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BMW 325 325es 1984-1990 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 325 / 325es Generation: E30 Production Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990 Codes Chassis Code: E30 👋 Introduction Market Position...
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BMW 325 325es 1984-1990 Service Repair Workshop ManualBMW 325 325es 1984-1990 Service Repair Workshop ManualBMW 325 325es 1984-1990 Service Repair Workshop ManualBMW 325 325es 1984-1990 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325 / 325es
Generation:
E30
Production Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990
Codes
Chassis Code:
E30
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Sports Sedan/Coupe
Brand Reputation:
BMW's reputation for performance, handling, and build quality
Competitive Analysis
Key Competitors:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Ford Sierra XR4i
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel drive, and engaging driving experience
Engine Configuration:
Smooth and torquey M20 inline-six engine
Design:
Classic, timeless E30 design by Claus Luthe
📋 Manual Details
Coverage Areas
Primary Focus:
Service, Repair, Workshop Procedures
Target Audience:
Professional Mechanics, DIY Enthusiasts
Page Count
Estimated Pages:
Varies by specific edition, typically 1000+ pages for comprehensive coverage
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF), Print (potential variations)
📖 Manual Coverage
Systems Covered
Engine:
M20 Engine (2.7L Inline-6), including fuel injection (Bosch L-Jetronic/Motronic), ignition, cooling, lubrication, emissions control
Transmission:
Getrag 260 5-speed manual, ZF 4HP22 4-speed automatic, clutch systems, driveline components
Brakes:
Hydraulic systems, ABS (where applicable), brake pad/rotor replacement, caliper service, brake fluid specifications
Suspension:
Front McPherson strut, rear semi-trailing arm, springs, dampers, bushings, wheel alignment specifications
Steering:
Power steering system, steering rack, tie rod ends, steering column
Electrical:
Wiring diagrams, fuse box layouts, starter, alternator, battery, lighting systems, instrumentation, accessory circuits
Body:
Body shell construction, exterior trim, doors, hood, trunk, bumpers, interior components, heating and ventilation
HVAC:
Air conditioning system (compressor, refrigerant, evaporator, condenser), heater core, blower motor, climate control panel
Fuel:
Fuel tank, fuel pump, fuel lines, fuel filter, fuel pressure regulator
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, spark plugs, coolant flushes), brake service, tire rotation
Diagnostics:
Troubleshooting guides, fault code identification (where applicable), diagnostic procedures for various systems
Repair:
Step-by-step repair instructions for all major systems, component removal and installation, rebuild procedures
Adjustments:
Valve adjustments, ignition timing adjustments (if applicable), idle speed adjustments
Specifications:
Torque specifications for critical fasteners, fluid capacities, engine data, alignment settings
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major overhaul and troubleshooting
Detail Level:
Detailed diagrams, illustrations, and technical explanations suitable for professional application
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF for efficient information retrieval
Print Quality
Digital Quality:
High-resolution scans or digital originals ensuring clarity of text and diagrams
Binding Type
Print Binding:
Spiral-bound or perfect-bound (common for workshop manuals to lay flat)
Paper Type
Print Paper:
Durable, possibly coated paper to withstand workshop conditions
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B27
Configuration:
2.7 Liter (2693cc) SOHC Inline-6
Bore X Stroke:
84.0 mm x 81.0 mm
Compression Ratio:
8.5:1 (for 325es/325e, lower for 325e for economy)
Valvetrain:
SOHC (Single Overhead Camshaft) with 2 valves per cylinder
Performance
Horsepower Est:
121-124 hp @ 4800 rpm (325es/325e - rated conservatively)
Torque Est:
170 lb-ft @ 3250 rpm (325es/325e)
Fuel System
Fuel Delivery:
Bosch Motronic (DME) Fuel Injection (likely Motronic 1.1 or 1.3)
