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BMW 325I E30 Service Repair Manual 1987-1991

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🏷️ Basic Information Identification Make: BMW Model: 325i Chassis Code: E30 Model Years Covered: 1987-1991 Specific Model Variant: 325i 👋 Introduction Market Position Vehicle Segment: Compact executive car (sports sedan/coupe)...
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BMW 325I E30 Service Repair Manual 1987-1991
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Chassis Code:
E30
Model Years Covered:
1987-1991
Specific Model Variant:
325i
👋 Introduction
Market Position
Vehicle Segment:
Compact executive car (sports sedan/coupe)
Target Audience:
Enthusiasts, DIY mechanics, owners seeking to maintain or restore their E30 325i
Competitive Analysis
Competitors Era:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75
Key Features
Sporting Heritage:
Renowned for its driving dynamics, balanced chassis, and rear-wheel-drive platform
Engine Philosophy:
Emphasized smooth power delivery and mechanical refinement characteristic of BMW
Manual Value
Benefit Statement:
Empowers owners with the knowledge to perform complex repairs and maintenance, reducing reliance on costly dealership services
📋 Manual Details
Coverage Areas
Overall Coverage:
Comprehensive service, repair, maintenance, rebuilding, refurbishing, and restoration
Page Count
Estimated Pages:
Hundreds of pages
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, tuning, cooling system, lubrication system, intake and exhaust systems, fuel injection system (Bosch Motronic)
Engine Management:
Ignition system, Motronic ECU diagnosis and repair, sensor troubleshooting
Transmission:
Manual and automatic transmission disassembly, inspection, repair, and overhaul; clutch service; driveshafts and CV joints
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering linkage, wheel alignment
Brakes:
Hydraulic brake system, ABS (if equipped), brake pad and rotor replacement, caliper overhaul, brake fluid service
Electrical System:
Complete wiring diagrams, battery, alternator, starter, lighting system, gauges, instrument cluster, power accessories, fuse box layout
Fuel System:
Fuel pump, fuel lines, fuel injectors, fuel pressure regulator, fuel tank service
Body And Chassis:
Body panel repair, rust prevention, door mechanisms, window regulators, interior trim removal, chassis lubrication
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, belt inspection and replacement
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation (where applicable), symptom-based troubleshooting guides
Component Overhaul:
Detailed instructions for rebuilding engine components (e.g., cylinder head, pistons), transmissions, and brake calipers
Component Replacement:
Step-by-step guides for replacing parts such as timing belts, water pumps, alternators, starter motors, fuel pumps, suspension components
Electrical Diagnostics:
Tracing electrical faults, testing circuits, component testing (e.g., relays, sensors)
Technical Depth
Depth:
In-depth, covering everything from basic checks to complete engine rebuilds and complex electrical diagnostics
📊 Manual Specifications
File Format
Format:
Digital PDF
Searchability:
Likely searchable text content for quick information retrieval
Print Quality
Clarity:
High-resolution images and clear text for easy readability and printing
Binding Type
Binding:
Not applicable (digital format)
Paper Type
Paper Type:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B25
Configuration:
Inline 6-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
8.8:1 or 9.7:1 (depending on variant/market)
Performance
Horsepower:
168-171 hp @ 5800-6000 rpm (approx.)
Torque:
164-167 lb-ft @ 4000-4300 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic ML-Jetronic (early) or M1.3 (later) electronic fuel injection
Fuel Type:
Premium Unleaded Gasoline
Ignition System
Type:
Distributorless Ignition System (DIS) with coil pack controlled by Motronic ECU
Cooling System
Type:
Pressurized, liquid-cooled
Lubrication System
Type:
Forced lubrication with wet sump
🔧 Transmission
Standard
Type:
Getrag 260 5-speed manual transmission
Optional
Type:
ZF 4HP22 4-speed automatic transmission
Features
Clutch Type:
Single dry plate, hydraulic actuation
Differential:
Limited-slip differential (LSD) often optional or standard on certain models
📐 Dimensions
Exterior
Wheelbase:
100.1 inches (2542 mm)
Length:
170.5 inches (4330 mm)
Width:
67.3 inches (1709 mm)
Height:
54.7 inches (1390 mm)
Weights
Curb Weight:
Approx. 2850-3050 lbs (1293-1383 kg), depending on body style and equipment
Cargo
Trunk Capacity:
Approx. 15.5 cubic feet (439 liters)
🛡️ Safety Features
Ratings
Crash Test History:
E30 chassis considered robust for its era, though lacking modern airbag systems as standard on all models.
Active Features
ABS:
Anti-lock Braking System (ABS) was optional on earlier models and standard on later ones.
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts
Body Structure:
Reinforced safety cage construction, crumple zones
💡 Technology Features
Infotainment
Radio:
Factory AM/FM cassette radio with optional premium sound systems.
Climate Control:
Manual or optional automatic climate control.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
OBD Port:
Early OBD-I diagnostic port for engine management system diagnostics.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 12 months, whichever comes first (recommended)
Timing Belt:
Replace every 50,000-60,000 miles (80,000-96,000 km) or 5 years due to interference engine design.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km)
Fluid Specifications
Engine Oil:
BMW Longlife-98 (LL-98) specifications, typically 15W-40 or 20W-50 synthetic or semi-synthetic oil
Coolant:
BMW Blue (G48 ethylene glycol-based) or compatible coolant
Brake Fluid:
DOT 3 or DOT 4 recommended
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil
Transmission Fluid Automatic:
ZF TE-ML 11A or 11B equivalent (e.g., Dexron III)
Known Issues
Fuel Injector Seals:
Leaking or degraded O-rings can cause fuel leaks or rough idling.
Heater Core:
Prone to leaks, leading to coolant loss and fogged windows.
Dashboard Cracking:
UV exposure can cause the dashboard to crack over time.
Coolant Leaks:
Old hoses, plastic radiator end tanks, and thermostat housings can degrade and leak.
Fuel Pump Reliability:
Early fuel pumps can be a point of failure.
Window Regulators:
Mechanism can wear out, causing windows to drop or become difficult to operate.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for building driver-focused, high-quality vehicles with excellent performance and engineering.
Model Evolution
E30 Generation:
Introduced in 1982, the E30 was a highly successful generation that solidified BMW's position in the compact executive market. The 325i, introduced later, represented a significant performance upgrade.
Production
Production Period:
E30 production: 1982-1994. 325i variant specific to later years of this generation.
Manufacturing Locations:
Germany, South Africa
🏆 Awards & Recognition
Recognitions
Automotive Press:
The E30 generation, including the 325i, was widely praised by automotive journalists for its handling, build quality, and performance, often featuring on 'best of' lists.
Model Legacy:
Considered a modern classic and a benchmark for sports sedans of its era.
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