BMW 3 Series 320 320i 323i 325i (E21) Service & Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E21 Engine Variants Covered: 320, 320i, 323i, 325i Codes Internal Codes: E21 Generation 👋 Introduction Market Position Target Audience:...

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Type: Car

Vendor:

Sku: 559048

Tags: 3 Series 320 320i 323i 325i BMW Car Cars E21

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Chassis Code:

Engine Variants Covered:

320, 320i, 323i, 325i

Codes

Internal Codes:

E21 Generation

👋 Introduction

Market Position

Target Audience:

BMW dealership mechanics and skilled DIY enthusiasts seeking professional-grade repair information.

Competitive Analysis

Manual Quality:

Considered one of the most comprehensive and authoritative resources for the E21 generation, directly from BMW's technical documentation.

Key Features

Instruction Style:

Step-by-step instructions facilitate complex repairs.

Visual Aid Quality:

Clear pictures and exploded views enhance understanding of component relationships and assembly.

Scope:

Encompasses all major mechanical, electrical, and body systems for the specified E21 models.

📋 Manual Details

Coverage Areas

Vehicle Coverage:

BMW 3 Series E21 chassis variants: 320, 320i, 323i, 325i

Page Count

Total Pages:

Manual Type

Type:

Service & Repair Manual (Dealership Level)

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, rebuilding, timing, valve adjustments, piston and rod installation, crankshaft and bearing service, cylinder head service, oil pump and system.

Engine Fuel System:

Carburetor (e.g., Zenith, Solex) overhaul and adjustment, fuel injection (K-Jetronic for later models) system diagnosis and repair, fuel pump and filter replacement, fuel lines.

Engine Cooling System:

Radiator, water pump, thermostat, hoses, fan clutch, coolant specifications and flushing procedures.

Engine Ignition System:

Distributor service, spark plug selection and gap, ignition timing, coil and lead testing, electronic ignition components (where applicable).

Transmission Manual:

Clutch service, gear selection mechanism, transmission disassembly and reassembly, gear oil specifications and capacities, driveshaft and CV joint service.

Transmission Automatic:

Automatic transmission diagnosis, fluid type and level checks, torque converter service, linkage adjustments (if applicable).

Brakes:

Disc brake service (front and rear), caliper overhaul, brake pad and rotor replacement, master cylinder, brake booster, parking brake adjustment, brake fluid specifications.

Suspension:

Front and rear suspension components, shock absorber replacement, ball joint and tie rod end service, wheel alignment specifications, bushings.

Steering:

Steering gear service, power steering system (if equipped), steering column, tie rods, and linkages.

Electrical System:

Wiring diagrams, battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses and relays, instrument cluster, starting and charging system troubleshooting.

Body And Chassis:

Body panel removal and installation, doors, hood, trunk, interior trim, glass replacement, chassis component identification, rust repair considerations.

Heating Ventilation Air Conditioning:

HVAC system components, blower motor, heater core, evaporator core, refrigerant types (R12 for this era), system leak testing, dash control panel.

Procedures Included

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic procedures for common drivability issues, electrical faults, cooling system problems, and brake system malfunctions.

Repair:

Step-by-step instructions for major component repairs and overhauls, including engine rebuilds, transmission repairs, and brake system overhauls.

Diagnostics:

Detailed diagnostic trees and fault code interpretation (if applicable for the era), using test equipment and visual inspection.

Special Tools:

Identification of specific tools and equipment required for various repair and maintenance procedures.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic maintenance and adjustments to full engine and transmission rebuilds, including detailed diagnostic information.

Illustrations:

Clear pictures and exploded view illustrations for component identification and assembly/disassembly guidance.

Schematics:

Inclusion of electrical wiring diagrams and vacuum schematics for accurate troubleshooting and repair.

Specifications:

Detailed technical specifications for all covered systems, including torque values, clearances, fluid capacities, and performance data.

