BMW 325i E30 Complete Workshop Service Repair Manual 1987 1988 1989 1990 1991

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🏷️ Basic Information Identification Make: BMW Model: 325i Chassis Code: E30 Generation Generation Identifier: E30 Codes Engine Code Common: M20B25 👋 Introduction Market Position Positioning: The BMW E30 325i occupied...

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Type: Car

Vendor:

Sku: 570740

Tags: 1987 1988 1989 1990 1991 325i BMW Car Cars E30 Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Generation

Generation Identifier:

Codes

Engine Code Common:

M20B25

👋 Introduction

Market Position

Positioning:

The BMW E30 325i occupied a key position in the premium compact sports sedan market, known for its driving dynamics and inline-six engine.

Competitive Analysis

Competitors:

Competed against vehicles like the Mercedes-Benz 190E, Audi 80/90, and Alfa Romeo 75.

Key Features

Driving Dynamics:

Renowned for its balanced chassis, rear-wheel drive layout, and engaging steering, providing a true driver's car experience.

Engine Performance:

The M20 inline-six engine offered a smooth power delivery and strong mid-range torque, characteristic of BMW's engine design.

Build Quality:

Embodied BMW's reputation for solid construction and durable engineering, contributing to its long-term appeal.

📋 Manual Details

Coverage Areas

Vehicle Years:

1987, 1988, 1989, 1990, 1991

Page Count

Estimated Pages:

Varies by specific manual version, but typically extensive for a complete workshop manual.

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system, fuel injection system.

Engine Electrical:

Ignition system, starter motor, alternator, battery, engine control unit (ECU) wiring diagrams, sensors, fuel pump control.

Transmission Manual:

Clutch, gearbox assembly, shift linkage, flywheel, torque specifications.

Transmission Automatic:

Torque converter, hydraulic control system, valve body, planetary gear sets, transmission control unit (TCU) wiring diagrams, fluid and filter service.

Drivetrain:

Driveshaft, universal joints, differential, axles, CV joints.

Suspension:

Front and rear suspension components (struts, shocks, control arms, springs, sway bars), wheel bearings, alignment specifications.

Steering:

Steering rack, power steering pump, steering column, tie rods, steering linkage, fluid specifications.

Brakes:

Front and rear brake systems (discs, pads, calipers, master cylinder, brake lines), parking brake, ABS (if equipped), bleeding procedures, specifications.

Electrical System:

Lighting systems (headlights, taillights, interior lights), power windows, power locks, horn, wiper system, fuse box diagrams, relay locations, wiring schematics.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulator, emissions control systems (e.g., EVAP).

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes, hangers, specifications.

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, glass replacement, structural components, rust prevention.

Heating And Air Conditioning:

HVAC system components, refrigerant handling, blower motor, climate controls, heater core, evaporator core.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes.

Troubleshooting:

Diagnostic charts for common problems, fault codes interpretation, symptom-based troubleshooting.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation for all major systems.

Diagnostics:

Electrical system diagnostics, engine performance diagnostics, fuel system diagnostics, ABS diagnostics.

Specifications And Measurements:

Torque specifications, clearances, dimensions, fluid capacities, electrical resistance values.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Printability:

Printable, allowing users to print specific sections or the entire manual.

Binding Type

Binding Type If Printed:

N/A (Downloadable Format)

Paper Type

Paper Type If Printed:

N/A (Downloadable Format)

Searchability

Text Search:

Typically searchable text within the PDF, enabling quick access to specific topics.

⚙️ Engine Specifications

Primary Engine

Engine Model:

M20B25

Engine Configuration:

Inline 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

2494 cc (2.5 Liters)

Performance

Horsepower:

Approximately 168 hp (125 kW) @ 5800 rpm (depending on market and specific year variations)

Torque:

Approximately 164 lb-ft (222 Nm) @ 4300 rpm (depending on market and specific year variations)

Fuel System

Fuel Delivery:

Bosch Motronic electronic fuel injection (EFI)

Fuel Type:

Unleaded gasoline (typically 91-98 RON / 87-93 AKI)

Cooling System

Coolant Type Specification:

BMW Blue Antifreeze/Coolant (G48 type) or equivalent glycol-based coolant with corrosion inhibitors.

Lubrication System

Oil Capacity With Filter:

Approximately 4.75 liters (5.0 US quarts) - consult manual for exact capacity and specific oil grades.

