BMW 325 325e 325es 1984-1990 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325, 325e, 325es Codes Chassis Code E: E30 Generation Generation Name: Second Generation (E30) Production Years Covered: 1984-1990 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible Reputation: Renowned for driving dynamics, build quality, and sporty appeal Competitive Analysis Key Competitors: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Saab 900 Key Features Driving Dynamics: Excellent handling and balance due to near 50/50 weight distribution Engine Lineup: Smooth and torquey M20 inline-six engines Build Quality: Solid construction and durable materials typical of BMW Design: Iconic E30 styling by Claus Luthe 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Regional Variations: Applicable to North American market models Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: M20 6-cylinder (2.7L eta and 2.5L variations) Fuel System: Bosch L-Jetronic and Motronic fuel injection, fuel pump, injectors, lines Ignition System: Electronic ignition, coil, distributor, spark plugs Transmission Manual: Getrag 260 5-speed, clutch assembly, shifter linkage Transmission Automatic: ZF 4HP22 4-speed automatic, torque converter, valve body, cooler Drivetrain: Rear-wheel drive, driveshaft, differential, half-shafts Suspension Front: MacPherson struts, control arms, sway bar, bushings Suspension Rear: Semi-trailing arm independent suspension, shock absorbers, springs, bushings Steering: Recirculating ball steering system, power steering pump, rack and pinion Brakes Front: Ventilated discs, calipers, brake pads, rotors Brakes Rear: Solid discs, calipers, brake pads, rotors Brake System General: ABS (Anti-lock Braking System) components, master cylinder, brake lines, bleeding procedures Electrical System: Wiring diagrams, alternator, starter, battery, fuses, relays Lighting System: Headlights, taillights, interior lights, bulb replacement Climate Control: HVAC system, blower motor, heater core, A/C compressor, refrigerant handling Bodywork Interior: Seats, door panels, dashboard, trim removal and installation Bodywork Exterior: Bumpers, fenders, hood, trunk lid, door alignment Glass Seals: Windshield, side windows, rear window, weatherstripping Procedures Included Routine Maintenance: Oil changes, filter replacements, tune-ups, fluid checks Engine Repair: Head gasket replacement, piston ring installation, valve adjustments, timing belt replacement (if applicable, though M20 typically has a chain) Fuel System Diagnostics: Injector testing, fuel pressure checks, troubleshooting injection system faults Transmission Overhaul: Manual transmission clutch replacement, automatic transmission servicing and minor repairs Suspension Component Replacement: Strut replacement, control arm bushing renewal, ball joint inspection/replacement Brake System Maintenance: Brake pad/rotor replacement, brake fluid flush and bleed, caliper service Electrical Troubleshooting: Diagnostic procedures for electrical faults, using wiring diagrams HVAC System Repair: Refrigerant handling, compressor replacement, blower motor diagnosis Body Panel Repair: Panel alignment, rust repair guidance (general), trim replacement Troubleshooting Guides: Diagnostic flowcharts for common problems Torque Specifications: Precise torque values for all critical fasteners Special Tools: Identification of necessary specialized BMW tools Technical Depth Depth: Comprehensive, from basic maintenance to major component overhaul and diagnostics Diagnostic Capabilities: Detailed diagnostic procedures and troubleshooting steps for electrical and mechanical systems Rebuild Procedures: Includes guidance for engine and transmission component rebuilding 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for keywords Print Quality Readability: High (assuming original or well-scanned source) Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code E: M20 Engine Type: Inline-six cylinder, SOHC Displacement 325E 325Es: 2.7 Liters (2693 cc) Bore Stroke 325E 325Es: 84.0 mm x 81.0 mm Compression Ratio 325E: 8.8:1 (approx.) Compression Ratio 325Es: 9.0:1 (approx.) Power 325E: 121 hp @ 4800 rpm (US Spec) Torque 325E: 170 lb-ft @ 3250 rpm (US Spec) Power 325Es: 124 hp @ 4800 rpm (US Spec, higher compression) Torque 325Es: 170 lb-ft @ 3200 rpm (US Spec) Fuel System Fuel Delivery: Bosch L-Jetronic or Motronic fuel injection Fuel Type: Unleaded Gasoline (Premium Recommended) 🔧 Transmission Standard Transmission Type: 5-speed Manual (Getrag 260) Optional Transmission Type: 4-speed Automatic (ZF 4HP22) Features Clutch Type: Hydraulic actuation Automatic Features: Standard torque converter, sport mode selector (on some models) 📐 Dimensions Exterior Length: Approx. 170.5 inches (4330 mm) Width: Approx. 65.7 inches (1670 mm) Height: Approx. 54.7 inches (1390 mm) Wheelbase: Approx. 101.2 inches (2570 mm) Weights Curb Weight: Approx. 2800-3000 lbs (1270-1360 kg), depending on body style and equipment 🛡️ Safety Features Ratings NHTSA Ratings: Not readily available in modern standardized formats for this era; designed to meet regulations of its time. Active Features ABS: Optional on most models, standard on some later variants Passive Features Airbags: Driver airbag became standard in later model years (late 80s onwards) Seat Belts: 3-point front, 2-point rear (later models may have 3-point rear) Crumple Zones: Designed with front and rear crumple zones 💡 Technology Features Infotainment Radio: AM/FM stereo with cassette player, often with optional premium sound systems. Onboard Computer: Optional BMW On-Board Computer (OBC) with basic trip data and diagnostics. Driver Assistance Cruise Control: Optional, mechanical/vacuum-operated system. Connectivity Bluetooth: Not available. Aux Input:...
