BMW 325i 1996 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Year: 1996 Codes Chassis Code: E36 Engine Code: M50B25TU (325i) 👋 Introduction Market Position Vehicle Segment: Compact Executive Sedan/Coupe Target Audience: Enthusiasts,...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code:

M50B25TU (325i)

👋 Introduction

Market Position

Vehicle Segment:

Compact Executive Sedan/Coupe

Target Audience:

Enthusiasts, DIY mechanics, owners seeking in-depth knowledge

Competitive Analysis

Competitors 1996:

Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus ES300, Infiniti J30

Key Features

Bmw Philosophy:

The 'Ultimate Driving Machine' focus on performance, handling, and driver engagement

Chassis Design:

E36 chassis known for excellent weight distribution and chassis rigidity

Engine Smoothness:

Inline-six engine renowned for its smooth operation and power delivery

📋 Manual Details

Coverage Areas

Coverage Type:

Full Service Repair

Vehicle Variants Covered:

All 1996 BMW 325i models (E36 chassis)

Page Count

Estimated Page Count:

1000+

Manual Type

Manual Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing components

Engine Management:

Fuel injection, ignition system, emissions control, sensors, actuators, ECU diagnostics, DME troubleshooting

Transmission Manual:

Clutch, gearbox overhaul, gear shift mechanism, driveshafts

Transmission Automatic:

Transmission overhaul, hydraulic system, torque converter, valve body, electronic controls

Drivetrain:

Differential, rear axle, wheel bearings

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment

Steering:

Power steering system, steering rack, steering column, tie rods

Brakes:

Hydraulic system, ABS, brake calipers, rotors, pads, master cylinder, brake lines, bleeding procedures

Electrical System:

12V battery system, alternator, starter, lighting, wiring diagrams, fuses, relays, diagnostic connectors

Body And Interior:

Body panels, doors, windows, locks, seats, dashboard, trim, sound insulation, sunroof

Heating And Air Conditioning:

HVAC system components, refrigerant system, climate control unit, blower motor, ductwork

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections/replacement

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems, symptom-based troubleshooting guides

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for every major system

Rebuilding Procedures:

Detailed instructions for engine and transmission rebuilding, including specifications and tolerances

Component Testing:

Testing procedures for electrical components, sensors, actuators, and mechanical parts

Diagnostic Trouble Codes:

Explanation of BMW diagnostic codes (OBD-I/OBD-II related for the era), symptom correlation

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to full engine/transmission rebuilds and advanced diagnostics

Diagnostic Tools Required:

Specifies requirements for specialized BMW diagnostic tools (e.g., GT1, DIS) and common tools

Torque Specifications:

Detailed torque values for all fasteners

Clearances And Tolerances:

Precise specifications for engine and drivetrain component clearances and rebuild tolerances

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Likely yes, if professionally scanned and indexed

Printable:

Print Quality

Image Clarity:

High resolution for diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Name:

M50B25TU (Slightly revised M50B25)

Engine Type:

Naturally Aspirated Inline-6 Cylinder

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.0:1

Performance

Horsepower:

189 hp @ 5900 rpm

Torque:

181 lb-ft @ 4200 rpm

Redline:

6500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Point Fuel Injection (Bosch Motronic M5.2)

Fuel Type:

Premium Unleaded (91 Octane Recommended)

Engine Oil Type:

BMW Longlife-01 (SAE 5W-30 or 5W-40)

Fluid Capacities

Engine Oil Capacity:

6.5 Liters (6.9 US Quarts) with filter change

Coolant Capacity:

8.0 Liters (8.5 US Quarts)

🔧 Transmission

Standard

Standard Transmission:

5-Speed Manual (Getrag 260/5)

Optional

Optional Transmission:

4-Speed Automatic (ZF 4HP22 EH)

Features

Transmission Fluid Manual:

Pentosin MTF LT-2 or equivalent (e.g., Red Line MTL)

Transmission Fluid Automatic:

ZF Lifeguardfluid 4 or equivalent (e.g., Dexron III)

Clutch Type:

Hydraulically actuated single dry plate

📐 Dimensions

Exterior

Wheelbase:

2700 mm (106.3 inches)

Length:

4433 mm (174.5 inches)

Width:

1711 mm (67.4 inches)

Height:

1373 mm (54.1 inches)

Front Track:

1430 mm (56.3 inches)

Rear Track:

1467 mm (57.8 inches)

Wheel Bolt Pattern:

5x120 mm

Wheel Size Standard:

15x7.0 inch

Tire Size Standard:

205/60 R15

Weights

Curb Weight Manual:

Approx. 1420 kg (3130 lbs)

Curb Weight Automatic:

Approx. 1450 kg (3195 lbs)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

4-star driver, 3-star passenger (approximate for era, may vary)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

3-point inertia-reel seatbelts with front pretensioners

Body Structure:

Reinforced safety cell, crumple zones

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Automatic Stability Control (ASC+T) on some models

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or CD player, optional premium sound systems (e.g., Harman Kardon)

Display:

Basic driver information display in instrument cluster (e.g., OBC - On-Board Computer)

Driver Assistance

Cruise Control:

Standard

Parking Assistance:

Rear parking sensors (optional on some models)

Connectivity

Phone Integration:

Optional early cellular phone integration kits

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500-10,000 miles or 12 months (BMW recommends condition-based service, but manual will likely list standard intervals).

Air Filter Replacement:

Every 15,000-30,000 miles

Spark Plug Replacement:

Every 60,000 miles (if using appropriate iridium or platinum plugs)

Coolant Flush:

Every 30,000-40,000 miles or 2-3 years

Transmission Fluid Change:

Manual: As needed/inspected. Automatic: Every 50,000-60,000 miles (BMW initially stated 'lifetime' fluid, but recommended changes for longevity).

Fluid Specifications

Brake Fluid Type:

DOT 4

Power Steering Fluid Type:

BMW PSF or Pentosin CHF 11S (check specific model requirement)

Known Issues

Common Issues Engine:

Oil pan gasket leaks, vacuum leaks (intake manifold), cooling system (plastic components cracking), VANOS solenoid issues

Common Issues Suspension:

Front control arm bushings (RTABs), shock absorber mounts, ball joints

Common Issues Electrical:

Heater control valve failure, ABS sensor failures, window regulator issues

Common Issues Body:

Headliner sagging, door panel separation

📚 Vehicle History

Brand Heritage

Bmw Heritage:

Founded in 1916, renowned for engineering excellence, performance vehicles, and luxury.

Model Evolution

E36 Generation:

The E36 generation (1990-2000) represented a significant advancement in BMW's compact executive line, focusing on improved dynamics, refinement, and technology over its E30 predecessor.

325I Positioning:

The 325i was positioned as a higher-performance variant within the E36 lineup, offering a potent inline-six engine.

Production

Production Period:

1991-1995 (for M50B25 engine, the 1996 models may carry over or be transitional)

Manufacturing Locations:

Germany (primarily Munich), also South Africa, Thailand, Mexico

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

E36 generation 3-series (including 325i variants) was a frequent recipient of Car and Driver's 10 Best list during its production run.

Ratings

User Reviews:

Generally praised for driving dynamics, build quality, and reliability when properly maintained.