🏷️ Basic Information

Make:

BMW

Model:

325 / 325i

Model Code:

E30

Chassis Code:

E30

Product Name:

BMW 325 325i 1987-1991 Factory Service Repair Manual

Product Description:

COMPLETE full service repair manual for BMW 325 325i 1987 1988 1989 1990 1991. Hundreds of pages allow you to print it out in its entirety or just the pages you need.

Vin Engine Code Example:

M20B25

👋 Introduction

Segment:

Compact Executive Sedan/Coupe

Usp:

Sporty driving dynamics, robust engineering, and premium build quality characteristic of BMW.

Key Competitors:

Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Volvo 240.

Driving Dynamics:

Renowned for its balanced chassis, rear-wheel-drive layout, and precise steering.

Engine Character:

The M20 inline-six engine provides a smooth, torquey power delivery.

Build Quality:

High-quality materials and solid construction typical of BMW vehicles of this era.

Target Audience:

BMW owners, DIY mechanics, enthusiasts, and restoration specialists.

Benefits:

Empowers users to perform maintenance, diagnose issues, and complete repairs accurately, saving time and money.

📋 Manual Details

Covered Years:

1987, 1988, 1989, 1990, 1991

Covered Models:

BMW 325, BMW 325i

Approximate Page Count:

Hundreds of pages

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of all engine components, including block, pistons, connecting rods, crankshaft, cylinder head, valves, camshafts, timing components.

Engine Management Electrical:

Ignition system, fuel injection system (Bosch Motronic), sensors, actuators, ECU diagnosis and repair, wiring diagrams.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, fuel lines, fuel tank, EVAP system.

Transmission Manual:

Removal, disassembly, inspection, repair, and reinstallation of the Getrag 260 5-speed manual transmission.

Transmission Automatic:

Removal, disassembly, inspection, repair, and reinstallation of the ZF 4HP22 4-speed automatic transmission (if applicable to specific models).

Drivetrain:

Clutch system, driveshaft, universal joints, differential, axle shafts.

Suspension:

Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, sway bars.

Steering:

Steering rack, power steering pump, hydraulic lines, tie rods, steering column.

Brakes:

Front and rear brake systems, brake calipers, rotors, pads, master cylinder, brake lines, ABS system (if equipped).

Electrical System:

Charging system (alternator, battery), starting system (starter motor), lighting system, power windows, power locks, mirrors, wipers, horn, instruments, fuse box and relays.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system components, blower motor, heater core, evaporator core, refrigerant system diagnostics and service.

Body And Chassis:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, underbody components, corrosion protection.

Interior Trim:

Seats, dashboard, door panels, headliner, carpeting, seat belts.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, exhaust pipes.

Basic Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, tire rotations.

Scheduled Maintenance:

Detailed service intervals and procedures for all major and minor maintenance tasks.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for identifying and resolving common and complex issues, including symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major vehicle systems.

Component Rebuilds:

Detailed procedures for rebuilding major components such as engines, transmissions, and brake calipers.

Electrical Diagnostics:

Wiring diagrams, component testing procedures, and troubleshooting for electrical faults.

Suspension Alignment:

Specifications and procedures for wheel alignment.

Cooling System Service:

Coolant flush, thermostat replacement, radiator repair/replacement.

Emission Control Service:

Diagnosis and repair of emission control systems, including catalytic converters and oxygen sensors.

Depth:

Comprehensive, from basic DIY maintenance to complete professional-level overhauls and diagnostics.

Detail Level:

Includes detailed exploded views, torque specifications, special tool requirements, and diagnostic trouble codes (DTCs).

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text (if digitally rendered appropriately)

Printability:

Printable (full or selected pages)

Binding Type For Print:

Not applicable for PDF download; implies comb, spiral, or perfect binding for printed copies.

Paper Type For Print:

Not applicable for PDF download; standard paper would be expected for printed manuals.

⚙️ Engine Specifications

Engine Code:

M20B25

Configuration:

Inline 6-cylinder, SOHC

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

8.8:1 or 9.7:1 (depending on market/variant)

Horsepower:

168 hp @ 5800 rpm (approximate, DIN)

Torque:

167 lb-ft @ 4300 rpm (approximate, DIN)

Fuel Injection:

Bosch Motronic (M1.3 or M1.7)

Fuel Type:

Unleaded Gasoline (Octane rating may be specified in manual)

Coolant Type:

Ethylene glycol-based antifreeze/coolant (specific BMW spec may be mentioned).