📊 Manual Specifications

File Format

Format:

Compatibility:

Windows, Mac, Linux

Print Quality

Printability:

Printable without restriction

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Searchability

Text Search:

Yes (typically for PDF manuals, allowing keyword searches)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-4 and Inline-6, SOHC, naturally aspirated

320/320I Engine Code:

M10 series (e.g., M10B18, M10B20)

320/320I Displacement:

1.8L (1766 cc) and 2.0L (1990 cc)

323I Engine Code:

M20 series (e.g., M20B23)

323I Displacement:

2.3L (2316 cc)

325I Engine Code:

M20 series (e.g., M20B25)

325I Displacement:

2.5L (2494 cc)

Performance

320I Hp Approx:

~100-105 hp (depending on market and specific version)

323I Hp Approx:

~140-143 hp

325I Hp Approx:

~170-171 hp

Fuel System

Induction Early Models:

Carbureted (e.g., Zenith 35/40 INAT, Solex C32/32 DIDTA)

Induction Later Models:

Bosch K-Jetronic CIS (Continuous Injection System) for 320i (M10), 323i, and 325i

Fuel Type:

Unleaded gasoline (premium recommended)

🔧 Transmission

Standard

Type:

4-speed manual, 5-speed manual ( Getrag 245)

Optional

Type:

3-speed ZF automatic (e.g., 3HP22)

Features

Clutch Type:

Single dry plate diaphragm spring clutch

Rear Axle:

Independent rear suspension with semi-trailing arms, limited-slip differential available on some models

📐 Dimensions

Exterior

Wheelbase:

Approx. 2565 mm (101.0 in)

Length:

Approx. 4350 mm (171.3 in)

Width:

Approx. 1610 mm (63.4 in)

Height:

Approx. 1380 mm (54.3 in)

Weights

Curb Weight:

~1150 - 1250 kg (2535 - 2755 lbs) depending on engine and equipment

🛡️ Safety Features

Ratings

Era Specific Ratings:

Limited official crash test data available from modern standards; designed to meet 1970s/1980s safety regulations.

Active Features

Brakes:

Front ventilated discs, rear discs (or drums on some early 320 models)

Steering:

Recirculating ball steering (power steering optional)

Passive Features

Seat Belts:

3-point seat belts (front), 2-point seat belts (rear, often optional or lap belts)

Body Structure:

Reinforced passenger cell, crumple zones (typical for the era)

💡 Technology Features

Infotainment

Radio:

Factory AM/FM radio, often with cassette player for later models. Aftermarket head units common.

Speakers:

Typically 2-4 speaker configuration.

Driver Assistance

Optional on some later models, particularly 6-cylinder variants.

Connectivity

Power Windows:

Optional on many models, standard on higher trims.

Air Conditioning:

Optional, often a dealer-installed or factory option.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, depending on driving conditions (refer to manual for precise intervals).

Coolant Flush Interval:

Every 2 years or 30,000 miles (48,000 km)

Spark Plug Replacement:

Approximately every 15,000 - 30,000 miles (24,000 - 48,000 km), depending on plug type and wear.

Fluid Specifications

Engine Oil:

API SG or SH, SAE 10W-40 or 15W-50 (check manual for specific recommendations based on climate)

Coolant:

BMW Antifreeze/Coolant (blue or green type, typically a 50/50 mix with distilled water)

Brake Fluid:

DOT 3 or DOT 4

Transmission Fluid Manual:

GL-4 gear oil, SAE 75W-90 or 80W-90 (specific BMW part numbers recommended in manual)

Transmission Fluid Automatic:

Dexron-III or equivalent (check manual for exact specification)

Known Issues

Rust Prone Areas:

Wheel wells, rocker panels, rear shock towers, door bottoms, battery tray area.

Cooling System:

Cracked radiator end tanks, leaking water pump seals, failed thermostat, worn fan clutch.

Fuel System Cis:

Leaking fuel distributor seals, faulty frequency valve, clogged injectors, vacuum leaks affecting mixture.

Electrical Components:

Degraded wiring insulation (especially around engine bay), faulty grounds, unreliable dashboard illumination, starter solenoid issues.

Suspension Bushings:

Worn control arm bushings, trailing arm bushings, and sway bar bushings leading to imprecise handling and knocking sounds.

📚 Vehicle History

Brand Heritage

Bmw Motorsport Legacy:

The E21 built upon BMW's reputation for sporty sedans and coupe-like styling, continuing the lineage of the highly successful 02 Series.

Model Evolution

Introduction:

Introduced in 1975 as a replacement for the BMW 02 Series, establishing the iconic 3 Series identity.

Design Philosophy:

Featured BMW's signature Hofmeister kink, kidney grille, and a driver-oriented cockpit.

Engine Lineup Expansion:

Initially offered with M10 4-cylinder engines (320i), later expanded to include the M20 6-cylinder engines (320/6, 323i, 325i) for increased performance.

Production

Production Years:

1975-1983

Manufacturing Locations:

Germany (e.g., Munich, Dingolfing)