Fuel Type:
Unleaded Gasoline (91+ Octane recommended)
Cooling
Cooling System:
Pressurized water-cooled system
Lubrication
Oil Capacity Quarts:
5.7 quarts (5.4 liters) with filter change
Recommended Oil Viscosity:
15W-40 or 10W-40 (depending on climate, refer to manual for specifics)
🔧 Transmission
Standard
Type:
Getrag 260 5-speed Manual Transmission
Optional
Type:
ZF 4HP22 4-speed Automatic Transmission
Features
Manual Clutch:
Hydraulically operated single dry plate clutch
Automatic Transmission Mode:
Standard P-R-N-D-3-2-1 selector pattern, potentially with 'Economy' and 'Sport' modes
Fluid Specifications
Manual Transmission Fluid:
GL-4 Gear Oil (e.g., Castrol Syntrans 75W-90 or equivalent, check manual for exact spec)
Automatic Transmission Fluid:
Dexron II or Dexron III (check manual for specific BMW approval)
📐 Dimensions
Exterior
Length Est:
170.5 inches (4330 mm)
Width Est:
65.6 inches (1665 mm)
Height Est:
54.7 inches (1390 mm)
Wheelbase Est:
101.2 inches (2570 mm)
Weights
Curb Weight Est Lbs:
2700-2850 lbs (1225-1293 kg), varies by transmission and options
Gross Vehicle Weight Rating Est Lbs:
3600-3800 lbs (1633-1724 kg)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited data from era; known for robust E30 chassis structure
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on later models or specific trims
Passive Features
Seatbelts:
Three-point front seat belts, two-point rear seat belts
Body Structure:
Reinforced safety cage, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional amplifier and upgraded speakers.
Display:
Analog gauges for speedometer, tachometer, fuel, and temperature. Warning lights for system status.
Driver Assistance
Cruise Control:
Optional electronic cruise control system.
Connectivity
Phone Integration:
None from factory; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km)
Spark Plugs:
Approximately every 30,000 miles (48,000 km) for standard plugs; check manual for recommended type and gap.
Timing Belt:
Critical: M20 engines use a timing belt. Replacement typically recommended every 60,000 miles (96,000 km) or 5 years due to potential catastrophic engine damage if it fails.
Fluid Specifications
Engine Coolant:
BMW Blue or G48 Ethylene Glycol Antifreeze mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (refer to manual for specific BMW specification)
Known Issues
Fuel Injector O-Rings:
Leaking O-rings can cause rough idle, vacuum leaks, and fuel smell.
Heater Control Valve:
Common failure point, leading to lack of heat or uncontrolled heat.
Window Regulators:
Can become weak or break, causing windows to not operate properly.
Rust:
Susceptible to rust in common areas: wheel arches, rocker panels, battery tray, around windshield.
Idle Control Valve:
Can get gummed up, leading to erratic idle or stalling.
Cooling System Components:
Radiator, hoses, and water pump are wear items and can fail with age.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's long history of producing driver-focused, performance-oriented vehicles
Model Evolution
E30 Introduction:
The E30 chassis replaced the E21 3 Series and was produced from 1982 to 1994 (globally), setting a benchmark for compact executive cars.
325Es Positioning:
The 'es' designation typically indicated the 'Eta' engine (M20B27) tuned for increased torque and fuel economy, often paired with an automatic transmission, though manual was available.
325I Vs 325Es:
The 325i featured a higher-revving, more powerful version of the M20 engine (M20B25) and was generally favored for pure performance.
Production
Manufacturing Locations:
Primarily Germany (Dingolfing plant)
Sales Significance:
The E30 generation was highly successful, significantly boosting BMW's sales and solidifying its market presence.
🏆 Awards & Recognition
Recognitions
E30 Legacy Awards:
Consistently ranked as one of the best driver's cars by automotive publications, especially for its handling and build quality.
Automotive Journalism Praise:
Praised for its balance, chassis rigidity, and the engaging nature of the M20 engine.
Certifications
Epa Certification:
Met emissions standards for its respective model years.
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