Oil Capacity:

Approx. 4.5 - 5.0 Liters (with filter)

Recommended Oil Viscosity:

10W-40 or 15W-50 (check manual for specific climate recommendations)

🔧 Transmission

Transmission Type:

Getrag 260 5-speed Manual Transmission

Transmission Type:

ZF 4HP22 4-speed Automatic Transmission (optional)

Manual Gear Ratios:

Specific ratios for 1st through 5th gear and reverse would be detailed in the manual.

Automatic Shift Modes:

Likely standard P, R, N, D, and potentially a sport/economy mode on some variants.

Manual Transmission Fluid:

GL-4 or GL-5 gear oil (specific viscosity and specification like ATF Dexron II for some earlier BMW manuals).

Automatic Transmission Fluid:

Dexron II (or equivalent specification)

Clutch Type:

Hydraulically operated, single dry plate

📐 Dimensions

Length:

Approx. 4340 mm (170.9 in) for Sedan/Coupe

Width:

Approx. 1675 mm (65.9 in)

Height:

Approx. 1380 mm (54.3 in) for Sedan/Coupe

Wheelbase:

Approx. 2570 mm (101.2 in)

Curb Weight:

Approx. 1290-1350 kg (2844-2976 lbs), varies by body style and equipment.

Gross Vehicle Weight Rating:

Typically around 1800 kg (3968 lbs).

Standard Wheel Size:

15 inches (e.g., BMW Style 1, Style 5).

Wheel Bolt Pattern:

5 x 120 mm

Standard Tire Size:

205/60VR15 (varies)

🛡️ Safety Features

Crash Test Data:

While official NHTSA/Euro NCAP ratings for this specific generation are limited compared to modern standards, the E30 chassis was known for its structural integrity for its era. Manual will cover safety system checks.

ABS:

Anti-lock Braking System (ABS) was an option on some models, detailed diagnosis and repair in the manual.

Limited Slip Differential:

Optional Limited-Slip Differential (LSD) available, contributing to traction and handling under acceleration.

Seat Belts:

Three-point seat belts for front occupants, two-point belts in the rear.

Body Structure:

Integrated safety cage design for enhanced occupant protection.

💡 Technology Features

Audio System:

Factory-installed radio/cassette player, often with limited speaker configurations. Upgrade options are common.

Cruise Control:

Optional cruise control system, coverage for operation and troubleshooting.

None:

No integrated connectivity features like Bluetooth or USB ports were standard.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, whichever comes first. Manual will provide specific BMW recommendations.

Spark Plug Replacement:

Around 30,000 miles (48,000 km) for standard plugs. Manual will specify type and gap.

Coolant Flush Interval:

Every 2-3 years or 30,000-40,000 miles (48,000-64,000 km).

Timing Belt Replacement:

The M20 engine uses a timing belt. Replacement interval is critical, typically around 60,000 miles (96,000 km) or 5 years. Critical failure if it breaks.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (check manual for precise specification).

Power Steering Fluid:

CHF 11S or equivalent hydraulic fluid (check manual, as BMW used specific fluids).

Coolant Capacity:

Approx. 7.5 Liters

Head Gasket:

Can be prone to head gasket failure, especially if overheated.

Oil Leaks:

Common leak points include valve cover gasket, oil pan gasket, and rear main seal.

Rubber Components:

Age-related degradation of rubber hoses, bushings, and mounts is common.

Fuel Pump:

Fuel pumps can eventually fail, leading to starting issues or power loss.

Oil Filter Example:

Mann-Filter W 920/17 or Mahle OC 102 (typical equivalents, actual BMW part number would be in manual).

Air Filter Example:

Mann-Filter C 23 220 / 2 (typical equivalent).

Spark Plug Example:

Bosch W8AC or W8AP (typical, check manual for exact fitment).

📚 Vehicle History

Bmw Philosophy:

BMW's commitment to 'The Ultimate Driving Machine' driving pleasure, engineering excellence, and sporty luxury.

E30 Generation Introduction:

The E30 generation was introduced in 1982 as a successor to the E21 3 Series. The 325 and 325i models were key performance variants introduced later in the E30's lifecycle.

325 Introduction Period:

The 325i, featuring the M20B25 engine, became prominent in the mid-1980s, offering a significant power upgrade over earlier 323i models.

E30 Lifecycle End:

The E30 generation was produced until 1991 in most markets, succeeded by the E36 3 Series.

Manufacturing Locations:

Primarily Germany, with some assembly in other locations.

Body Styles Available:

2-door sedan, 4-door sedan, convertible, and touring (wagon) variants, though the 325/325i designation was most common on sedans and coupes.

🏆 Awards & Recognition

Automotive Press Acclaim:

The E30 3 Series, including the 325i, was widely praised by automotive journalists for its driving dynamics and build quality, cementing BMW's reputation.