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BMW 3 Series 325i 1992-1998 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Specific Model: 325i Body Style: Sedan (E36 chassis), Coupe (E36 chassis) Generation Chassis Code: E36 Generation Years: 1992-1998 (North America market...
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BMW 3 Series 325i 1992-1998 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Specific Model:
325i
Body Style:
Sedan (E36 chassis), Coupe (E36 chassis)
Generation
Chassis Code:
E36
Generation Years:
1992-1998 (North America market for 325i)
👋 Introduction
Market Position
Market Position:
The BMW 3 Series E36 was a highly successful compact executive car, known for its sporty handling, refined engineering, and premium feel. The 325i represented a strong mid-range performance offering within the E36 lineup.
Competitive Analysis
Competitors:
Primary competitors included the Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS, and Infiniti G20.
Key Features
Key Features:
Rear-wheel drive, sophisticated independent suspension, inline-six engines, driver-focused interior, robust build quality.
📋 Manual Details
Coverage Areas
Covered 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
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Transmission (manual and automatic), clutch, drive shafts, differential, axles
Chassis:
Suspension (front and rear), steering system, brakes (hydraulic, ABS), wheels and tires
Electrical:
Engine control unit (ECU), lighting, instruments, power windows, mirrors, central locking, audio system, wiring diagrams
Body:
Exterior body panels, interior trim, seats, airbags, HVAC system
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component repair, electrical troubleshooting
Diagnostics:
Troubleshooting charts, symptom analysis, fault code interpretation (where applicable for the era)
Technical Depth
Technical Depth:
Comprehensive, covering routine maintenance to major component overhauls and diagnostics. Includes detailed torque specifications and procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, suitable for clear printing of all diagrams and text.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
Searchability
Searchability:
Typically text-searchable PDF, allowing for quick access to specific topics.
⚙️ Engine Specifications
Primary Engine
Engine Code:
M50B25 (most common)
Engine Type:
Inline 6-cylinder, DOHC, 24-valve
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
Approx. 189 hp @ 5900 rpm
Torque:
Approx. 245 Nm (181 lb-ft) @ 4200 rpm
Fuel System
Fuel Injection:
Bosch Motronic M3.3 (early) or M5.2 (later)
Fuel Type:
Unleaded Premium Unleaded Gasoline (91 Octane or higher recommended)
Cooling System
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 specification) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission (Getrag 260/5)
Optional
Transmission Type:
4-Speed Automatic Transmission (ZF 4HP22 EH)
Features
Rear Axle Ratio:
Typically 3.46:1 (manual), 3.15:1 (automatic)
Fluid Specifications
Manual Transmission Fluid:
SAE 75W-90 Synthetic Gear Oil (BMW recommends specific types; consult manual for exact PN)
Automatic Transmission Fluid:
ZF Lifeguardfluid 5 (LF-5) or equivalent Dexron III/Mercon
📐 Dimensions
Exterior
Length:
Approx. 174.5 inches (Sedan)
Width:
Approx. 67.3 inches
Height:
Approx. 54.5 inches (Sedan)
Weights
Curb Weight:
Approx. 3200-3350 lbs (depending on body style and options)
Wheelbase:
Approx. 106.1 inches
Cargo
Trunk Capacity:
Approx. 14.2 cu ft (Sedan)
🛡️ Safety Features
Ratings
Crash Test Ratings:
While specific NHTSA ratings for this model year may vary, BMWs of this era were generally well-regarded for their safety structure. Consult insurance institute archives for detailed tests.
Active Features
Traction Control:
Optional ASC+T (Automatic Stability Control + Traction)
Braking System:
Four-wheel Anti-lock Braking System (ABS) standard.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
Front and rear three-point safety belts.
💡 Technology Features
Infotainment
Audio System:
Standard cassette player with optional CD player. BMW Professional RDS radio available.
Speaker System:
Typically 6 or 10 speaker Hi-Fi system options.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Onboard Computer:
Optional OBC (On-Board Computer) providing fuel economy, range, and basic system checks.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (or as indicated by the vehicle's Condition Based Service - CBS - system, though early versions were more mileage-based). Consult the manual for precise intervals based on driving conditions.
Spark Plug Replacement:
Approximately every 30,000-60,000 miles, depending on spark plug type (standard vs. long-life platinum/iridium). Manual will specify.
Coolant Flush Interval:
Every 2-4 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change.
Engine Oil Viscosity:
SAE 5W-30 or 5W-40 Synthetic (BMW recommends specific grades; check manual for precise PN and specs).
Brake Fluid Type:
DOT 4 (or BMW Super Blue if available for specific applications, but DOT 4 is standard).
Known Issues
Cooling System Failures:
Plastic coolant expansion tanks can become brittle and crack; water pump impeller can degrade; plastic thermostat housings can leak.
Vanos System:
Variable Valve Timing (VANOS) system can develop issues with seals, leading to rough idle or power loss, though less prevalent than on later M50/M52 variants.
Window Regulators:
Window regulator mechanisms can fail, causing windows to drop.
Oil Leaks:
Valve cover gasket and oil pan gasket are common leak points.
📚 Vehicle History
Brand Heritage
Brand Philosophy:
BMW's heritage is rooted in performance, engineering excellence, and the 'Ultimate Driving Machine' philosophy.
Model Evolution
E36 Introduction:
The E36 generation of the 3 Series was introduced in 1990 (Europe) and 1991 (North America), replacing the highly successful E30. It featured a more modern design, improved aerodynamics, and a stiffer chassis.
325I Positioning:
The 325i was a key model in the E36 lineup, offering a balance of performance and luxury, positioned above the 320i and 325is (which often shared the same engine but different body styles/suspension tuning in some markets) and below the M3.
Production
Production Period:
The E36 325i was produced from 1990 to 1995 globally, with the North American market receiving it from 1992-1995. (The manual covers the specific North American range).
Manufacturing Locations:
Primarily Germany, with some assembly in other locations.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E36 3 Series, including variants like the 325i, was a frequent recipient of Car and Driver's '10Best' list during its production run, acknowledging its exceptional driving dynamics and value.
World Car Of The Year:
While not directly awarded to the 325i, the E36 generation as a whole was highly acclaimed internationally.
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