BMW 325i 1992-1998 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: 325i Codes Chassis Code: E36 Generation Generation Designation: E36 👋 Introduction Market Position Vehicle Class: Compact Executive Sedan/Coupe/Convertible Target Demographic: Sporty luxury buyers seeking performance, handling, and build quality. Competitive Analysis Key Competitors: Mercedes-Benz C-Class (W202), Audi 80/A4 (B4/B5), Lexus ES300, Infiniti J30. Key Features Driving Dynamics: Renowned for balanced chassis, rear-wheel drive, and engaging driving experience. Engine Performance: Smooth and powerful inline-six engine. Build Quality: Typical BMW solid construction and premium interior materials. 📋 Manual Details Coverage Areas Years Covered: 1992, 1993, 1994, 1995, 1996, 1997, 1998 Page Count Estimated Page Count: Thousands (typical for comprehensive workshop manuals, exact count not provided in product info) Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English (Assumed, standard for international market manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Detailed procedures for M50B25 inline-six engine, including maintenance, diagnosis, and overhaul. Fuel System: Fuel injection system (Bosch Motronic), fuel pump, injectors, fuel pressure regulator, diagnostics. Cooling System: Radiator, water pump, thermostat, hoses, fan, coolant specifications, troubleshooting. Lubrication System: Oil pump, oil filter, oil pan, oil pressure diagnosis, oil specifications. Exhaust System: Exhaust manifold, catalytic converter, mufflers, oxygen sensors, emissions control. Ignition System: Spark plugs, ignition coils, ECU control, ignition timing, troubleshooting. Transmission Service: Manual and automatic transmission servicing, fluid changes, component replacement, diagnostics. Drivetrain: Driveshaft, universal joints, CV joints, differential, axle shafts, maintenance and repair. Suspension: Front and rear suspension components (struts, control arms, bushings, springs, shock absorbers), alignment procedures. Steering System: Power steering system, steering rack, tie rods, power steering fluid, troubleshooting. Brake System: Front and rear disc brakes, ABS system (Anti-lock Braking System), brake fluid, bleeding procedures, component replacement. Electrical System: Battery, charging system (alternator), starting system (starter motor), wiring diagrams, fuses, relays. Lighting System: Headlights, taillights, interior lighting, bulb replacement, circuit diagnosis. HVAC System: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, diagnostics. Body And Chassis: Body panels, doors, hood, trunk, interior trim, chassis components, corrosion protection. Safety Systems: Airbag system components and diagnostics, seatbelt mechanisms. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement. Diagnostic Procedures: Troubleshooting guides for common drivability, electrical, and mechanical issues. Repair Procedures: Step-by-step instructions for component removal, repair, and installation for all major vehicle systems. Engine Rebuild: Detailed procedures for engine disassembly, inspection, machining recommendations, and reassembly. Transmission Overhaul: Instructions for complete disassembly, inspection, and reassembly of both manual and automatic transmissions. Brake Service: Procedures for pad and rotor replacement, caliper service, brake fluid flush, and ABS bleeding. Electrical Troubleshooting: Use of wiring diagrams to diagnose and repair electrical faults. Suspension Geometry Adjustment: Alignment specifications and procedures. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to complete component overhaul and diagnostics. Diagnostic Tools: Information likely includes diagnostic trouble codes (DTCs) and guidance on using BMW-specific diagnostic tools (e.g., DIS, GT1, although specific tool names may not be present in a general manual). Torque Specifications: Detailed torque values for all critical fasteners. Wiring Diagrams: Complete electrical schematics for all vehicle systems. Special Tools: Identification and usage of specialized tools required for certain repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for quick information retrieval. Print Quality Image Resolution: Expected to be high-resolution for clear diagrams and illustrations. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: M50B25 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: 10.0:1 Valve Train: DOHC, 4 valves per cylinder, VANOS (Variable Valve Timing) on later models within this range. Performance Horsepower Peak: 189 hp @ 5900 rpm (approximate, may vary slightly by year/market) Torque Peak: 181 lb-ft @ 4200 rpm (approximate, may vary slightly by year/market) Fuel System Fuel Delivery: Bosch Motronic Engine Management System with Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission (Getrag 260/5 or similar) Optional Transmission Type: 4-Speed Automatic Transmission (ZF 4HP22 or similar) Features Clutch Type: Hydraulically Actuated Single Dry Plate Clutch (Manual) Gear Ratios: Specific ratios available in detailed technical sections of the manual. Automatic Transmission Features: Standard Drive, Sport mode (on some models), locking torque converter. 📐 Dimensions Exterior Wheelbase: 106.1 inches (2695 mm) Length: 174.5 - 177.2 inches (4433 - 4499 mm) depending on body style (Sedan, Coupe, Convertible) Width: 67.3 inches (1709 mm) Height: 54.5 - 55.3 inches (1384 - 1405 mm) depending on body style Weights Curb Weight: Approximately 3100 - 3400 lbs (1406 - 1542 kg) depending on body style and equipment. Gross Vehicle Weight Rating Gvwr: Specified in manual, typically around 4300 - 4500...

