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BMW 3 Series 325is 1984-1990 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Trim: 325is Codes Chassis Code: E30 Engine Code Family: M20 👋 Introduction Market Position Era Context: The BMW 3 Series E30...
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BMW 3 Series 325is 1984-1990 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Trim:
325is
Codes
Chassis Code:
E30
Engine Code Family:
M20
👋 Introduction
Market Position
Era Context:
The BMW 3 Series E30 represented BMW's entry into a more compact, sporty segment, establishing the benchmark for premium compact executive cars of its era.
Competitive Analysis
Competitors:
Competed directly with cars like the Mercedes-Benz 190E, Audi 80/90, and the Alfa Romeo 75, offering a blend of performance, luxury, and handling that often surpassed its rivals.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, RWD architecture, and communicative steering, making it a driver's car of choice.
Design Philosophy:
The E30's enduring appeal lies in its timeless, functional design and robust engineering, a hallmark of BMW's build quality.
📋 Manual Details
Coverage Areas
Applicable Years:
1984, 1985, 1986, 1987, 1988, 1989, 1990
Page Count
Page Count:
550
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, including cylinder head, pistons, crankshaft, timing belt, lubrication system, cooling system.
Fuel System:
Fuel injection system (Bosch Motronic), fuel pump, fuel injectors, fuel pressure regulator, fuel tank, lines.
Ignition System:
Ignition coils, spark plugs, distributor, ignition module, ECU control.
Transmission Manual:
Clutch assembly, gearbox, shift linkage, lubrication, removal and installation procedures.
Transmission Automatic:
Transmission identification, fluid types, service procedures, electronic control (if applicable).
Drivetrain Suspension:
Front and rear suspension components (struts, control arms, bushings), driveshafts, differentials, wheel bearings.
Brakes:
Hydraulic system, brake calipers, rotors, pads, master cylinder, ABS system (if equipped), bleeding procedures.
Steering:
Power steering system, steering rack, tie rods, steering column, alignment.
Electrical System:
Battery, alternator, starter, wiring diagrams, lighting, fuses, relays, diagnostic connectors.
Body And Chassis:
Body panel removal and installation, doors, windows, locks, seals, underbody protection, chassis components.
Heating Ventilation Air Conditioning:
HVAC system components, refrigerant, blower motor, evaporator, condenser, diagnostic and repair.
Procedures Included
Scheduled Maintenance:
Detailed oil change intervals, filter replacements, spark plug service, fluid checks and changes.
Troubleshooting Diagnostics:
System-specific troubleshooting guides, common fault finding, diagnostic error codes (where applicable).
Engine Repair:
Step-by-step engine rebuild procedures, torque specifications, clearances, gasket replacement.
Transmission Service:
Transmission fluid change, filter replacement, clutch adjustment and replacement, gearbox disassembly and reassembly.
Brake System Repair:
Brake pad and rotor replacement, caliper servicing, brake line repair, ABS component testing.
Electrical Diagnostics:
Reading wiring diagrams, testing sensors, actuators, and control modules, circuit tracing.
Suspension Alignment:
Alignment specifications, procedure for adjusting camber, caster, and toe.
Body Repair:
Procedures for removing and installing body panels, trim, glass, and seals.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes and component replacements to full engine and transmission rebuilds.
Diagrams Illustrations:
Includes detailed exploded diagrams, wiring schematics, and step-by-step procedural illustrations to aid in understanding complex repairs.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, suitable for printing clear copies of all pages and diagrams.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Manual Completeness
Completeness:
This is a comprehensive workshop manual, designed for professional technicians and advanced DIY mechanics, covering all aspects of repair and maintenance.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, SOHC (M20B25)
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Performance
Horsepower:
171 hp @ 5800 RPM (Approx.)
Torque:
170 lb-ft @ 4300 RPM (Approx.)
Fuel System
Injection System:
Bosch Motronic Fuel Injection (e.g., Motronic 1.3)
Fuel Type:
Unleaded Premium Gasoline (91+ Octane)
Engine Mechanical
Compression Ratio:
8.8:1
Cooling System:
Pressurized coolant system with thermostatically controlled fan.
