BMW 325 325i 1992-1998 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series (E36) Specific Model Variant: 325i Codes Chassis Code: E36 Engine Code Family: M50/M52 👋 Introduction Market Position Positioning: The BMW 3 Series (E36) was a highly successful executive sports sedan and coupe, renowned for its driving dynamics, build quality, and sophisticated engineering. It competed against models like the Mercedes-Benz C-Class and Audi A4. Competitive Analysis Competitors: Mercedes-Benz W202 C-Class, Audi B5 A4, Alfa Romeo 155, Lexus ES300 (though less sporty). Key Features Driving Dynamics: Excellent handling, balanced chassis, rear-wheel-drive bias, responsive steering. Powertrain: Smooth and powerful inline-six engines, renowned for their refinement. Build Quality: Typical BMW solid construction and durable materials. 📋 Manual Details Coverage Areas Year Coverage: 1992, 1993, 1994, 1995, 1996, 1997, 1998 Model Coverage: 325i (E36 Sedan, Coupe, Convertible, Touring) Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, M50B25 (2.5L inline-6) engine, DOHC, VANOS system, ignition system, fuel injection (DME, Bosch Motronic), cooling system, lubrication system, exhaust system Transmission Systems: Manual transmission (Getrag 250G), Automatic transmission (ZF 4HP22EH), clutch system, driveshafts, differential, axles Chassis Systems: Suspension (front strut, rear multi-link), steering system (power assisted), braking system (front vented discs, rear solid discs, ABS), wheels and tires Electrical Systems: Wiring diagrams, lighting systems, engine management sensors, instrument cluster, power windows, central locking, audio systems, climate control, onboard diagnostics (OBD-I/OBD-II transition) Body And Interior: Body panel removal and installation, interior trim, seats, safety systems (airbags, seatbelts), HVAC system, convertible top mechanisms (if applicable) Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid replacement, belt inspections and replacement Repair Procedures: Engine component removal and installation (e.g., head gasket, water pump, alternator), transmission overhaul, clutch replacement, brake caliper rebuild, suspension component replacement, electrical component testing and replacement Troubleshooting Guides: Diagnostic flowcharts for common drivability issues, electrical faults, cooling system problems, starting and charging issues Technical Data And Specs: Torque specifications for all fasteners, fluid capacities, diagnostic trouble codes (DTCs) and their meanings, alignment specifications, component testing procedures Technical Depth Depth: Comprehensive coverage from basic maintenance to advanced engine and transmission rebuilds, including detailed diagnostic procedures and electrical system troubleshooting. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable pages. Print Quality Printability: Designed for easy printing of individual sections or the entire manual. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: M50B25 (upgraded to M52B25 in later years, manual covers both if applicable) Engine Type: 2.5 Liter Inline 6-Cylinder, DOHC 24-Valve Performance Horsepower: Approximately 189 hp @ 5900 rpm (M50B25) Torque: Approximately 181 lb-ft @ 4200 rpm (M50B25) Fuel System Fuel Injection: Bosch Motronic (DME) Electronic Fuel Injection Fuel Type: Unleaded Gasoline (Premium) Engine Management Vanos: Variable Valve Timing (VANOS) system on intake camshaft 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission (Getrag 250G) Optional Transmission Type: 4-Speed Automatic Transmission (ZF 4HP22EH) Features Clutch: Hydraulic clutch actuation Differential: Open differential (limited-slip optional on some models/trims) Fluid Specifications Manual Transmission Fluid: BMW Manual Transmission Fluid (MTF-LT-2) or equivalent (e.g., Red Line MTL 75W80 GL-4) Automatic Transmission Fluid: ZF Lifeguardfluid 5 or equivalent ATF fluid (e.g., Dexron III H) 📐 Dimensions Exterior Wheelbase: Approximately 106.0 inches (2692 mm) Length: Approximately 174.5 - 179.0 inches (4432 - 4547 mm) depending on body style Weights Curb Weight: Approximately 3100 - 3400 lbs (1406 - 1542 kg) depending on body style and options 🛡️ Safety Features Ratings NHTSA Ratings: Refer to specific model year testing; generally performed well for its era. *Note: Early E36 models pre-date rigorous modern NHTSA/IIHS testing protocols.* Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels Traction Control: Optional ASC+T (Automatic Stability Control and Traction) available on some models. Passive Features Airbags: Driver and front passenger airbags standard from around 1994/1995 onwards; earlier models may have optional airbags or none. Seatbelts: Front and rear seatbelts, front seatbelt pretensioners. 💡 Technology Features Infotainment Audio System: Factory BMW E36 radio (often a cassette player with optional CD changer), with basic AM/FM and seek functions. Speaker system varied by trim. Driver Assistance Cruise Control: Optional cruise control system. Connectivity OBD Standard: Primarily OBD-I with the transition to OBD-II towards the later years of this generation. Manual will cover diagnostic connectors and procedures for both. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 to 10,000 miles or 12 months (check OBC - On-Board Computer - recommendations or manual for specific interval based on driving conditions). Coolant Flush Interval: Every 2 years or 30,000 miles. Spark Plug Replacement: Approximately every 60,000 miles (depending on plug type, e.g., copper...
The BMW 3 Series (E36) was a highly successful executive sports sedan and coupe, renowned for its driving dynamics, build quality, and sophisticated engineering. It competed against models like the Mercedes-Benz C-Class and Audi A4.