Head gasket replacement, piston ring installation, valve adjustments, timing belt replacement (if applicable, though M20 typically has a chain)
Fuel System Diagnostics:
Injector testing, fuel pressure checks, troubleshooting injection system faults
Transmission Overhaul:
Manual transmission clutch replacement, automatic transmission servicing and minor repairs
Suspension Component Replacement:
Strut replacement, control arm bushing renewal, ball joint inspection/replacement
Brake System Maintenance:
Brake pad/rotor replacement, brake fluid flush and bleed, caliper service
Electrical Troubleshooting:
Diagnostic procedures for electrical faults, using wiring diagrams
HVAC System Repair:
Refrigerant handling, compressor replacement, blower motor diagnosis
Body Panel Repair:
Panel alignment, rust repair guidance (general), trim replacement
Troubleshooting Guides:
Diagnostic flowcharts for common problems
Torque Specifications:
Precise torque values for all critical fasteners
Special Tools:
Identification of necessary specialized BMW tools
Technical Depth
Depth:
Comprehensive, from basic maintenance to major component overhaul and diagnostics
Diagnostic Capabilities:
Detailed diagnostic procedures and troubleshooting steps for electrical and mechanical systems
Rebuild Procedures:
Includes guidance for engine and transmission component rebuilding
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable for keywords
Print Quality
Readability:
High (assuming original or well-scanned source)
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code E:
M20
Engine Type:
Inline-six cylinder, SOHC
Displacement 325E 325Es:
2.7 Liters (2693 cc)
Bore Stroke 325E 325Es:
84.0 mm x 81.0 mm
Compression Ratio 325E:
8.8:1 (approx.)
Compression Ratio 325Es:
9.0:1 (approx.)
Power 325E:
121 hp @ 4800 rpm (US Spec)
Torque 325E:
170 lb-ft @ 3250 rpm (US Spec)
Power 325Es:
124 hp @ 4800 rpm (US Spec, higher compression)
Torque 325Es:
170 lb-ft @ 3200 rpm (US Spec)
Fuel System
Fuel Delivery:
Bosch L-Jetronic or Motronic fuel injection
Fuel Type:
Unleaded Gasoline (Premium Recommended)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (Getrag 260)
Optional
Transmission Type:
4-speed Automatic (ZF 4HP22)
Features
Clutch Type:
Hydraulic actuation
Automatic Features:
Standard torque converter, sport mode selector (on some models)
📐 Dimensions
Exterior
Length:
Approx. 170.5 inches (4330 mm)
Width:
Approx. 65.7 inches (1670 mm)
Height:
Approx. 54.7 inches (1390 mm)
Wheelbase:
Approx. 101.2 inches (2570 mm)
Weights
Curb Weight:
Approx. 2800-3000 lbs (1270-1360 kg), depending on body style and equipment
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not readily available in modern standardized formats for this era; designed to meet regulations of its time.
Active Features
ABS:
Optional on most models, standard on some later variants
Passive Features
Airbags:
Driver airbag became standard in later model years (late 80s onwards)
Seat Belts:
3-point front, 2-point rear (later models may have 3-point rear)
Crumple Zones:
Designed with front and rear crumple zones
💡 Technology Features
Infotainment
Radio:
AM/FM stereo with cassette player, often with optional premium sound systems.
Onboard Computer:
Optional BMW On-Board Computer (OBC) with basic trip data and diagnostics.
Driver Assistance
Cruise Control:
Optional, mechanical/vacuum-operated system.
Connectivity
Bluetooth:
Not available.
Aux Input:
Not available on factory head units.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles or 12 months, whichever comes first (check manual for exact recommendations based on driving conditions).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on conditions.
Spark Plug Replacement:
Every 30,000-60,000 miles (depending on plug type used).
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Brake Fluid Flush:
Every 2 years (critical for performance and ABS).
Timing Component Inspection:
The M20 engine uses a timing chain, not a belt, which typically requires inspection for wear rather than periodic replacement, but guides and tensioners can wear.
Fluid Specifications
Engine Oil:
API SF or SG, SAE 20W-50 or 10W-40 (refer to manual for optimal choice based on climate and wear).
Coolant:
BMW-approved antifreeze/coolant concentrate mixed 50/50 with distilled water. Typically a phosphate-based coolant for this era.
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Manual:
GL-4 gear oil (e.g., 75W-90).
Transmission Fluid Automatic:
Dexron II or equivalent (check manual for specific specification).
Power Steering Fluid:
ATF Dexron II or equivalent.
Known Issues
Cooling System:
Cracking plastic coolant expansion tanks, water pump failure, thermostat sticking.
Cracked dashboard (especially under sunlight), deteriorating seat foam, sagging headliner.
Rust:
Common areas include wheel arches, rocker panels, battery tray, and strut towers.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW is known for its 'Ultimate Driving Machine' philosophy, emphasizing performance and engineering.
Model Evolution
E30 Introduction:
The E30 generation replaced the E21 and was produced from 1982-1994 (globally), with the US market receiving it from 1984.
325E Introduction:
The 'e' (eta) models were introduced to meet fuel economy standards, featuring a detuned, high-torque 2.7L engine. The 'es' designation typically referred to a sportier trim of the 325e.
325I Introduction:
The 325i, with its higher-revving 2.5L M20 engine (approx. 168 hp), was introduced later in the E30's lifecycle (1987 US model year) and is not explicitly covered by this manual's title, though some overlap in systems may exist.
Production
Manufacturing Locations:
Primarily Germany (Munich, Dingolfing)
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E30 3 Series (including 325i) was a frequent recipient of Car and Driver's 10Best list during its production run, highlighting its enduring appeal and performance.
Automotive Journalism Praise:
Consistently praised for its handling, balance, and driver engagement.
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