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Sku: 383646

Collections: ALL BMW

Availability: In stock

Tags: 1992 1993 1994 1995 1996 1997 1998 325i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Codes

Chassis Code:

Generation

Generation Designation:

👋 Introduction

Market Position

Vehicle Class:

Compact Executive Sedan/Coupe/Convertible

Target Demographic:

Sporty luxury buyers seeking performance, handling, and build quality.

Competitive Analysis

Key Competitors:

Mercedes-Benz C-Class (W202), Audi 80/A4 (B4/B5), Lexus ES300, Infiniti J30.

Key Features

Driving Dynamics:

Renowned for balanced chassis, rear-wheel drive, and engaging driving experience.

Engine Performance:

Smooth and powerful inline-six engine.

Build Quality:

Typical BMW solid construction and premium interior materials.

📋 Manual Details

Coverage Areas

Years Covered:

1992, 1993, 1994, 1995, 1996, 1997, 1998

Page Count

Estimated Page Count:

Thousands (typical for comprehensive workshop manuals, exact count not provided in product info)

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English (Assumed, standard for international market manuals)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Service:

Detailed procedures for M50B25 inline-six engine, including maintenance, diagnosis, and overhaul.

Fuel System:

Fuel injection system (Bosch Motronic), fuel pump, injectors, fuel pressure regulator, diagnostics.

Cooling System:

Radiator, water pump, thermostat, hoses, fan, coolant specifications, troubleshooting.

Lubrication System:

Oil pump, oil filter, oil pan, oil pressure diagnosis, oil specifications.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, oxygen sensors, emissions control.

Ignition System:

Spark plugs, ignition coils, ECU control, ignition timing, troubleshooting.

Transmission Service:

Manual and automatic transmission servicing, fluid changes, component replacement, diagnostics.

Drivetrain:

Driveshaft, universal joints, CV joints, differential, axle shafts, maintenance and repair.

Suspension:

Front and rear suspension components (struts, control arms, bushings, springs, shock absorbers), alignment procedures.

Steering System:

Power steering system, steering rack, tie rods, power steering fluid, troubleshooting.

Brake System:

Front and rear disc brakes, ABS system (Anti-lock Braking System), brake fluid, bleeding procedures, component replacement.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), wiring diagrams, fuses, relays.

Lighting System:

Headlights, taillights, interior lighting, bulb replacement, circuit diagnosis.

HVAC System:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, diagnostics.

Body And Chassis:

Body panels, doors, hood, trunk, interior trim, chassis components, corrosion protection.

Safety Systems:

Airbag system components and diagnostics, seatbelt mechanisms.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement.

Diagnostic Procedures:

Troubleshooting guides for common drivability, electrical, and mechanical issues.

Repair Procedures:

Step-by-step instructions for component removal, repair, and installation for all major vehicle systems.

Engine Rebuild:

Detailed procedures for engine disassembly, inspection, machining recommendations, and reassembly.

Transmission Overhaul:

Instructions for complete disassembly, inspection, and reassembly of both manual and automatic transmissions.

Brake Service:

Procedures for pad and rotor replacement, caliper service, brake fluid flush, and ABS bleeding.

Electrical Troubleshooting:

Use of wiring diagrams to diagnose and repair electrical faults.

Suspension Geometry Adjustment:

Alignment specifications and procedures.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to complete component overhaul and diagnostics.

Diagnostic Tools:

Information likely includes diagnostic trouble codes (DTCs) and guidance on using BMW-specific diagnostic tools (e.g., DIS, GT1, although specific tool names may not be present in a general manual).

Torque Specifications:

Detailed torque values for all critical fasteners.

Wiring Diagrams:

Complete electrical schematics for all vehicle systems.

Special Tools:

Identification and usage of specialized tools required for certain repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable for quick information retrieval.

Print Quality

Image Resolution:

Expected to be high-resolution for clear diagrams and illustrations.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M50B25

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:

10.0:1

Valve Train:

DOHC, 4 valves per cylinder, VANOS (Variable Valve Timing) on later models within this range.

