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BMW 3-Series (E30) 325i 1987-1991 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3-Series Chassis Code: E30 Specific Model Variant: 325i Codes Engine Code Group: M20 Engine Code: M20B25 Body Style Variants Covered: 2-door sedan, 4-door sedan, convertible, (potentially touring variants if applicable to 325i) 👋 Introduction Market Position Positioning: The BMW E30 3-Series, particularly the 325i, was positioned as a compact executive sports sedan and coupe, known for its engaging driving dynamics and build quality. Competitive Analysis Competitors: Competed with models like the Mercedes-Benz 190E, Audi 80/90, Ford Sierra, and various Japanese luxury sedans of the era. Key Features Driving Dynamics: Renowned for its balanced chassis, rear-wheel-drive layout, and responsive handling, making it a driver's car. Engine Reputation: The M20 inline-six engine provided a smooth and torquey power delivery, a hallmark of BMW's engineering. 📋 Manual Details Coverage Areas Covered Years: 1987, 1988, 1989, 1990, 1991 Page Count Estimated Pages: Hundreds (specific count not provided, but implies comprehensive depth) Manual Type Type: Official Factory Service Repair Manual Language Language: English (typical for official BMW manuals of this era) Format Format: Printable (allows printing entire manual or selected pages) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (M20B25), fuel system (Bosch Motronic), ignition system, cooling system, exhaust system Drivetrain: Manual and automatic transmissions (Getrag 260, ZF 4HP22), clutch, driveshaft, differential, axle shafts Suspension And Steering: Front and rear suspension components, shock absorbers, springs, bushings, steering rack, power steering system Brakes: Front and rear brake systems (disc brakes), ABS (if equipped), brake lines, master cylinder, calipers, pads, rotors Electrical: 12V electrical system, battery, alternator, starter, lighting, instrumentation, wiring diagrams, fuses, relays Body: Body panels, doors, hood, trunk, bumpers, glass, interior trim, climate control (HVAC) Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement Repair: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnosis and replacement Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems Technical Data: Torque specifications, clearances, alignments, diagnostic trouble codes (DTCs) for applicable systems Technical Depth Depth: Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds) 📊 Manual Specifications File Format Digital Format: Likely PDF, but product description emphasizes printability Print Quality Printability: High (designed for professional printing of all or selected pages) Binding Type Physical Binding: N/A (as it's a digital product for printing, binding not applicable) Paper Type Recommended Paper: N/A (user dependent upon printing, but quality implies standard paper is sufficient for home printing) ⚙️ Engine Specifications Primary Engine Engine Code: M20B25 Configuration: 2.5L (2494cc) SOHC Inline-6 Bore X Stroke: 84 mm x 75 mm Compression Ratio: 8.8:1 Performance Horsepower Hp: 168-171 hp @ 5800-6000 rpm (depending on market and minor variations) Torque Lb-Ft: 164-167 lb-ft @ 4300-4500 rpm Fuel System Induction: Bosch LE2-Jetronic or LE3-Jetronic fuel injection Fuel Type: Unleaded gasoline (premium recommended) Ignition System Type: Electronic ignition with distributor and coil 🔧 Transmission Standard Type: Getrag 260 5-speed manual transmission Optional Type: ZF 4HP22 4-speed automatic transmission Features Clutch: Hydraulically actuated single dry plate clutch Final Drive: Limited-slip differential (optional, commonly found on 325i) 📐 Dimensions Exterior Wheelbase: 101.2 inches (2570 mm) Length: 170.5 inches (4330 mm) Width: 65.4 inches (1661 mm) Height: 54.7 inches (1390 mm) Weights Curb Weight Kg: Approx. 1250-1350 kg (depending on body style and equipment) 🛡️ Safety Features Ratings Crash Test History: E30 models generally performed well for their era, though specific ratings for these years vary by testing authority and are less standardized than modern tests. Focus was on occupant protection through crumple zones and safety cage. Active Features ABS: Anti-lock Braking System (ABS) available as an option on many 325i models. Passive Features Seatbelts: Three-point inertia-reel seatbelts front and rear Steering Column: Collapsible steering column for improved impact absorption 💡 Technology Features Infotainment Audio System: Factory cassette player with AM/FM radio, optional CD player available later in production. Basic sound systems, often with 4 or 6 speakers. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on the 325i. Connectivity Connectivity Features: No modern connectivity features (Bluetooth, USB, etc.). Original connectivity was limited to power antenna and speaker outputs. Climate Control HVAC: Manual climate control with fan speed and temperature selection. Optional air conditioning. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil used (consult manual for specific BMW recommendations). Spark Plug Replacement: Approx. 30,000 miles for original type spark plugs (e.g., Bosch Super Plus W8AC or equivalent). Timing Belt Replacement: Crucial! M20 engines use a timing belt. Recommended replacement interval is typically every 30,000-45,000 miles or 3-4 years due to the risk of catastrophic engine damage if it breaks. Fluid Specifications Engine Oil: BMW Longlife-98 or equivalent synthetic oil, typically SAE 5W-30 or 10W-40 depending on climate. Capacity: Approx....