Recommended Oil Viscosity:

SAE 20W-50 or 15W-40 for warmer climates, SAE 10W-40 or 5W-40 for colder climates. Consult manual for specific BMW LL-XX approvals.

🔧 Transmission

Standard

Transmission Type:

5-speed manual transmission

Optional

Transmission Type:

4-speed automatic transmission (ZF 4HP22)

Features

Clutch Type:

Single dry plate, hydraulic actuation

Manual Transmission Fluid Spec:

BMW MTF LT-1 or an equivalent high-quality manual transmission fluid (GL-4 rated).

Automatic Transmission Fluid Spec:

Dexron III or an equivalent ATF (Automatic Transmission Fluid) meeting the specified quality.

📐 Dimensions

Exterior

Length:

Approx. 4330 mm (170.5 in)

Width:

Approx. 1680 mm (66.1 in)

Height:

Approx. 1380 mm (54.3 in)

Wheelbase:

Approx. 2570 mm (101.2 in)

Weights

Curb Weight:

Approx. 1260-1300 kg (2778-2866 lbs) depending on equipment.

🛡️ Safety Features

Ratings

Crash Test Results:

Specific official crash test ratings for this era might be limited. However, the E30 chassis was known for its robust safety cell and good structural integrity for its time.

Active Features

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

Passive Features

Airbags:

Driver-side airbag became standard in later E30 production years (around 1990/1991), optional prior.

Seatbelts:

Three-point inertia-reel seatbelts for front and rear occupants.

Chassis Design:

Reinforced A and B pillars, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory premium sound system (e.g., Bavaria C) with AM/FM radio, cassette player. Aftermarket head unit installation is common.

Driver Assistance

Available ABS (as noted in safety section) provided early electronic stability intervention.

Connectivity

Original Connectivity:

Limited to analog systems; no integrated Bluetooth or advanced telematics. Analog radio antenna is standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, depending on driving conditions and oil used. Consult manual for precise recommendations.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Platinum plugs often rated for 60,000-100,000 miles (96,000-160,000 km). Consult manual for specific plug type and interval.

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).

Timing Belt Replacement:

Crucial maintenance item. Typically every 60,000 miles (96,000 km) or 5 years for M20 engines. Failure results in catastrophic engine damage.

Fluid Specifications

Brake Fluid:

DOT 4 or DOT 3 (consult manual for exact specification and performance requirements).

Power Steering Fluid:

Pentosin CHF 11S or an equivalent hydraulic fluid meeting BMW specifications.

Known Issues

Engine Management:

E28/E30 M20 engines can suffer from AFM (Air Flow Meter) issues, failing fuel pump relays, and coolant temperature sensor failures.

Suspension Wear:

Worn control arm bushings, ball joints, and shock absorbers are common due to age and mileage. Subframe bushings can also degrade.

Rust:

Common rust areas include wheel arches, rocker panels, battery tray, and rear strut towers. Proper inspection and prevention are vital.

Electrical Gremlins:

Age-related degradation of wiring insulation, corrosion in connectors, and failing relays can lead to various electrical issues.

Headliner:

The fabric headliner can sag and delaminate over time.

📚 Vehicle History

Brand Heritage

Heritage Context:

BMW has a long-standing reputation for performance, engineering, and driver-focused vehicles, tracing its roots back to the early 20th century.

Model Evolution

E30 Lineage:

The E30 generation (produced from 1982 to 1994) was a pivotal model for BMW, establishing the compact executive car segment and evolving significantly through its production run.

325I Introduction:

The 325i variant, featuring the M20 inline-six engine, became a benchmark for performance and refinement in its class, particularly from the mid-1980s onwards.

Production

Production Years For E30:

1982-1991 (sedan, coupe, convertible), 1983-1991 (touring), 1986-1991 (convertible), with specific 325i variants covered by this manual from 1987-1991.

Manufacturing Locations:

Primarily produced in Germany (Munich), with some assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Automotive Press:

The E30 3 Series was widely praised by automotive journalists for its handling, performance, and build quality, often appearing on 'best of' lists for its era.

Performance Credentials:

Successful in motorsport, including touring car championships, reinforcing its performance image.

Certifications

Design Awards:

The E30's clean and timeless design is often cited as a BMW design classic, contributing to its enduring popularity.