Lubrication System
Oil Capacity:
5.5 Liters (5.8 US Quarts) with filter change.
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-speed Manual Transmission
Optional
Transmission Type:
ZF 4HP22 4-speed Automatic Transmission
Features
Clutch Type:
Hydraulically actuated single dry plate clutch.
Rear Axle Ratio:
Typically 3.73:1 for manual, 3.46:1 for automatic (subject to specific market or option).
Transmission Fluid Manual
Fluid Type:
BMW recommends SAE 75W-90 synthetic gear oil (e.g., BMW's own or equivalent).
Transmission Fluid Automatic
Fluid Type:
ATF Dexron-III or equivalent.
📐 Dimensions
Exterior
Wheelbase:
2565 mm (101 inches)
Length:
4345 mm (171.1 inches)
Width:
1675 mm (65.9 inches)
Height:
1380 mm (54.3 inches)
Weights
Curb Weight:
Approx. 1200-1300 kg (2645-2866 lbs) depending on equipment.
Wheels Tires
Standard Wheel Size:
15 x 6.0 inch (Optional 15x7 inch 'Bottle Cap' or BBS wheels).
Standard Tire Size:
205/55VR15
Bolt Pattern:
5 x 120 mm
🛡️ Safety Features
Ratings
Crash Test Results:
While official ratings from modern bodies like NHTSA or IIHS for this era are scarce, the E30 was built to high safety standards for its time, featuring a strong unibody construction.
Active Features
ABS:
Anti-lock Braking System (ABS) was an option on most models, including the 325is.
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners.
Steering Column:
Collapsible steering column for improved occupant protection.
Body Structure:
Reinforced passenger cell and crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory premium audio systems were optional, often with cassette decks and limited tuner capabilities. Aftermarket upgrades are common.
Driver Assistance
ABS:
As mentioned in safety, ABS was an optional electronic driver aid.
Connectivity
Diagnostics:
Early forms of diagnostic connectors (e.g., OBD-I type connections for Motronic system) were present, but lacked the widespread standardization and data richness of modern systems.
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first.
Spark Plugs:
Replace every 30,000 miles (48,000 km). Recommended: Bosch W8AC or equivalent.
Timing Belt:
Replace every 40,000-60,000 miles (64,000-96,000 km) or 4 years, due to the M20 engine's interference design. Crucial for preventing catastrophic engine damage.
Fluid Specifications
Engine Oil:
SAE 15W-40 or 10W-40 synthetic or semi-synthetic oil meeting BMW Longlife-98 or API SG/SH specification.
Coolant:
BMW Blue Antifreeze/Coolant (50/50 mix with distilled water) or equivalent ethylene glycol-based coolant.
Brake Fluid:
DOT 4 brake fluid.
Known Issues
Coolant System:
Plastic coolant expansion tank can become brittle and crack, leading to leaks. Heater control valves are also prone to failure.
Fuel System:
Fuel pressure regulator diaphram can fail, leading to rich running conditions. Injector seals can degrade.
Engine Mounts:
Hydraulic engine mounts often fail, causing excessive vibration and engine movement.
Suspension:
Front control arm bushings and rear shock mounts are common wear items.
Electrical System:
Corrosion in electrical connectors, failing headlight relays, and dashboard warning light issues are not uncommon.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused luxury sports sedans and coupes, a legacy cemented by models like the 3 Series.
Model Evolution
E30 Introduction:
The E30 generation replaced the E21 3 Series in late 1982 for the 1983 model year and ran through 1991, with the 325is being a significant performance variant.
325Is Development:
The 325is model, specifically with the M20 2.5L engine, was introduced to offer a more potent performance option, building upon the success of the earlier 323i and 325e models.
Production
Production Years:
1984-1990 for the 325is model.
Manufacturing Locations:
Primarily Germany (Munich and Dingolfing).
🏆 Awards & Recognition
Recognitions
Historical Acclaim:
The E30 chassis, including the 325is variant, is widely regarded as one of BMW's finest driver's cars and a modern classic, frequently appearing on 'best of' lists for sports sedans and coupes.
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