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BMW 3-Series (E30) 325i 1987-1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3-Series
Chassis Code:
E30
Specific Model Variant:
325i
Codes
Engine Code Group:
M20
Engine Code:
M20B25
Body Style Variants Covered:
2-door sedan, 4-door sedan, convertible, (potentially touring variants if applicable to 325i)
👋 Introduction
Market Position
Positioning:
The BMW E30 3-Series, particularly the 325i, was positioned as a compact executive sports sedan and coupe, known for its engaging driving dynamics and build quality.
Competitive Analysis
Competitors:
Competed with models like the Mercedes-Benz 190E, Audi 80/90, Ford Sierra, and various Japanese luxury sedans of the era.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel-drive layout, and responsive handling, making it a driver's car.
Engine Reputation:
The M20 inline-six engine provided a smooth and torquey power delivery, a hallmark of BMW's engineering.
📋 Manual Details
Coverage Areas
Covered Years:
1987, 1988, 1989, 1990, 1991
Page Count
Estimated Pages:
Hundreds (specific count not provided, but implies comprehensive depth)
Manual Type
Type:
Official Factory Service Repair Manual
Language
Language:
English (typical for official BMW manuals of this era)
Format
Format:
Printable (allows printing entire manual or selected pages)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals (M20B25), fuel system (Bosch Motronic), ignition system, cooling system, exhaust system
Drivetrain:
Manual and automatic transmissions (Getrag 260, ZF 4HP22), clutch, driveshaft, differential, axle shafts
Suspension And Steering:
Front and rear suspension components, shock absorbers, springs, bushings, steering rack, power steering system
Brakes:
Front and rear brake systems (disc brakes), ABS (if equipped), brake lines, master cylinder, calipers, pads, rotors
Electrical:
12V electrical system, battery, alternator, starter, lighting, instrumentation, wiring diagrams, fuses, relays
Body:
Body panels, doors, hood, trunk, bumpers, glass, interior trim, climate control (HVAC)
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement
Repair:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnosis and replacement
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems
Technical Data:
Torque specifications, clearances, alignments, diagnostic trouble codes (DTCs) for applicable systems
Technical Depth
Depth:
Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds)
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, but product description emphasizes printability
Print Quality
Printability:
High (designed for professional printing of all or selected pages)
Binding Type
Physical Binding:
N/A (as it's a digital product for printing, binding not applicable)
Paper Type
Recommended Paper:
N/A (user dependent upon printing, but quality implies standard paper is sufficient for home printing)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B25
Configuration:
2.5L (2494cc) SOHC Inline-6
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
8.8:1
Performance
Horsepower Hp:
168-171 hp @ 5800-6000 rpm (depending on market and minor variations)
Torque Lb-Ft:
164-167 lb-ft @ 4300-4500 rpm
Fuel System
Induction:
Bosch LE2-Jetronic or LE3-Jetronic fuel injection
Fuel Type:
Unleaded gasoline (premium recommended)
Ignition System
Type:
Electronic ignition with distributor and coil
🔧 Transmission
Standard
Type:
Getrag 260 5-speed manual transmission
Optional
Type:
ZF 4HP22 4-speed automatic transmission
Features
Clutch:
Hydraulically actuated single dry plate clutch
Final Drive:
Limited-slip differential (optional, commonly found on 325i)
📐 Dimensions
Exterior
Wheelbase:
101.2 inches (2570 mm)
Length:
170.5 inches (4330 mm)
Width:
65.4 inches (1661 mm)
Height:
54.7 inches (1390 mm)
Weights
Curb Weight Kg:
Approx. 1250-1350 kg (depending on body style and equipment)
🛡️ Safety Features
Ratings
Crash Test History:
E30 models generally performed well for their era, though specific ratings for these years vary by testing authority and are less standardized than modern tests. Focus was on occupant protection through crumple zones and safety cage.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option on many 325i models.
