BMW 3-Series (E30) 325i 1987 -1991 Full Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3-Series (E30) Specific Model Variant: 325i Product Name: BMW 3-Series (E30) 325i 1987 -1991 Full Service Repair Manual Generation Generation Code: E30 Model Years Covered: 1987, 1988, 1989, 1990, 1991 👋 Introduction Market Position Bmw E30 Market Segment: Compact executive sports sedan/coupe Bmw E30 Reputation: Renowned for its driving dynamics, build quality, and classic BMW styling Competitive Analysis Key Competitors: Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Ford Sierra XR4i Key Features Driving Experience: Excellent handling, responsive steering, balanced chassis Engine Characteristics: Smooth and torquey M20 inline-six engine Build Quality: Typical BMW solid construction and attention to detail Manual Value Proposition Time Saving: Guaranteed to save precious time through clear instructions and organized information Ease Of Use: Easy-to-read text sections with top-quality diagrams and instructions Accessibility: Accessible for both DIY owners and experienced mechanics 📋 Manual Details Coverage Areas Manual Scope: Complete Service and Repair Target Audience: Do-it-yourself enthusiasts and professional mechanics Page Count Estimated Page Count: Varies by specific publisher, but professional manuals typically exceed 800 pages for this model Manual Type Manual Type: Full Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, and overhaul of the M20 inline-six engine (including specific variants for 325i) Fuel System: Fuel injection system (Bosch Motronic), fuel pump, injectors, fuel lines, tank Ignition System: Ignition coils, distributor, spark plugs, timing, Motronic control Cooling System: Radiator, fan, water pump, thermostat, hoses, coolant specifications Exhaust System: Exhaust manifolds, catalytic converter, muffler, piping Transmission: Manual and automatic transmission service, repair, fluid specifications, and clutch replacement Drivetrain: Driveshaft, universal joints, differential, axle shafts Suspension: Front and rear suspension components, shock absorbers, struts, bushings, alignment specifications Steering: Power steering system, steering rack, tie rods, steering column Brakes: Front and rear brake systems (disc brakes), brake pads, rotors, calipers, master cylinder, ABS (if equipped), bleeding procedures Electrical System: Battery, alternator, starter, lighting system, fuses, relays, wiring diagrams Engine Management System: Bosch Motronic M1.3, sensor diagnostics, ECU troubleshooting Climate Control: HVAC system, blower motor, A/C system components, heater core Body And Chassis: Body panel removal and installation, frame, structural components, rust repair considerations Interior: Seat removal, dashboard components, trim panels, headliner Paint And Bodywork: Information on refinishing and minor body repairs Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs Troubleshooting: Systematic diagnostic procedures for common and uncommon issues Repair: Step-by-step instructions for component replacement and repair Rebuilds: Complete engine and transmission rebuild procedures Adjustment: Valve adjustments, idle speed adjustments, timing adjustments Diagnosis: Diagnostic trouble codes (DTCs) and sensor testing procedures Technical Depth Depth Of Information: Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls Diagrams And Illustrations: High-quality exploded view diagrams and detailed illustrations Wiring Diagrams: Full electrical system wiring diagrams 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Zoom Functionality: Zoom IN/OUT enabled Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software Requirements: Adobe PDF Reader, WinZip (for extraction if zipped) Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: M20B25 Engine Type: Inline 6-cylinder, SOHC Displacement: 2.5 liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 8.5:1 Performance Horsepower: 168 hp @ 5800 rpm (approx.) Torque: 225 Nm (166 lb-ft) @ 4300 rpm (approx.) Fuel System Fuel Delivery: Bosch Motronic M1.3 Fuel Injection Fuel Type: Unleaded gasoline (Octane rating typically 91 RON or higher recommended) Cooling System Coolant Type: Ethylene glycol based antifreeze (e.g., BMW Blue or equivalent) Oil Specifications Engine Oil Grade: SAE 20W-50 or 15W-40 (depending on climate and manufacturer recommendations) Engine Oil Capacity: Approx. 4.25 liters (4.5 US quarts) with filter change 🔧 Transmission Standard Transmission Type: Getrag 260 5-speed manual transmission Optional Transmission Type: ZF 4HP22 4-speed automatic transmission Features Manual Clutch Type: Hydraulically operated single dry plate clutch Fluid Specifications Manual Transmission Fluid: SAE 75W-90 or 80W-90 API GL-4 gear oil Automatic Transmission Fluid: Dexron II or III (check specific manual for precise BMW specification) 📐 Dimensions Exterior Wheelbase: 2568 mm (101.1 inches) Length: 4340 mm (170.9 inches) Width: 1674 mm (65.9 inches) Height: 1380 mm (54.3 inches) Weights Curb Weight: Approx. 1240-1320 kg (2734-2910 lbs), depending on transmission and equipment Gross Vehicle Weight Rating Gvwr: Approx. 1700 kg (3748 lbs) Wheels And Tires Standard Wheel Size: 14-inch or 15-inch alloy wheels Wheel Bolt Pattern: 5x120 mm Standard Tire Size: 195/65R14 or 205/55R15 (depending on trim/options) 🛡️ Safety Features Ratings Crash Test Performance: E30 chassis generally considered safe for its era, but lacks modern advanced safety features. Specific NHTSA/Euro NCAP ratings for these years may not be readily available in modern databases but were evaluated based on...
