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BMW 325 325i 1984-1990 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325 / 325i Model Code: E30 Generation: First Generation (E30) Body Style: 2-door Sedan, 4-door Sedan, Convertible, (Touring Wagon unofficial) Codes Engine Codes:...
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BMW 325 325i 1984-1990 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325 / 325i
Model Code:
E30
Generation:
First Generation (E30)
Body Style:
2-door Sedan, 4-door Sedan, Convertible, (Touring Wagon unofficial)
Codes
Engine Codes:
M20B27 (2.7L), M20B25 (2.5L)
Chassis Codes:
E30
👋 Introduction
Market Position
Segment:
Compact Executive Sports Sedan
Reputation:
Renowned for its driving dynamics, build quality, and sporty appeal. Often considered a benchmark in its class during its production run.
Competitive Analysis
Key Competitors:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Ford Sierra XR4i, Opel Monza
Key Features
Driving Experience:
Engaging handling, responsive steering, well-balanced chassis (often cited as one of the best handling BMWs of its era).
Powertrain Characteristics:
Smooth and torquey M20 inline-six engines, known for their linear power delivery.
Manual Value Proposition
Target Audience:
BMW enthusiasts, owners undertaking DIY maintenance and repairs, classic car restorers, independent workshops specializing in European vehicles.
📋 Manual Details
Coverage Areas
Vehicle Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990
Model Variants Covered:
325, 325i
Page Count
Total Pages:
554
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (M20 inline-6), Fuel System, Ignition System, Cooling System, Exhaust System, Transmission (Manual & Automatic)
Chassis:
Suspension (Front & Rear), Steering System, Braking System (ABS included where applicable)
Electrical:
Wiring Diagrams, Lighting System, Instrumentation, Power Accessories, Engine Control Unit (ECU), Fuses & Relays
Body And Interior:
Body Panel Repair, Doors, Windows, Seats, HVAC System, Trim Components
Procedures Included
Maintenance:
Scheduled Maintenance (Oil changes, filter replacements, tune-ups), Fluid Checks and Replacements, Belt Inspections and Replacements
Diagnostics:
Troubleshooting Common Problems, Diagnostic Trouble Codes (DTCs) for ECU and ABS, Component Testing Procedures
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair and Replacement
Disassembly And Assembly:
Detailed step-by-step instructions for component removal, overhaul, and reinstallation
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, detailed diagnostics, component-level repair, and complete overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Likely searchable text (depending on original scan quality)
Printable:
Yes
Print Quality
Quality Assessment:
Variable (dependent on original source scan, but generally expected to be high for professional manuals)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Engine Family:
BMW M20
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
8.5:1 (typically for 325i)
Valve Train:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
Performance
Horsepower:
168-170 hp @ 5800-6000 rpm (approx. for 325i)
Torque:
164-167 lb-ft @ 4300-4750 rpm (approx. for 325i)
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Premium Gasoline (91 Octane or higher recommended)
Engine Management
Ignition System:
Electronic Ignition with Knock Control
Cooling System
Cooling Type:
Liquid-Cooled
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-Speed Manual Transmission
Optional
Transmission Type:
ZF 4HP22 4-Speed Automatic Transmission
Features
Clutch:
Hydraulically Actuated Single Dry Plate Clutch
Differential:
Standard Open Differential, Optional Limited Slip Differential (LSD)
📐 Dimensions
Exterior
Length:
Approx. 4340 mm (170.9 in)
Width:
Approx. 1675 mm (65.9 in)
Height:
Approx. 1375 mm (54.1 in)
Wheelbase:
Approx. 2570 mm (101.2 in)
Weights
Curb Weight:
Approx. 1250-1350 kg (2756-2976 lbs) depending on body style and equipment
Gross Vehicle Weight Rating:
Varies by model and configuration
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official data available from this era; E30 chassis generally known for robust construction and good crashworthiness for its time.
Active Features
Brakes:
Front: Ventilated Discs, Rear: Solid Discs. Optional ABS (Anti-lock Braking System) on later models.
Suspension:
Independent Front Suspension (MacPherson struts), Semi-Trailing Arm Rear Suspension (designed for stability).
Passive Features
Seatbelts:
3-point front and rear seat belts
Body Construction:
Unitized steel body construction with crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory premium audio systems (e.g., Blaupunkt, Bavaria C) with cassette player. Optional CD players available on later models or as aftermarket upgrades.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) on some models, typically 4-wheel ABS.
Cruise Control:
Available as an option on most models.
Connectivity
Connectivity Features:
None in the modern sense (no Bluetooth, USB, etc.). Primarily analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (e.g., standard vs. long-life).
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Fluid Specifications
Engine Oil Type:
API SG/SH or ACEA A2/A3 rated synthetic oil. Viscosity typically 5W-30, 5W-40, or 10W-40 depending on climate. Consult manual for exact specs.
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 Quarts) with filter change.
Coolant Type:
BMW Blue Antifreeze/Coolant or equivalent ethylene glycol-based coolant (50/50 mix with distilled water).
Transmission Fluid Manual:
SAE 75W-90 or SAE 75W-80 GL-4 Gear Oil.
Transmission Fluid Automatic:
Dexron II or Dexron III ATF (Automatic Transmission Fluid).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Failures:
Cooling system component degradation (radiator, hoses, water pump), aging rubber bushings (suspension, engine mounts), fuel distributor issues, fuel pump failure, electrical gremlins (due to age of wiring), timing belt wear (M20 is a timing belt engine).
Rust Prone Areas:
Wheel wells, rocker panels, jacking points, rear shock towers, battery tray.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused, sporty vehicles with excellent engineering and build quality.
Model Evolution
E30 Introduction:
The E30 platform was introduced in 1982 as the successor to the E21 3 Series. It marked a significant evolution in BMW's compact executive car line.
325 Introduction:
The 325 and 325e (Eta) models, featuring the larger M20 engine, were introduced in 1983 for the 1984 model year. The 325i (higher compression) arrived later, offering improved performance.
Production
Production Years:
1982-1994 (for the E30 platform globally), with 325/325i models prominent in the later half of this range (1985-1991).
Manufacturing Locations:
Primarily Germany (Dingolfing, Munich)
🏆 Awards & Recognition
Recognitions
Automotive Press Accolades:
Consistently praised by automotive journalists of the era for its driving dynamics, build quality, and sporty character. Often featured on 'best of' lists for sports sedans.
Ratings
Performance Class:
Sport Compact / Entry-Luxury Sports Sedan
Certifications
Manufacturer Standards:
Adheres to BMW's rigorous engineering and quality standards of the period.
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