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts front and rear
Steering Column:
Collapsible steering column for improved impact absorption
💡 Technology Features
Infotainment
Audio System:
Factory cassette player with AM/FM radio, optional CD player available later in production. Basic sound systems, often with 4 or 6 speakers.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on the 325i.
Connectivity
Connectivity Features:
No modern connectivity features (Bluetooth, USB, etc.). Original connectivity was limited to power antenna and speaker outputs.
Climate Control
HVAC:
Manual climate control with fan speed and temperature selection. Optional air conditioning.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil used (consult manual for specific BMW recommendations).
Spark Plug Replacement:
Approx. 30,000 miles for original type spark plugs (e.g., Bosch Super Plus W8AC or equivalent).
Timing Belt Replacement:
Crucial! M20 engines use a timing belt. Recommended replacement interval is typically every 30,000-45,000 miles or 3-4 years due to the risk of catastrophic engine damage if it breaks.
Fluid Specifications
Engine Oil:
BMW Longlife-98 or equivalent synthetic oil, typically SAE 5W-30 or 10W-40 depending on climate. Capacity: Approx. 4.25 liters (4.5 US quarts) with filter.
Coolant:
BMW Blue coolant or a compatible ethylene glycol-based antifreeze mixed 50/50 with distilled water. Capacity: Approx. 7.0 liters (7.4 US quarts).
Brake Fluid:
DOT 4 brake fluid (e.g., ATE Typ 200).
Transmission Fluid Manual:
API GL-4 or GL-5 SAE 75W-90 or 80W-90 gear oil. Capacity: Approx. 1.2 liters (1.3 US quarts).
Transmission Fluid Automatic:
Dexron II or III automatic transmission fluid (ATF). Capacity: Approx. 1.5 liters (1.6 US quarts) for torque converter drain.
Known Issues
Fuel Pump:
Early E30 fuel pumps (inline) can be a failure point, later models had in-tank pumps.
O Ring Leaks:
Fuel injector O-rings, oil pan gasket, and valve cover gasket are common areas for leaks.
E Brake Shoes:
Rear drum-in-hat parking brake shoes can seize or fail to hold.
Window Regulators:
Manual and electric window regulators can become stiff or break.
Heater Core:
Heater core leaks are a common issue, often leading to a sweet smell in the cabin and coolant loss.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's 'Ultimate Driving Machine' ethos was deeply ingrained in the E30 generation, emphasizing performance, handling, and driver engagement.
Model Evolution
E30 Introduction:
The E30 generation replaced the E21 3-Series and was produced from 1982 to 1994, with significant updates and model variants throughout its lifecycle.
325I Introduction:
The 325i model, featuring the M20B25 engine, was introduced in mid-1987 (as a 1987.5 model) replacing the 325e/325es models, offering a significant performance upgrade.
Production
Production Period For Model:
1987-1991 for the 325i E30 variant.
Manufacturing Locations:
Primarily Germany (Munich, Dingolfing), also South Africa and assembled in other markets.
🏆 Awards & Recognition
Recognitions
Automotive Press Accolades:
The E30 3-Series, including the 325i, was widely praised by automotive journalists for its handling, build quality, and performance, often appearing on 'best of' lists for sporty sedans of its era.
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