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BMW 3 Series 325 1992-1998 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Sub Model: 325i / 325is / 325ic Codes Chassis Code: E36 Generation Generation: Third Generation (E36) Generation Years: 1991-1999 (North America:...
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BMW 3 Series 325 1992-1998 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Sub Model:
325i / 325is / 325ic
Codes
Chassis Code:
E36
Generation
Generation:
Third Generation (E36)
Generation Years:
1991-1999 (North America: 1992-1998 for 325 models)
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe/Convertible
Target Audience:
Enthusiast owners, independent repair shops, and DIY mechanics seeking detailed technical information for maintenance and repair.
Competitive Analysis
Competitors:
Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS (XE10), Infiniti G20 (P10).
Key Features
Vehicle Appeal:
Renowned for its driving dynamics, balanced chassis, premium interior, and inline-six engine performance.
Manual Value Proposition:
Provides comprehensive, factory-level repair and maintenance guidance, empowering owners to service their vehicles effectively and reduce reliance on costly dealerships.
📋 Manual Details
Coverage Areas
Applicable Years:
1992, 1993, 1994, 1995, 1996, 1997, 1998
Page Count
Page Count:
750
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling.
Engine Electrical:
Ignition system, fuel injection (Bosch Motronic variants), starting system, charging system, engine sensors and control units (DME).
Transmission:
Manual and automatic transmission service, overhaul, clutch, torque converter, shift mechanisms, fluid specifications, gearbox diagnostics.
Drivetrain:
Driveshafts, CV joints, differential, axle shafts, wheel bearings, universal joints.
Suspension:
Front and rear suspension components, struts, shock absorbers, control arms, bushings, springs, anti-roll bars, wheel alignment procedures and specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, hydraulic pump, fluid specifications, bleeding procedures.
Brakes:
Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System) diagnostics and repair, brake fluid specifications, bleeding procedures, caliper and rotor replacement.
Electrical System:
Full vehicle wiring diagrams, lighting systems, instrument cluster, switches, relays, fuses, power windows, central locking, mirrors, audio system, climate control module.
Bodywork:
Body panel removal and installation, door mechanisms, hood and trunk latches, interior trim, bumpers, glass replacement, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system diagnostics, refrigerant handling, compressor, condenser, evaporator, blower motor, control panel.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulation, EVAP system.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, belt inspections and replacement.
Diagnostics Troubleshooting:
Step-by-step diagnostic flowcharts for common and uncommon issues, error code interpretation, symptom-based troubleshooting.
Repair Overhaul:
Detailed instructions for component removal, disassembly, inspection, repair, assembly, and reinstallation of all major vehicle systems.
Component Replacement:
Specific procedures for replacing parts such as alternators, starter motors, water pumps, fuel pumps, radiators, brake calipers, suspension components.
Wiring Diagrams:
Comprehensive and clear wiring schematics for all electrical systems, including pinouts and connector details.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications, and performance data.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Format Details:
Portable Document Format (PDF), allowing for digital access, searchability, and printing.
Print Quality
Image Clarity:
High-resolution images, diagrams, and schematics ensuring clarity for repair and diagnostic purposes.
Binding Type
Binding Type:
Digital (PDF), no physical binding required.
Paper Type
Paper Type Equivalent:
N/A (Digital Format). High-quality digital rendering suitable for screen viewing and printing on standard paper.
⚙️ Engine Specifications
Primary Engine
Engine Code:
M50B25 (Early) / M52B25 (Later)
Engine Type:
Inline 6-cylinder, DOHC (Double Overhead Camshaft), 24 valves
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
189 hp @ 5900-6000 rpm (M50B25); 170 hp @ 5500 rpm (M52B25 in some markets/years)
Torque:
181 lb-ft @ 4200-4700 rpm (M50B25); 177 lb-ft @ 3950 rpm (M52B25)
Redline:
6500 rpm
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Engine Management
Dme System:
Digital Motor Electronics (DME) control unit, typically Motronic M3.3 or M3.3.1.
🔧 Transmission
Standard
Standard Transmission:
Getrag 260/5 (5-speed manual)
Optional
Optional Transmission:
ZF 4HP22 (4-speed automatic)
Features
Clutch Type:
Single dry plate, hydraulically actuated diaphragm spring clutch (manual).
Transmission Fluid Manual:
BMW MTF-LT-1 or equivalent (Manual); ATF Dexron III or equivalent (Automatic).
📐 Dimensions
Exterior
Sedan Length:
Approx. 174.5 inches (4432 mm)
Coupe Length:
Approx. 174.5 inches (4432 mm)
Convertible Length:
Approx. 174.5 inches (4432 mm)
Width:
Approx. 67.3 inches (1709 mm)
Height Sedan Coupe:
Approx. 54.7 inches (1390 mm)
Height Convertible:
Approx. 53.5 inches (1359 mm)
Wheelbase:
Approx. 106.1 inches (2695 mm)
Cargo
Trunk Volume Sedan Coupe:
Approx. 13.5 cu ft (382 liters)
Weights
Curb Weight Manual:
Approx. 3260-3350 lbs (1480-1520 kg)
Curb Weight Automatic:
Approx. 3370-3470 lbs (1530-1575 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Four stars (for 1997 model)
NHTSA Front Impact Passenger:
Four stars (for 1997 model)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional ASC+T (Automatic Stability Control and Traction)
Passive Features
Airbags:
Driver and passenger airbags standard.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners.
Body Structure:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory cassette or CD players, often with premium sound system options (e.g., Harman Kardon).
Climate Control:
Manual or automatic climate control (ECC - Electronic Climate Control) with recirculate and defog functions.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Features:
Basic connectivity features for the era, including power outlets and provision for car phone integration (optional).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions and oil type used (check manual for specifics).
Coolant Flush Interval:
Every 2-3 years or as recommended by the manual.
Brake Fluid Flush Interval:
Every 2 years.
Spark Plug Interval:
Approximately 60,000 miles (96,000 km) for standard plugs, potentially longer for platinum/iridium variants.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or equivalent synthetic oil, typically SAE 0W-40 or 5W-40.
Engine Oil Capacity:
Approx. 6.5 quarts (6.2 liters) with filter change.
Coolant Type:
BMW Blue Antifreeze or equivalent (50/50 mix with distilled water).
Power Steering Fluid:
Pentosin CHF 11S or equivalent hydraulic fluid.
Known Issues
Cooling System:
Plastic expansion tank can become brittle and crack; water pump and thermostat failures are common with age.
Suspension Bushings:
Front control arm bushings and rear trailing arm bushings wear out, leading to vague steering and poor handling.
Headliner:
The fabric adhesive fails over time, causing the headliner to sag.
Oil Filter Housing Gasket:
Oil leaks from the oil filter housing gasket are common on M52 engines.
Window Regulators:
Plastic components in window regulators can break, causing windows to fall down.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Known for 'The Ultimate Driving Machine', emphasizing performance, engineering, and driver engagement.
Model Evolution
E36 Introduction:
Introduced in Europe in 1990 and North America in 1991 for the 1992 model year. Replaced the successful E30 generation.
E36 Facelift:
Minor facelift (LCI) occurred in 1996, with subtle styling tweaks and updated interior features.
Production
Manufacturing Locations:
Primary production in Dingolfing, Germany. Some assembly in Rosslyn, South Africa.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Car and Driver's 10Best list multiple times during its production run.
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