🏷️ Basic Information

Make:

BMW

Model:

325i

Model Variant:

325

Year:

1991

Chassis Code:

E30

👋 Introduction

Market Segment:

Compact Executive Sedan/Coupe

Target Audience:

Enthusiasts, DIY mechanics, independent repair shops seeking authentic BMW repair data.

Key Competitors:

Mercedes-Benz 190E, Audi 90, Acura Legend, Lexus ES250

Vehicle Reputation:

Known for sporty handling, robust build quality, and driver engagement.

Manual Value Proposition:

Provides authorized factory procedures, diagrams, and specifications for accurate and efficient maintenance and repair.

📋 Manual Details

Engine Coverage:

M20B25 inline-six engine

Transmission Coverage:

Getrag 260 5-speed manual, ZF 4HP22 4-speed automatic

Drivetrain Coverage:

Rear-wheel drive (RWD)

Chassis Coverage:

Suspension, steering, brakes, body structure

Electrical Coverage:

Wiring diagrams, component testing, diagnostic procedures

Body Coverage:

Body panels, interior trim, glass, seals

Specific Systems:

Fuel injection (Bosch Motronic 1.3), ignition, cooling, HVAC, emissions control

Estimated Page Count:

Hundreds of pages (exact number varies by source, but typically 1000+ for factory manuals)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, disassembly, assembly, internal components, timing belt, seals, gaskets

Fuel System:

Fuel pump, injectors, fuel pressure regulator, fuel filter replacement

Ignition System:

Spark plugs, ignition coils, distributor, ECU control

Cooling System:

Radiator, water pump, thermostat, hoses, coolant specifications

Exhaust System:

Catalytic converter, mufflers, pipes, O2 sensors

Transmission Mechanical:

Clutch replacement, gearbox overhaul, internal components (manual), torque converter, valve body (automatic)

Drivetrain Components:

Driveshaft, CV joints, differential, rear axle assembly

Suspension System:

Struts, shocks, control arms, ball joints, bushings, springs, alignment specifications

Steering System:

Power steering pump, steering rack, tie rods, steering column

Brake System:

Brake pads, rotors, calipers, master cylinder, brake fluid specifications, bleeding procedures, ABS diagnostics

Electrical System Diagnostics:

Troubleshooting circuits, component testing, voltage/resistance checks

Lighting System:

Headlights, taillights, interior lighting, bulb types

Instrument Cluster:

Gauges, warning lights, odometer repair

HVAC System:

Air conditioning compressor, heater core, blower motor, refrigerant types, climate control unit

Emissions Control:

Catalytic converter, EGR valve, charcoal canister, evaporative emissions system

Safety Systems:

Seat belt mechanisms, airbag system (if applicable for the year/model, though limited on early E30s)

Routine Maintenance:

Oil change, filter replacement, coolant flush, brake fluid flush, spark plug replacement, belt inspection/replacement

Diagnostic Procedures:

Troubleshooting common symptoms, fault code interpretation (where applicable), component testing

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment

Rebuild Procedures:

Detailed instructions for engine and transmission overhauls

Alignment Specifications:

Front and rear wheel alignment angles, torque specifications for suspension components

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Torque Specifications:

Precise torque values for critical fasteners across all systems

Depth Level:

Comprehensive Factory-Level Detail

Diagnostic Capability:

Advanced diagnostics for engine management, ABS, and other electronic systems (using specific BMW diagnostic tools of the era).

Rebuild Capability:

Full rebuild procedures for engine, transmission, differential, and major mechanical assemblies.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, searchable text and clear diagrams for printing.

Binding Type:

Digital Download (PDF) - allows for on-demand printing of specific pages or the entire manual.

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

M20B25

Engine Configuration:

2.5L SOHC Inline-six (6-cylinder)

Bore X Stroke:

84 mm x 75 mm

Compression Ratio:

8.5:1

Horsepower:

168 hp @ 5800 rpm

Torque:

164 lb-ft @ 4750 rpm

Fuel Delivery:

Bosch Motronic 1.3 Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 87 octane minimum (91 octane recommended for optimal performance)

Timing Belt Interval:

Replace every 40,000 - 60,000 miles or 3-5 years (critical maintenance item).