Performance

Horsepower Peak:

189 hp @ 5900 rpm (approximate, may vary slightly by year/market)

Torque Peak:

181 lb-ft @ 4200 rpm (approximate, may vary slightly by year/market)

Fuel System

Fuel Delivery:

Bosch Motronic Engine Management System with Multi-Point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission (Getrag 260/5 or similar)

Optional

Transmission Type:

4-Speed Automatic Transmission (ZF 4HP22 or similar)

Features

Clutch Type:

Hydraulically Actuated Single Dry Plate Clutch (Manual)

Gear Ratios:

Specific ratios available in detailed technical sections of the manual.

Automatic Transmission Features:

Standard Drive, Sport mode (on some models), locking torque converter.

📐 Dimensions

Exterior

Wheelbase:

106.1 inches (2695 mm)

Length:

174.5 - 177.2 inches (4433 - 4499 mm) depending on body style (Sedan, Coupe, Convertible)

Width:

67.3 inches (1709 mm)

Height:

54.5 - 55.3 inches (1384 - 1405 mm) depending on body style

Weights

Curb Weight:

Approximately 3100 - 3400 lbs (1406 - 1542 kg) depending on body style and equipment.

Gross Vehicle Weight Rating Gvwr:

Specified in manual, typically around 4300 - 4500 lbs.

Towing Capacity:

Not typically recommended or specified by BMW for this model.

🛡️ Safety Features

Ratings

NHTSA Ratings:

Ratings from this era are not directly comparable to modern standards. However, the E36 chassis was known for its robust structure.

Active Features

Standard Anti-lock Braking System (ABS).

Traction Control:

ASC+T (Automatic Stability Control and Traction) available on some models/options.

Passive Features

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Stock cassette or CD player with AM/FM radio, optional CD changer. Basic speaker systems.

Display:

No central color display; basic LCD for radio/climate control settings.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Sensors:

Not available during this production period.

Connectivity

Bluetooth:

Not available.

Auxiliary Input:

Not standard, aftermarket solutions available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles or 12 months, whichever comes first, depending on driving conditions and oil used. The manual will detail specific recommendations.

Spark Plug Replacement:

Refer to manual for specific mileage, often around 60,000 miles for standard plugs, potentially longer for platinum/iridium.

Coolant Flush:

Typically every 2-3 years or specific mileage interval outlined in the manual.

Fluid Specifications

Engine Oil:

BMW Longlife-98 specification or equivalent synthetic oil, typically 5W-30 or 5W-40. Manual will confirm exact spec and capacity (approx. 6.5 quarts).

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, specific viscosity recommended in manual (e.g., 75W-90).

Transmission Fluid Automatic:

Dexron III or equivalent ATF fluid. Manual will specify exact type and capacity.

Brake Fluid:

DOT 3 or DOT 4 brake fluid. Manual will specify.

Power Steering Fluid:

Pentosin CHF 11S or equivalent hydraulic fluid. Manual will specify.

Known Issues

Cooling System Components:

Plastic expansion tanks prone to cracking, water pump bearing failures, thermostat housing leaks.

Suspension Bushings:

Wear in control arm bushings (bushings are often replaceable separately from the arm), rear subframe mounts.

Oil Leaks:

Valve cover gasket, oil pan gasket, oil filter housing gasket commonly known to leak.

Electrical Gremlins:

Corrosion in wiring harnesses and connectors, particularly in engine bay and door jambs, can lead to intermittent issues.

Vanos System:

Early VANOS systems can develop issues with seals and solenoids, affecting performance and fuel economy (if equipped).

Heater Control Valve:

Failure of the heater control valve can lead to inconsistent cabin heating.

📚 Vehicle History

Brand Heritage

Brand Legacy:

BMW (Bayerische Motoren Werke AG) has a long-standing reputation for producing performance-oriented luxury vehicles.

Model Evolution

E36 Introduction:

The E36 generation replaced the E30 3 Series and was produced from 1990 (in Europe) to 2000.

E36 Body Styles:

Available as Sedan, Coupe, Convertible, Touring (Wagon), and Compact (318ti).

325I Placement:

Positioned as a mid-range performance model within the E36 lineup, above the 320i/325i (in some markets) and below the M3.

Production

Production Years:

1992-1998 (for the 325i model variant covered by this manual).

Manufacturing Locations:

Primarily Germany, with some production in other global facilities.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E36 3 Series (including variants like the 325i) was a frequent recipient of Car and Driver's '10Best' lists during its production run, particularly for its handling and performance.