions:
The E30 generation consistently received praise from automotive publications for its handling, build quality, and driver engagement. Often cited as one of the best driver's cars of its era.
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