🔧 Transmission

Standard Transmission:

Getrag 260 5-speed Manual Transmission

Optional Transmission:

ZF 4HP22 4-speed Automatic Transmission

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (check manual for specific cross-reference)

Automatic Transmission Fluid:

Dexron III/Mercon or equivalent (check manual for specific BMW specification)

📐 Dimensions

Wheelbase:

101.2 inches (2570 mm)

Length:

170.5 inches (4330 mm)

Width:

66.1 inches (1680 mm)

Height:

55.1 inches (1400 mm)

Curb Weight:

Approx. 2,950 - 3,050 lbs (1340 - 1380 kg), depending on body style and options.

Gross Vehicle Weight Rating:

Varies by model, consult vehicle's VIN plate.

🛡️ Safety Features

Crash Test Results:

No comprehensive NHTSA/IIHS ratings available for this specific year/model from that era. Early E30s relied on robust chassis engineering and seat belts as primary safety features. Later models added some airbags.

Anti Lock Brakes:

Optional ABS (Anti-lock Braking System) was available on some 1991 models.

Seat Belts:

3-point retractable front seat belts, 2-point lap belts in rear (early models) or 3-point belts in rear (later E30 variants).

Airbags:

Driver's side airbag was an optional feature on later E30 models, including some 1991 variants, but not standard.

💡 Technology Features

Infotainment System:

Basic AM/FM stereo radio with cassette player. Optional CD player on some later models. Analog gauges for instrumentation.

Driver Assistance Features:

Limited to ABS (optional). No electronic stability control or traction control systems.

Connectivity Features:

No Bluetooth, USB, or modern connectivity features. Primarily mechanical and basic electrical systems.

🔧 Maintenance

Oil Change Interval:

Every 7,500 - 10,000 miles or 1 year, whichever comes first (using synthetic oil). Check manual for specific recommendation.

Spark Plug Replacement Interval:

Every 30,000 miles for standard plugs, up to 60,000 miles for platinum/iridium plugs.

Brake Fluid Flush Interval:

Every 2 years or as per manual recommendations, as brake fluid absorbs moisture.

Engine Oil Type:

BMW High Performance SAE 15W-40 or 10W-40 (synthetic recommended).

Engine Oil Capacity:

Approx. 4.5 - 5.0 US quarts (4.2 - 4.7 liters) with filter change.

Coolant Type:

BMW Blue Antifreeze/Coolant or equivalent with corrosion inhibitors (typically a 50/50 mix with distilled water).

Power Steering Fluid:

Pentosin CHF 11S or compatible hydraulic fluid (check manual for exact spec).

Common Issues 1:

Timing belt failure (critical to follow replacement schedule), cooling system leaks (radiator, hoses, water pump), fuel injector failure, fuel tank sender unit issues, rear shock mount reinforcement.

Common Issues 2:

Door panel separation, front end creaks and rattles, differential leaks, seized brake calipers.

Preventative Maintenance:

Regular inspection of cooling hoses, timely timing belt replacement, keeping fuel system clean, and addressing any fluid leaks promptly.

📚 Vehicle History

Bmw Philosophy:

The 3 Series is BMW's cornerstone model, renowned for its 'Ultimate Driving Machine' ethos and sporty performance.

E30 Generation:

The E30 generation (1982-1994) is a celebrated and highly regarded BMW chassis, known for its pure driving dynamics and iconic styling. The 325i was a prominent and popular model within this generation.

Production Period:

The E30 generation was produced from 1982 to 1994 globally. The 325i specifically gained popularity in the mid-to-late 1980s and continued into the early 1990s.

🏆 Awards & Recognition

Automotive Press Awards:

The E30 generation, and the 325i in particular, received numerous accolades from automotive publications during its production run for its driving dynamics, build quality, and performance. Often cited as a benchmark for sport sedans.

Club Ratings:

Consistently ranked highly by BMW enthusiast clubs and modern automotive journalists as one of the greatest BMWs ever produced.