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BMW 325 325i 1989 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Year: 1989 Codes Chassis Code: E30 Engine Code Common: M20B25 👋 Introduction Market Position Vehicle Segment: Compact Executive Sedan/Coupe Target Audience: Performance-oriented luxury car buyers, enthusiasts Competitive Analysis Primary Competitors 1989: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Volvo 240/740 Competitive Advantage: Superior handling and driving dynamics, advanced engineering, brand prestige Key Features Driving Experience: Renowned for its balanced chassis, rear-wheel drive, and engaging driving feel Design Heritage: Part of the iconic E30 generation, known for its timeless and muscular design Engineering Philosophy: Typical BMW focus on driver engagement, performance, and build quality 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Component Coverage: Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Climate Control, Fuel System, Exhaust System, Cooling System, Lubrication System, Interior Trim, Exterior Trim, Diagnostics Page Count Estimated Page Count: Approximately 1000+ pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: Likely Printed (Original Factory) or PDF Digital Format 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, valves, lubrication, cooling system overhaul, fuel injection system (Bosch Motronic M2.7 or M2.8) Engine Management: Ignition system, fuel delivery, emissions control, troubleshooting of electronic control unit (ECU) and sensors Transmission Manual: Gearbox overhaul, clutch replacement, driveshaft service Transmission Automatic: Automatic transmission servicing, troubleshooting, overhaul (if applicable to 325i models of this year) Suspension And Steering: Front and rear suspension components, shock absorbers, springs, control arms, subframes, steering rack, power steering system Brakes: Front and rear brake systems (discs), caliper service, master cylinder, ABS system (if equipped), brake bleeding procedures Electrical System: Wiring diagrams, lighting, starter, alternator, battery, fuses, relays, instrument cluster, power windows, central locking Body And Chassis: Body panel removal and installation, door mechanisms, glass replacement, structural repair guidance, rust prevention Climate Control: HVAC system diagnosis and repair, refrigerant handling (R12) Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug changes, fluid checks and top-offs, belt inspection and replacement Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (where applicable) Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls Component Replacement: Detailed instructions for replacing specific parts like alternators, starters, fuel pumps, radiators, water pumps, CV joints Adjustment And Calibration: Valve adjustments (if applicable), timing belt tension adjustment, idle speed adjustment Technical Depth Level Of Detail: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts Diagnostic Capabilities: Includes diagnostic charts, symptom-to-cause analysis, and electrical troubleshooting based on wiring diagrams Torque Specifications: Detailed torque values for all critical fasteners Special Tools: Lists and descriptions of special tools required for specific procedures Diagrams And Illustrations: Extensive use of exploded views, schematics, and detailed illustrations for clarity 📊 Manual Specifications File Format Digital Format: PDF (if digital), typically with searchable text and high-resolution images Print Quality Printed Quality: High-quality printing with durable paper stock and clear diagrams (for original manuals) Binding Type Printed Binding: Professional binding (e.g., perfect bound, spiral bound) for ease of use in a workshop environment Paper Type Printed Paper: Durable, often glossy paper to withstand workshop conditions and highlight diagrams ⚙️ Engine Specifications Primary Engine Engine Type: Inline-6 Cylinder, DOHC (Double Overhead Camshaft) Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84 mm x 75 mm Compression Ratio: 8.5:1 or 9.0:1 (depending on specific engine variant) Engine Code: M20B25 Performance Horsepower: 168-171 hp @ 5800-6000 rpm (depending on market and specific tuning) Torque: 164-167 lb-ft (222-226 Nm) @ 4300-4500 rpm Fuel System Fuel Injection: Bosch Motronic Electronic Fuel Injection (EFI), either M2.7 or M2.8 Fuel Type: Unleaded Gasoline (Octane rating as per owner's manual) Cooling System Cooling Type: Water-cooled, pressurized system Lubrication System Oil Capacity: Approx. 5.0-5.5 liters (with filter) Timing Timing Belt Type: Timing Belt (CRITICAL REPLACEMENT INTERVAL) 🔧 Transmission Standard Transmission Type: Getrag 260 5-speed Manual Transmission Optional Transmission Type: ZF 4HP22 4-speed Automatic Transmission Features Clutch: Hydraulically actuated single dry plate clutch Driveshaft: RWD (Rear Wheel Drive) with universal joints and guibo flex disc Fluid Specifications Manual Transmission Fluid: API GL-4 Gear Oil (e.g., Pentosin MTF 75W-80 or equivalent) Automatic Transmission Fluid: ATF Dexron II or Dexron III (check manual for exact spec) 📐 Dimensions Exterior Length: Approx. 4340 mm (170.9 in) Width: Approx. 1670 mm (65.7 in) Height: Approx. 1380 mm (54.3 in) Wheelbase: Approx. 2570 mm (101.2 in) Weights Curb Weight: Approx. 1250-1350 kg (2756-2976 lbs) Gross Vehicle Weight Rating: Varies by body style and options Cargo Trunk Capacity: Approx. 430 liters (15.2 cu ft) 🛡️ Safety Features Ratings Crash Test Performance: While official ratings from modern agencies are not directly comparable, the E30 chassis was known for its robust safety cage and build quality for its era. Active Features...
