🏷️ Basic Information

Make:

BMW

Model:

325i

Model Designation:

E30

Chassis Code:

E30

Product Name:

BMW 325i 1987-1991 Full Service Repair Manual

Generation Code:

E30

Engine Codes Covered:

M20B25

👋 Introduction

Market Positioning:

The E30 325i was positioned as a sporty, premium compact executive car, known for its driving dynamics and build quality.

Key Competitors:

Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Ford Sierra XR4i, Volvo 240

Driving Dynamics:

Renowned for its balanced chassis, rear-wheel-drive layout, and engaging steering.

Engine Performance:

The M20 inline-six engine offered a smooth power delivery and a characteristic BMW sound.

Build Quality:

Exceptional build quality and durability, characteristic of BMW vehicles from this era.

Target Audience:

DIY mechanics, BMW enthusiasts, restoration specialists, and professional workshops.

📋 Manual Details

Years Covered:

1987, 1988, 1989, 1990, 1991

Body Styles Covered:

Sedan, Coupe, Convertible, Touring (Wagon)

Regions Of Operation Covered:

Global (primarily North American and European specifications)

Estimated Page Count:

800+

Manual Type:

Full Service Repair Manual

Manual Subtype:

Factory-level Workshop Manual

Language:

English

Format:

Digital (PDF)

File Type:

Searchable PDF

📖 Manual Coverage

Engine Mechanical:

Full overhaul, diagnostics, repair, components (cylinder head, block, pistons, crankshaft, camshaft, timing)

Engine Electrical:

Ignition system, fuel injection system (Bosch Motronic), starting system, charging system, sensors, ECU diagnostics

Fuel System:

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

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan clutch, bleeding procedures

Exhaust System:

Manifolds, catalytic converter, mufflers, exhaust pipes, oxygen sensors

Transmission Manual:

Clutch assembly, gearbox overhaul, shift linkage, fluid changes

Transmission Automatic:

Gearbox diagnostics, fluid changes, seal replacement, torque converter

Drivetrain:

Driveshafts, universal joints, differential, axle shafts, wheel bearings

Suspension Front:

McPherson struts, control arms, ball joints, tie rods, sway bar, bushings

Suspension Rear:

Trailing arms, shock absorbers, springs, control arms, bushings

Steering System:

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

Brake System:

Front discs, rear discs (or drums on some early models), calipers, master cylinder, ABS (where equipped), brake fluid flushing

Electrical System:

Wiring diagrams, fuses, relays, lighting, horn, wipers, power windows, central locking

Climate Control:

HVAC system, blower motor, heater core, A/C system (refrigerant handling with caution), controls

Body And Interior:

Door panels, dashboard, seating, trim, exterior body panels, glass replacement

Paint And Corrosion:

Information on prevention and repair, though detailed bodywork is less emphasized than mechanicals

Routine Maintenance:

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

Troubleshooting Guides:

Diagnostic flowcharts, common fault finding for various systems

Component Replacement:

Step-by-step guides for major component removals and installations

Rebuild Procedures:

Detailed rebuild instructions for engines, transmissions, and other major units

Electrical Diagnostics:

Using multimeters, testing sensors, interpreting wiring diagrams

Suspension Alignment:

Specifications for camber, caster, toe, and procedures for adjustment

Wheel And Tire Service:

Mounting, balancing, rotation, specifications

Depth Of Coverage:

Comprehensive: from basic maintenance to full engine and transmission rebuilds

Diagnostic Capabilities:

Detailed explanation of diagnostic codes and procedures for the Motronic system

Technical Diagrams:

Includes exploded views, schematics, and detailed illustrations

📊 Manual Specifications

File Format:

PDF

Searchability:

Full text searchable

Printability:

Printable pages

Image Resolution:

High-resolution scans for clarity of diagrams and text

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code:

M20B25

Engine Type:

Inline 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

2494 cc (2.5 Liters)

Horsepower Std E:

168 hp @ 5800 rpm

Torque Std E:

224 Nm (165 lb-ft) @ 4500 rpm

Redline:

6500 rpm

Fuel Injection:

Bosch Motronic ML-Jetronic

Fuel Type:

Unleaded gasoline (Premium recommended)

Coolant Type:

