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BMW 325 325i 1987 1988 1989 1990 1991 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325 / 325i Generation Code: E30 Generation Start Year: 1987 End Year: 1991 Codes Chassis Code: E30 👋 Introduction Market Position Segment: Compact...
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BMW 325 325i 1987 1988 1989 1990 1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325 / 325i
Generation Code:
E30
Generation
Start Year:
1987
End Year:
1991
Codes
Chassis Code:
E30
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Reputation:
Known for sporty handling, robust engineering, and driver engagement.
Competitive Analysis
Competitors:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Volvo 240.
Key Features
Design:
Iconic Chris Bangle-influenced design, quintessential BMW proportions.
Performance Focus:
Rear-wheel drive platform, balanced chassis, responsive engines.
Build Quality:
Typical BMW build quality, designed for longevity.
📋 Manual Details
Coverage Areas
Covered Years:
1987, 1988, 1989, 1990, 1991
Page Count
Total Pages:
227
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, fuel injection (Bosch Motronic), ignition system, cooling system, exhaust system, engine mechanicals (cylinder head, block, crankshaft, pistons, connecting rods).
Transmission:
Manual and automatic transmission repair, clutch operation, gearbox components, driveshafts, differential.
Brakes:
Hydraulic system, ABS (where applicable), brake pads, rotors, calipers, master cylinder, brake lines, parking brake.
Electrical:
Complete wiring diagrams, starter motor, alternator, battery, lighting systems, fuses, relays, instrument cluster, power windows, power locks, radio, control modules.
Suspension Steering:
Front and rear suspension components, shock absorbers, struts, springs, bushings, wheel bearings, power steering system, steering rack, tie rod ends.
Body Chassis:
Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, chassis lubrication, rust prevention.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair, blower motor, heater core, evaporator, refrigerant.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspection and replacement.
Diagnostics:
Troubleshooting guides for common problems, diagnostic fault codes (where applicable), component testing procedures.
Repair:
Step-by-step repair instructions for all major vehicle systems, including component disassembly, cleaning, inspection, and reassembly.
Adjustment:
Valve adjustments, parking brake adjustment, idle speed adjustment.
Lubrication:
Lubrication points and schedules, grease types, oil specifications.
Specification Settings:
Torque specifications for critical fasteners, engine timing settings, wheel alignment specifications.
Technical Depth
Depth:
Comprehensive: Covers everything from routine maintenance and minor repairs to complete engine and transmission overhauls. Includes detailed diagnostic procedures and exploded views.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans, often searchable text for ease of navigation.
Printability:
Printable pages for convenient workshop use.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B27 (often referring to the 2.7L) / M20B25 (2.5L for 325i)
Engine Type:
Inline 6-cylinder, SOHC
Displacement 325I:
2.5 Liters (2494 cc)
Bore X Stroke 325I:
84 mm x 75 mm
Compression Ratio 325I:
8.5:1 or 9.1:1 depending on market/version
Performance
Horsepower 325I:
168-170 hp @ 5800-6000 rpm (varies by market and specific engine variant)
Torque 325I:
220-230 Nm (162-169 lb-ft) @ 4300-4800 rpm (varies by market and specific engine variant)
Fuel System
Fuel Delivery:
Bosch Motronic electronic fuel injection (EFI)
Fuel Type:
Unleaded gasoline (RON 91 or higher recommended)
Ignition System
Ignition Type:
Distributorless ignition system (DIS) or distributor-based with electronic control (depending on specific year/market variant).
🔧 Transmission
Standard
Type 325I:
Getrag 260 5-speed manual transmission
Optional
Type 325I:
ZF 4HP22 4-speed automatic transmission
Features
Clutch Type:
Hydraulically operated single dry plate clutch (manual)
Differential:
Standard open differential; optional limited-slip differential (LSD) available on some models.
📐 Dimensions
Exterior
Body Styles:
2-door coupe, 4-door sedan
Wheelbase:
Approximately 2565 mm (101 inches)
Length:
Approximately 4340 mm (170.9 inches)
Width:
Approximately 1677 mm (66 inches)
Height:
Approximately 1365 mm (53.7 inches)
Weights
Curb Weight:
Approximately 1250-1350 kg (2755-2976 lbs), depending on body style and options.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official NHTSA/IIHS ratings for this era; anecdotal evidence suggests reasonable structural integrity for its time.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on later models.
Passive Features
Airbags:
Driver's side airbag was optional and became more common in later production years.
Seatbelts:
3-point inertia reel seatbelts with pretensionsers.
💡 Technology Features
Infotainment
Audio System:
Factory premium sound systems available (e.g., Bavaria C) with cassette player. Aftermarket head unit compatibility is common.
Display:
Basic analog gauges and warning lights on the instrument cluster.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
Phone Integration:
No factory integration; requires aftermarket solutions.
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually.
Spark Plugs:
Every 30,000 miles (48,000 km), typically using copper-core spark plugs (e.g., NGK BPR6ES).
Timing Belt Chain:
The M20 engine uses a timing chain, which is generally considered maintenance-free unless stretched or worn. Replacement would be on an as-needed basis, often diagnosed by noise.
Fluid Specifications
Engine Oil:
API SF or SG, SAE 10W-40 or 15W-40 (check manual for specific viscosity based on ambient temperature). Capacity: Approx. 4.25 Liters (4.5 Quarts) with filter.
Coolant:
BMW Blue Longlife Coolant or equivalent, mixed 50/50 with distilled water. Capacity: Approx. 6.5 Liters (6.9 Quarts).
Transmission Fluid Manual:
API GL-4, SAE 75W-90 gear oil. Capacity: Approx. 1.5 Liters (1.6 Quarts).
Transmission Fluid Automatic:
Dexron II or Dexron III ATF. Capacity: Approx. 3.5 Liters (3.7 Quarts) for torque converter refill.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Capacity: Approx. 1 Liter (1.1 Quarts).
Known Issues
Common Problems:
Cooling system leaks (hose failures, cracked expansion tanks), fuel injector seal leaks, AFM (Air Flow Meter) issues, fuel pump failures, seized heater blowers, differential seal leaks, E30 specific rust areas (rockers, rear wheel arches).
Maintenance Tip:
Proactive replacement of cooling system components (hoses, water pump, thermostat) is highly recommended due to age.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for performance, luxury, and engineering excellence.
Model Evolution
E30 Introduction:
The E30 generation replaced the E21 and established BMW's dominance in the compact executive segment.
325 Introduction:
The 325 designation and the M20 engine signified a performance upgrade over previous 323i models.
Production
Production Period:
1982-1994 (E30 overall); 1987-1991 for 325/325i models covered by manual.
Manufacturing Locations:
Germany (Dingolfing, Munich)
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive journalists for its driving dynamics and build quality. Often cited as a benchmark in its class for sportiness.
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