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BMW 325 325i 1989 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325i
Year:
1989
Codes
Chassis Code:
E30
Engine Code Common:
M20B25
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Sedan/Coupe
Target Audience:
Performance-oriented luxury car buyers, enthusiasts
Competitive Analysis
Primary Competitors 1989:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Volvo 240/740
Competitive Advantage:
Superior handling and driving dynamics, advanced engineering, brand prestige
Key Features
Driving Experience:
Renowned for its balanced chassis, rear-wheel drive, and engaging driving feel
Design Heritage:
Part of the iconic E30 generation, known for its timeless and muscular design
Engineering Philosophy:
Typical BMW focus on driver engagement, performance, and build quality
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Component Coverage:
Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Climate Control, Fuel System, Exhaust System, Cooling System, Lubrication System, Interior Trim, Exterior Trim, Diagnostics
Page Count
Estimated Page Count:
Approximately 1000+ pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Likely Printed (Original Factory) or PDF Digital Format
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, valves, lubrication, cooling system overhaul, fuel injection system (Bosch Motronic M2.7 or M2.8)
Engine Management:
Ignition system, fuel delivery, emissions control, troubleshooting of electronic control unit (ECU) and sensors
Transmission Manual:
Gearbox overhaul, clutch replacement, driveshaft service
Transmission Automatic:
Automatic transmission servicing, troubleshooting, overhaul (if applicable to 325i models of this year)
Suspension And Steering:
Front and rear suspension components, shock absorbers, springs, control arms, subframes, steering rack, power steering system
Brakes:
Front and rear brake systems (discs), caliper service, master cylinder, ABS system (if equipped), brake bleeding procedures
Electrical System:
Wiring diagrams, lighting, starter, alternator, battery, fuses, relays, instrument cluster, power windows, central locking
Body And Chassis:
Body panel removal and installation, door mechanisms, glass replacement, structural repair guidance, rust prevention
Climate Control:
HVAC system diagnosis and repair, refrigerant handling (R12)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug changes, fluid checks and top-offs, belt inspection and replacement
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (where applicable)
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls
Component Replacement:
Detailed instructions for replacing specific parts like alternators, starters, fuel pumps, radiators, water pumps, CV joints
Adjustment And Calibration:
Valve adjustments (if applicable), timing belt tension adjustment, idle speed adjustment
Technical Depth
Level Of Detail:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts
Diagnostic Capabilities:
Includes diagnostic charts, symptom-to-cause analysis, and electrical troubleshooting based on wiring diagrams
Torque Specifications:
Detailed torque values for all critical fasteners
Special Tools:
Lists and descriptions of special tools required for specific procedures
Diagrams And Illustrations:
Extensive use of exploded views, schematics, and detailed illustrations for clarity
📊 Manual Specifications
File Format
Digital Format:
PDF (if digital), typically with searchable text and high-resolution images
Print Quality
Printed Quality:
High-quality printing with durable paper stock and clear diagrams (for original manuals)
Binding Type
Printed Binding:
Professional binding (e.g., perfect bound, spiral bound) for ease of use in a workshop environment
Paper Type
Printed Paper:
Durable, often glossy paper to withstand workshop conditions and highlight diagrams
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, DOHC (Double Overhead Camshaft)
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
8.5:1 or 9.0:1 (depending on specific engine variant)
Engine Code:
M20B25
Performance
Horsepower:
168-171 hp @ 5800-6000 rpm (depending on market and specific tuning)
Torque:
164-167 lb-ft (222-226 Nm) @ 4300-4500 rpm
Fuel System
Fuel Injection:
Bosch Motronic Electronic Fuel Injection (EFI), either M2.7 or M2.8
Fuel Type:
Unleaded Gasoline (Octane rating as per owner's manual)
Cooling System
Cooling Type:
Water-cooled, pressurized system
Lubrication System
Oil Capacity:
Approx. 5.0-5.5 liters (with filter)
Timing
Timing Belt Type:
Timing Belt (CRITICAL REPLACEMENT INTERVAL)
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-speed Manual Transmission
Optional
Transmission Type:
ZF 4HP22 4-speed Automatic Transmission
Features
Clutch:
Hydraulically actuated single dry plate clutch
Driveshaft:
RWD (Rear Wheel Drive) with universal joints and guibo flex disc
Fluid Specifications
Manual Transmission Fluid:
API GL-4 Gear Oil (e.g., Pentosin MTF 75W-80 or equivalent)
Automatic Transmission Fluid:
ATF Dexron II or Dexron III (check manual for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 4340 mm (170.9 in)
Width:
Approx. 1670 mm (65.7 in)
Height:
Approx. 1380 mm (54.3 in)
Wheelbase:
Approx. 2570 mm (101.2 in)
Weights
Curb Weight:
Approx. 1250-1350 kg (2756-2976 lbs)
Gross Vehicle Weight Rating:
Varies by body style and options
Cargo
Trunk Capacity:
Approx. 430 liters (15.2 cu ft)
🛡️ Safety Features
Ratings
Crash Test Performance:
While official ratings from modern agencies are not directly comparable, the E30 chassis was known for its robust safety cage and build quality for its era.