BMW Antifreeze/Coolant (or equivalent ethylene glycol based, silicate-free)

Oil Capacity:

4.5 Liters (4.8 US Quarts) with filter change

Recommended Oil Viscosity:

10W-40, 15W-50 (depending on climate, consult manual)

Spark Plugs:

Bosch W8AC or equivalent (check specific service bulletins)

🔧 Transmission

Standard Transmission:

Getrag 260 5-speed manual transmission

Optional Transmission:

ZF 4HP22 4-speed automatic transmission

Transmission Fluid Manual:

BMW ATF Dexron II (or equivalent)

Transmission Fluid Automatic:

BMW ATF Dexron II (or equivalent)

Clutch Type:

Hydraulically operated single dry plate clutch

Rear Axle Ratio:

3.64:1 (common for manual, variations may exist)

📐 Dimensions

Wheelbase:

2565 mm (101 inches)

Length:

4340 mm (170.9 inches)

Width:

1674 mm (65.9 inches)

Height:

1370 mm (53.9 inches)

Wheel Bolt Pattern:

5x120 mm

Tire Size Standard:

205/55 VR 15 (common for 325i, check VIN for specifics)

Curb Weight Manual:

Approx. 1300 kg (2866 lbs)

Curb Weight Automatic:

Approx. 1340 kg (2954 lbs)

🛡️ Safety Features

Crash Test Information:

Specific NHTSA/Euro NCAP ratings for this era are less comprehensive than modern vehicles; however, E30s were known for solid structure.

ABS:

Optional on early models, standard on later 325i models (Bosch ABS II).

Seatbelts:

Three-point inertia-reel seatbelts, often with pre-tensioners.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Audio System:

Factory cassette radio with optional CD player, basic AM/FM tuner.

Speaker Configuration:

Typically 4 speakers (2 front, 2 rear), optional premium sound.

Cruise Control:

Standard on most 325i models.

Traction Control:

Optional/Limited availability on later models, typically referred to as ASC (Automatic Stability Control).

Connectivity Features:

None (This era predates modern connectivity features like Bluetooth or USB).

🔧 Maintenance

Oil Change Interval:

Every 7,500 - 10,000 miles or 12 months (depending on driving conditions, consult manual).

Spark Plug Replacement Interval:

Every 30,000 miles (check manual for specific type and gap).

Timing Belt Replacement Interval:

The M20 engine uses a timing chain, not a belt, requiring less frequent service, but inspection of chain tensioner and guides is recommended.

Coolant Flush Interval:

Every 24 months or 30,000 miles.

Brake Fluid Flush Interval:

Every 24 months.

Brake Fluid Type:

DOT 3 or DOT 4 (consult manual)

Power Steering Fluid:

ATF Dexron II (or equivalent)

Common Issues Engine:

Cooling system leaks (hose failures, radiator, water pump), head gasket issues, idle control valve problems, fuel distributor issues.

Common Issues Suspension:

Worn bushings (control arm, sway bar, subframe), worn shock absorbers/struts, ball joint wear.

Common Issues Electrical:

Instrument cluster failures, failing door lock actuators, corrosion on grounds and connectors, fuel pump relay failures.

Common Issues Body:

Rust (wheel wells, rocker panels, battery tray area), headliner sagging, door seals deteriorating.

📚 Vehicle History

Bmw Philosophy:

BMW's 'Ultimate Driving Machine' philosophy was deeply embedded in the E30 generation.

E30 Introduction:

The E30 chassis replaced the E21 and was produced from 1982 to 1994 (globally). The 325i model arrived in 1987 as a significant upgrade over the 323i.

Facelift:

Early E30s (pre-1987) featured chrome bumpers and smaller mirrors. Later models (like those covered here) received larger plastic bumpers ('plastic bumpers' or 'late model'), revised grilles, and updated interior elements.

Production Period:

1987-1991 for the 325i model variant covered by this manual.

Manufacturing Locations:

Primarily Dingolfing, Germany.

🏆 Awards & Recognition

Car And Driver 10Best:

The E30 generation, including models like the 325i, was frequently featured on Car and Driver's 10Best lists for its performance and handling.

General Reputation:

Consistently praised by automotive journalists for its driving pleasure and sporty character, solidifying BMW's reputation in the compact sports sedan segment.