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BMW 325i 1987-1991 Car Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Generation: E30 Codes Chassis Code: E30 👋 Introduction Market Position Vehicle Segment: Compact Executive Sports Sedan/Coupe Target Audience: Enthusiasts seeking performance, handling,...
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BMW 325i 1987-1991 Car Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Generation:
E30
Codes
Chassis Code:
E30
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Sports Sedan/Coupe
Target Audience:
Enthusiasts seeking performance, handling, and BMW's renowned driving dynamics.
Competitive Analysis
Key Competitors:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, precise steering, and engaging driving experience.
Engine Performance:
Smooth and responsive M20 inline-six engine providing ample power for its class.
Build Quality:
Characteristic BMW build quality and durable construction.
Manual Value Proposition
Essential Resource:
Indispensable for maintaining, diagnosing, and repairing the BMW 325i E30, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Model Years Covered:
1987, 1988, 1989, 1990, 1991
Engine Variants Covered:
M20B25 (2.5L Inline-6)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Comprehensive Service & Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures, component specifications, timing belt replacement, valve adjustments, cooling system diagnostics and repair, lubrication system.
Engine Electrical:
Ignition system, fuel injection system (Bosch Motronic), starter, alternator, engine sensors, wiring diagrams.
Transmission:
Manual and Automatic transmission overhaul, clutch service, driveshaft and differential maintenance, gear linkage adjustment.
Suspension And Steering:
Front and rear suspension component replacement, shock absorber and strut replacement, power steering system service, wheel alignment specifications.
Brakes:
Front and rear brake system overhaul (discs and calipers), brake fluid replacement, parking brake adjustment, ABS system diagnostics (if equipped).
Electrical System:
Comprehensive wiring diagrams, lighting system, instrument cluster, power windows, central locking, fuse box diagrams, battery and charging system.
Body And Chassis:
Body panel repair, door mechanisms, trunk lid, hood, bumper repair, chassis lubrication, rust prevention and repair.
Procedures Included
Routine Maintenance:
Oil change intervals and specifications, filter replacement, spark plug replacement, coolant flush, air filter replacement.
Troubleshooting:
Diagnostic charts for common issues, fault code interpretation (where applicable), symptom-based troubleshooting guides.
Component Replacement:
Step-by-step instructions for replacing major components (e.g., water pump, alternator, starter, fuel pump).
Special Tools Requirements:
Identification and usage of specialized tools required for specific procedures.
Technical Depth
Depth:
Detailed diagnostic procedures, torque specifications, component clearances, electrical schematics, and overhaul instructions suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Searchable Text:
Yes
Printable:
Yes
Print Quality
Image Clarity:
High-resolution diagrams and images.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B25
Engine Type:
Inline-6, SOHC
Displacement:
2494 cc (2.5 Liters)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower:
168 hp @ 5800 rpm (approx.)
Torque:
225 Nm (166 lb-ft) @ 4300 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic Injection (LE-Jetronic/L-Jetronic variants)
Recommended Fuel:
Unleaded Premium (91+ Octane)
Lubrication
Oil Capacity:
5.0 Liters (5.3 US Quarts) with filter
Cooling
Coolant Capacity:
8.0 Liters (8.5 US Quarts)
Ignition
Ignition System:
Electronic Ignition with Knock Sensor
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-Speed Manual
Optional
Transmission Type:
ZF 4HP22 4-Speed Automatic
Features
Clutch Type:
Hydraulic
Differential Type:
Limited Slip Differential (Optional)
Fluid Specs
Manual Transmission Fluid:
BMW Manual Gearbox Oil (e.g., SAE 75W-90, specific BMW part numbers available in manual)
Automatic Transmission Fluid:
Dexron II or equivalent (specific BMW ATF part numbers available in manual)
📐 Dimensions
Exterior
Wheelbase:
2570 mm (101.2 in)
Length:
4340 mm (170.9 in)
Width:
1670 mm (65.7 in)
Height:
1380 mm (54.3 in)
Weights
Curb Weight:
Approx. 1270 kg (2800 lbs) - Sedan
Gross Vehicle Weight Rating:
Varies by model and configuration
Wheels Tires
Wheel Bolt Pattern:
5x120
Standard Tire Size:
195/65R14 or 205/55VR14
Optional Wheel Size:
15-inch alloy wheels
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official crash test data for this era, but E30 chassis known for robust construction.
Active Features
ABS:
Optional Anti-lock Braking System (ABS)
Passive Features
Seatbelts:
3-point front seatbelts, optional rear seatbelts.
Driver Airbag:
Not standard on all models, introduced later in the generation.
Crumple Zones:
Engineered front and rear crumple zones for improved occupant protection.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM cassette player with optional premium sound system. Manual covers basic operation and speaker replacement.
Driver Assistance
Cruise Control:
Optional cruise control system. Manual details operation and common fault diagnosis.
Connectivity
Exterior Antennae:
Power antenna for radio reception. Manual covers antenna replacement and wiring.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500-10,000 miles (or 12,000-16,000 km) or 1 year, whichever comes first.
Timing Belt Replacement Interval:
Every 60,000 miles (96,000 km) or 5 years.
Coolant Flush Interval:
Every 2 years or 30,000 miles (48,000 km).
Fluid Specifications
Engine Oil Specification:
API SG, ACEA A3/B3, SAE 10W-40 or 15W-50 (refer to manual for precise recommendations based on climate).
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Head Gasket Leaks:
Can be prone to head gasket failures if overheated, especially the M20 engine. Manual details diagnosis and replacement.
Timing Belt Failure:
Critical to adhere to replacement intervals due to catastrophic engine damage if it breaks.
Fuel Injector Issues:
Potential for clogged or failing fuel injectors leading to poor idle or performance.
Rubber Component Degradation:
Hoses, bushings, and seals can degrade over time due to age, requiring replacement. Manual provides guidance.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW's reputation for building driver-focused vehicles with superior engineering and performance.
Model Evolution
E30 Introduction:
The E30 platform, introduced in 1982, revolutionized BMW's compact executive segment, offering a sportier alternative to its predecessors.
325I Positioning:
The 325i represented the pinnacle of the E30's mainstream performance offerings, bridging the gap to the M3.
Production
Production Years:
1982-1994 (E30 platform), 325i specific variants 1987-1991 in this context.
Manufacturing Locations:
Germany (primarily Dingolfing Plant)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E30 3 Series, including variants like the 325i, was a consistent recipient of Car and Driver's '10Best' list during its production run for its exceptional driving characteristics.
Ratings
Handling Reviews:
Universally praised by automotive journalists for its sublime handling, steering feel, and driver engagement.
Certifications
Oem Standard:
This manual adheres to OEM diagnostic and repair standards as expected for BMW documentation of this era.
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