Diagnostic trouble codes (DTCs) and sensor testing procedures
Technical Depth
Depth Of Information:
Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls
Diagrams And Illustrations:
High-quality exploded view diagrams and detailed illustrations
Wiring Diagrams:
Full electrical system wiring diagrams
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
Zoom IN/OUT enabled
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for extraction if zipped)
Operating System Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B25
Engine Type:
Inline 6-cylinder, SOHC
Displacement:
2.5 liters (2494 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
8.5:1
Performance
Horsepower:
168 hp @ 5800 rpm (approx.)
Torque:
225 Nm (166 lb-ft) @ 4300 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic M1.3 Fuel Injection
Fuel Type:
Unleaded gasoline (Octane rating typically 91 RON or higher recommended)
Cooling System
Coolant Type:
Ethylene glycol based antifreeze (e.g., BMW Blue or equivalent)
Oil Specifications
Engine Oil Grade:
SAE 20W-50 or 15W-40 (depending on climate and manufacturer recommendations)
Engine Oil Capacity:
Approx. 4.25 liters (4.5 US quarts) with filter change
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-speed manual transmission
Optional
Transmission Type:
ZF 4HP22 4-speed automatic transmission
Features
Manual Clutch Type:
Hydraulically operated single dry plate clutch
Fluid Specifications
Manual Transmission Fluid:
SAE 75W-90 or 80W-90 API GL-4 gear oil
Automatic Transmission Fluid:
Dexron II or III (check specific manual for precise BMW specification)
📐 Dimensions
Exterior
Wheelbase:
2568 mm (101.1 inches)
Length:
4340 mm (170.9 inches)
Width:
1674 mm (65.9 inches)
Height:
1380 mm (54.3 inches)
Weights
Curb Weight:
Approx. 1240-1320 kg (2734-2910 lbs), depending on transmission and equipment
Gross Vehicle Weight Rating Gvwr:
Approx. 1700 kg (3748 lbs)
Wheels And Tires
Standard Wheel Size:
14-inch or 15-inch alloy wheels
Wheel Bolt Pattern:
5x120 mm
Standard Tire Size:
195/65R14 or 205/55R15 (depending on trim/options)
🛡️ Safety Features
Ratings
Crash Test Performance:
E30 chassis generally considered safe for its era, but lacks modern advanced safety features. Specific NHTSA/Euro NCAP ratings for these years may not be readily available in modern databases but were evaluated based on contemporary standards.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some models
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts
Head Restraints:
Front and rear head restraints
Chassis Design:
Reinforced safety cage, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory fitted cassette player with optional CD changer, basic AM/FM radio.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel, and coolant temperature. Check control panel for warning lights.
Driver Assistance
Cruise Control:
Optional cruise control system
Connectivity
Phone Integration:
N/A (No factory integrated Bluetooth or smartphone connectivity)
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, whichever comes first.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on conditions.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) using appropriate spark plug type.
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km).
Brake Fluid Flush:
Every 2 years to maintain system performance.
Fluid Specifications
Power Steering Fluid:
BMW ATF (Automatic Transmission Fluid) or Dexron II/III equivalent
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific requirement)
Known Issues
Common Issues:
Cracked dashboard, failing heater core O-rings, fuel injector O-ring leaks, idle control valve issues, coolant expansion tank cracks, front control arm bushings, rear trailing arm bushings, differential mounts, door seal leaks, window regulator failures, sunroof drain blockages.
Engine Issues:
M20 engines can suffer from head gasket failures if overheated, oil leaks from various seals (camshaft seal, front crank seal), and potential for rod bearing wear at high mileage.
Electrical Issues:
Corroded grounds, aging wiring harnesses, fuel pump relays, and alternator failures can occur.
📚 Vehicle History
Brand Heritage
Bmw Brand Philosophy:
Sheer Driving Pleasure, focus on performance, engineering, and driver engagement
Model Evolution
E30 Introduction:
Introduced in 1982, the E30 replaced the successful E21 3-Series.
E30 Variants:
Offered in sedan (4-door), coupe (2-door), convertible, and estate (Touring) body styles. The 325i represented the higher-performance, fuel-injected six-cylinder variant.
E30 Facelift:
The E30 received a significant facelift in 1987, introducing revised bumpers, aerodynamic improvements, and updated interior features, which this manual covers.
Production
Production Period:
1982-1994 (global production for E30 platform)
Manufacturing Locations:
Primarily Germany, but also South Africa and other locations
Legacy
E30 Collectibility:
Highly sought after by enthusiasts and collectors for its classic styling and driving experience.
🏆 Awards & Recognition
Recognitions
General Reputation:
The E30 generation is widely considered one of BMW's most iconic and beloved models, praised for its driving dynamics and timeless design.
Sporting Heritage:
The E30 platform was successful in various motorsport disciplines, including touring car racing (e.g., DTM) and rallying.