Competitive Analysis
Competitors:
Mercedes-Benz W202 C-Class, Audi B5 A4, Alfa Romeo 155, Lexus ES300 (though less sporty).
Body panel removal and installation, interior trim, seats, safety systems (airbags, seatbelts), HVAC system, convertible top mechanisms (if applicable)
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid replacement, belt inspections and replacement
Repair Procedures:
Engine component removal and installation (e.g., head gasket, water pump, alternator), transmission overhaul, clutch replacement, brake caliper rebuild, suspension component replacement, electrical component testing and replacement
Troubleshooting Guides:
Diagnostic flowcharts for common drivability issues, electrical faults, cooling system problems, starting and charging issues
Technical Data And Specs:
Torque specifications for all fasteners, fluid capacities, diagnostic trouble codes (DTCs) and their meanings, alignment specifications, component testing procedures
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to advanced engine and transmission rebuilds, including detailed diagnostic procedures and electrical system troubleshooting.
Designed for easy printing of individual sections or the entire manual.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M50B25 (upgraded to M52B25 in later years, manual covers both if applicable)
Engine Type:
2.5 Liter Inline 6-Cylinder, DOHC 24-Valve
Performance
Horsepower:
Approximately 189 hp @ 5900 rpm (M50B25)
Torque:
Approximately 181 lb-ft @ 4200 rpm (M50B25)
Fuel System
Fuel Injection:
Bosch Motronic (DME) Electronic Fuel Injection
Fuel Type:
Unleaded Gasoline (Premium)
Engine Management
Vanos:
Variable Valve Timing (VANOS) system on intake camshaft
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission (Getrag 250G)
Optional
Transmission Type:
4-Speed Automatic Transmission (ZF 4HP22EH)
Features
Clutch:
Hydraulic clutch actuation
Differential:
Open differential (limited-slip optional on some models/trims)
Fluid Specifications
Manual Transmission Fluid:
BMW Manual Transmission Fluid (MTF-LT-2) or equivalent (e.g., Red Line MTL 75W80 GL-4)
Automatic Transmission Fluid:
ZF Lifeguardfluid 5 or equivalent ATF fluid (e.g., Dexron III H)
📐 Dimensions
Exterior
Wheelbase:
Approximately 106.0 inches (2692 mm)
Length:
Approximately 174.5 - 179.0 inches (4432 - 4547 mm) depending on body style
Weights
Curb Weight:
Approximately 3100 - 3400 lbs (1406 - 1542 kg) depending on body style and options
🛡️ Safety Features
Ratings
NHTSA Ratings:
Refer to specific model year testing; generally performed well for its era. *Note: Early E36 models pre-date rigorous modern NHTSA/IIHS testing protocols.*
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels
Traction Control:
Optional ASC+T (Automatic Stability Control and Traction) available on some models.
Passive Features
Airbags:
Driver and front passenger airbags standard from around 1994/1995 onwards; earlier models may have optional airbags or none.
Seatbelts:
Front and rear seatbelts, front seatbelt pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory BMW E36 radio (often a cassette player with optional CD changer), with basic AM/FM and seek functions. Speaker system varied by trim.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
OBD Standard:
Primarily OBD-I with the transition to OBD-II towards the later years of this generation. Manual will cover diagnostic connectors and procedures for both.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles or 12 months (check OBC - On-Board Computer - recommendations or manual for specific interval based on driving conditions).
Coolant Flush Interval:
Every 2 years or 30,000 miles.
Spark Plug Replacement:
Approximately every 60,000 miles (depending on plug type, e.g., copper vs. platinum).
Fluid Specifications
Engine Oil Specification:
BMW Longlife-98 (LL-98) or LL-01 approved synthetic oil, typically 5W-30 or 5W-40.
Coolant Specification:
BMW Blue Antifreeze/Coolant (G48) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Specification:
DOT 4 or DOT 4 Plus brake fluid.
Known Issues
Cooling System:
Plastic coolant expansion tank prone to cracking, water pump failure (plastic impeller), thermostat housing leaks.
Vanos:
VANOS solenoid failure or seal degradation leading to camshaft timing issues, rough idle, and power loss.
Suspension:
Worn control arm bushings, ball joints, and rear shock mounts leading to vague steering and clunking noises.
Electrical:
Heater control valve failure, ABS/ASC sensor issues, dead pixels in instrument cluster, frayed wiring harnesses in door jambs.
Common Repairs
Common Repairs:
Replacement of coolant expansion tanks, water pumps, VANOS solenoids/seals, fuel pump, ignition coils, window regulators.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused vehicles with superior engineering and performance characteristics. The 3 Series is its cornerstone model.
Model Evolution
E36 Generation:
The E36 generation replaced the E30 3 Series and was produced from 1990 (model year 1991) to 2000. The 325i was a popular mid-range model, later replaced by the 328i in most markets.
Production
Production Years:
1992-1998 for the 325i variant covered by this manual. Global production of E36 spanned 1990-2000.
Manufacturing Locations:
Primary manufacturing in Germany (Munich, Dingolfing), with some assembly in other BMW plants worldwide.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E36 3 Series (including 325i/328i) was frequently listed on Car and Driver's '10 Best Cars' list during its production run.
Ratings
Driving Enthusiast Reviews:
Consistently praised by automotive journalists and enthusiasts for its engaging driving experience and balanced chassis.
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