Active Features
ABS:
Anti-lock Braking System (ABS) was an option, typically on rear wheels or all four wheels on later models.
Passive Features
Airbags:
Driver-side airbag was optional and became more common in later E30 production years. Passenger airbags were not generally available.
Seatbelts:
Three-point seatbelts in front and rear (rear lap belts might be present in earlier models).
Rollover Protection:
Reinforced A-pillars and roof structure typical of BMW build quality.
💡 Technology Features
Infotainment
Head Unit:
Factory-installed premium sound system or aftermarket replacements. Limited connectivity by modern standards.
On Board Computer:
Optional On-Board Computer (OBC) with functions like MPG, average speed, and service interval reminders. Often prone to pixel failure.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
Connectivity Options:
Primarily analog. No Bluetooth, USB, or factory navigation. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles or 12 months, using synthetic oil for best protection.
Timing Belt Replacement:
CRITICAL: Every 50,000 - 60,000 miles or 5 years. Failure can cause catastrophic engine damage.
Coolant Flush:
Every 2-3 years or 30,000 miles.
Spark Plug Replacement:
Approximately every 30,000-50,000 miles depending on plug type.
Fluid Specifications
Engine Oil Spec:
SAE 15W-40 or 10W-40 (check manual for specific viscosity recommendations based on climate). API SG/SH or higher.
Coolant Type:
BMW Blue Coolant (G48) or equivalent ethylene glycol based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (DOT 4 recommended for improved performance).
Known Issues
Cooling System Weaknesses:
Plastic coolant expansion tanks are prone to cracking; radiator hoses can degrade; water pump seals can fail.
Fuel System Issues:
Fuel pump failure, clogged injectors, failing fuel pressure regulator.
Electrical Gremlins:
Corroded grounds, failing headlight relays, malfunctioning OBC (On-Board Computer) and instrument cluster components.
Suspension Wear:
Worn control arm bushings (eccentric bushings), ball joints, and tie rod ends are common due to age and mileage.
Rust Prone Areas:
Wheel arches, rocker panels, battery tray area, front strut towers, rear trailing arm mounts.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for engineering excellence, 'Ultimate Driving Machine' philosophy.
Model Evolution
E30 Generation Timeline:
Introduced in 1982, the E30 generation replaced the E21. The 325i model was introduced in 1987, succeeding the 323i, and continued through the end of the E30's production.
Facelift Impact:
The 1989 model year represents a later stage of the E30's lifecycle, possibly incorporating minor updates from the 1987 facelift (e.g., larger bumpers, revised interior trim).
Production
Manufacturing Location:
Primarily Germany (Munich, Dingolfing), with some assembly in other global locations.
Production Years E30:
1982-1991 (sedan/coupe), 1987-1991 (convertible)
🏆 Awards & Recognition
Recognitions
Performance Reviews:
Consistently praised by automotive journalists of the era for its handling, balance, and driver-focused experience.
Collectible Status:
The E30 M3 is a highly sought-after collectible, but the 325i is also recognized as a classic BMW with strong enthusiast following.
Ratings
Jd Power Reliability:
Modern reliability ratings are not applicable. However, E30s are known for durability when properly maintained.
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