BMW 325 325i 1996 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Year: 1996 Chassis Code: E36 Codes Engine Code Primary: M50B25TU 👋 Introduction Market Position Vehicle Class: Compact Executive Sedan/Coupe/Convertible. Competitors 1996: Mercedes-Benz...

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Type: Car

Vendor:

Sku: 433651

Tags: 1996 325 325i BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Chassis Code:

Codes

Engine Code Primary:

M50B25TU

👋 Introduction

Market Position

Vehicle Class:

Compact Executive Sedan/Coupe/Convertible.

Competitors 1996:

Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus ES 300, Infiniti G20.

Competitive Analysis

Key Selling Points:

Rear-wheel drive dynamics, refined inline-six engine, build quality, sporty handling, driver-focused interior.

Key Features

Platform Name:

Body Styles Available:

Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon - less common in US).

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Pages:

Hundreds of pages (specific count not provided, but comprehensive)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing chain, lubrication system, cooling system.

Engine Electrical:

Engine control unit (ECU) diagnostics, ignition system, fuel injection system (DME), sensors, actuators, wiring diagrams.

Transmission Manual:

Clutch, gearbox assembly, shift linkage, internal components, servicing, repair.

Transmission Automatic:

Gearbox assembly, hydraulic control system, electronic control unit (TCU), torque converter, servicing, repair.

Drivetrain:

Driveshafts, CV joints, differential, rear axle assembly, servicing, repair.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel bearings, alignment procedures.

Steering:

Power steering system, steering rack, steering column, tie rods, fluid specifications, bleeding procedures.

Brakes:

Front and rear brake systems (discs), ABS (Anti-lock Braking System), hydraulic components, bleeding procedures, pad and rotor replacement, caliper overhaul.

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, wipers, horn, power accessories, fuses, relays, complete wiring diagrams.

Climate Control:

HVAC system, air conditioning (A/C) system, heater core, blower motor, refrigerant handling, diagnostics.

Body And Frame:

Body panel removal and installation, doors, hood, trunk lid, bumpers, interior trim, chassis structure, rust prevention and repair.

Safety Systems:

Airbag system (SRS) diagnostics and replacement procedures, seat belts.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid level checks and top-offs, brake fluid flush, coolant flush.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls, electrical system diagnostics and repair.

Component Replacement:

Detailed instructions for replacing virtually every major and minor component of the vehicle.

Torque Specifications:

Accurate torque values for all critical fasteners.

Diagnostic Procedures:

Step-by-step guidance for diagnosing electrical and mechanical issues, including use of diagnostic tools.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic fluid changes and filter replacements to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repair.

Diagnostic Tools:

Information implicitly supports the use of BMW's proprietary diagnostic tools (e.g., GT1) and general automotive diagnostic equipment.

Special Tools:

Details required special tools for specific procedures.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Readability:

High resolution, allowing for clear printing of text and diagrams.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Simulation:

Simulated, with page breaks and layout consistent with a printed manual.

Searchability

Text Search:

Likely searchable text within the PDF for quick topic retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Engine Code:

M50B25TU (Technical Update)

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Performance

Horsepower:

189 hp @ 5900 rpm

Torque:

181 lb-ft (245 Nm) @ 4200 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Bosch Motronic M5.2)

Fuel Type:

Unleaded Premium Gasoline (91 Octane Recommended)

Engine Management

Bosch Motronic M5.2

Cooling System

Coolant Type:

BMW Blue Antifreeze (or equivalent silicate-free G48 type)

Lubrication System

Oil Capacity:

6.5 Liters (with filter)

Recommended Oil Viscosity:

SAE 5W-30 or 5W-40 (Synthetic recommended)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual (Getrag 260/5)

Optional

Transmission Type:

4-Speed Automatic (ZF 4HP22 EH)

Features

Manual Gear Ratios:

1st: 4.23:1, 2nd: 2.52:1, 3rd: 1.67:1, 4th: 1.24:1, 5th: 1.00:1, Reverse: 3.71:1

Automatic Gear Ratios:

1st: 2.48:1, 2nd: 1.48:1, 3rd: 1.00:1, 4th: 0.71:1

Fluid Specs

Manual Transmission Fluid:

MTF LT-2 (or equivalent API GL-4 75W-90)

Automatic Transmission Fluid:

ATF LT 71141 (or equivalent Dexron III)

Fluid Capacity

Manual Transmission Capacity:

1.5 Liters

Automatic Transmission Capacity:

8.0 Liters (total fill)

📐 Dimensions

Exterior

Length:

Sedan: 174.5 in (4432 mm), Coupe: 171.7 in (4361 mm)

Width:

69.1 in (1755 mm)

Height:

Sedan: 55.4 in (1407 mm), Coupe: 53.6 in (1361 mm)

Wheelbase:

Sedan: 106.0 in (2690 mm), Coupe: 104.7 in (2659 mm)

Weights

Curb Weight:

Approx. 3200-3400 lbs (1450-1540 kg) depending on body style and equipment.

Gross Vehicle Weight Rating:

Approx. 4200 lbs (1905 kg)

Cargo

Trunk Volume:

Approx. 15.0 cu ft (425 L)

🛡️ Safety Features

Ratings

NHTSA Crash Test Ratings:

Driver Front: 4-Star, Passenger Front: 4-Star (results may vary slightly by year/configuration, but generally strong for the era).

Active Features

Standard (Anti-lock Braking System)

Traction Control:

Optional (ASC+T - Automatic Stability Control and Traction)

Passive Features

Airbags:

Driver and Front Passenger Airbags (SRS)

Seatbelts:

3-point inertia-reel seat belts front and rear.

💡 Technology Features

Infotainment

Radio System:

Factory BMW Business or Professional CD/Cassette systems. Optional Nakamichi or other premium audio upgrades.

Display Technology:

Basic LCD displays for radio, climate control, and onboard computer (if equipped).

Driver Assistance

Cruise Control:

Standard

Onboard Computer:

Optional (Check Control system for basic vehicle monitoring)

Connectivity

Auxiliary Input:

N/A (Aftermarket adapter required for modern devices)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, using synthetic oil.

Spark Plug Replacement:

Approximately every 60,000 miles (100,000 km) with quality iridium or platinum plugs.

Coolant Flush:

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

Brake Fluid Flush:

Every 2 years regardless of mileage.

Fluid Specifications

Power Steering Fluid:

ATF Dexron II/III (or Pentosin CHF 11S for some hydraulic systems, check specific system).

Brake Fluid:

DOT 4

Windshield Washer Fluid:

Water/Washer Fluid Mixture

Known Issues

Cooling System:

Plastic coolant expansion tanks prone to cracking, water pump impeller failure (plastic), thermostat housing leaks.

Suspension:

Front control arm bushings (bushings tear), rear trailing arm bushings, sway bar links, shock absorber mounts.

Engine:

VANOS unit issues (rattle on startup, loss of low-end torque), oil pan gasket leaks, CCV (Crankcase Ventilation) system clogging leading to vacuum leaks.

Electrical:

Abs module failures, fuel pump failures, alternator bearing noise, window regulator failures, dashboard illumination issues.

Interior:

Headliner sagging, door panel adhesive failure, seat bolster wear.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure, engineering excellence, performance-oriented luxury.

Model Evolution

E36 Generation:

Third generation of the 3 Series, succeeded the E30 and preceded the E46. Known for significant advancements in chassis, suspension, and engine technology.

1996 Updates:

The M50B25 engine received the 'TU' (technical update) which included VANOS (Variable Valve Timing) on both intake and exhaust camshafts for improved low-end torque and smoother power delivery.

Production

Production Years:

E36 Series: 1990-2000 (specific for 325i: ~1992-1995/1996 in most markets).

Manufacturing Locations:

Germany (Main), South Africa, Austria, Thailand.

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The E36 3 Series platform (including the 325i variants) was a frequent recipient of Car and Driver's '10Best' list during its production run, lauded for its balance of performance, luxury, and value.

Automotive Journalism Praise:

Consistently praised by automotive critics for its driving dynamics, build quality, and overall refinement, establishing the benchmark for its class.