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BMW 325 325i 1987-1991 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Model Code: E30 Production Years: 1987-1991 Codes Engine Code: M20B27 (I6) 👋 Introduction Market Position Positioning: The BMW 3 Series (E30) established...
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BMW 325 325i 1987-1991 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Model Code:
E30
Production Years:
1987-1991
Codes
Engine Code:
M20B27 (I6)
👋 Introduction
Market Position
Positioning:
The BMW 3 Series (E30) established BMW's reputation for sporty, driver-focused sedans and coupes in the premium compact executive segment. The 325i was a highly sought-after performance variant.
Competitive Analysis
Competitors:
Competed with Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, and various American luxury compacts of the era.
Key Features
Design Philosophy:
Renowned for its balanced chassis, rear-wheel-drive dynamics, responsive steering, and build quality synonymous with BMW.
Manual Value:
Essential for owners and independent mechanics maintaining or restoring these classic BMWs, providing accurate procedures and specifications to preserve performance and originality.
📋 Manual Details
Coverage Areas
Coverage:
All Models & Configurations within specified years
Page Count
Estimated Page Count:
600+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnostics, fuel injection, ignition, cooling, lubrication, exhaust
Transmission:
Manual and Automatic transmission overhaul, diagnostics, fluid service
Drivetrain:
Driveshafts, differential, rear axle, hub assembly, CV joints
Suspension:
Front struts, rear shocks, control arms, bushings, ball joints, steering linkage
Brakes:
Disc brake systems (front & rear), ABS diagnostics, brake fluid service, parking brake
Steering:
Power steering system, steering rack, tie rods, column
Electrical System:
Wiring diagrams, battery, alternator, starter, lighting, fuses, relays, instrumentation
Body And Chassis:
Body panel removal/installation, interior trim, glass, bumpers, rust repair, structural components
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system troubleshooting and repair
Fuel System:
Fuel pump, injectors, fuel lines, EVAP system
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks & changes, belt replacement, spark plug replacement
Troubleshooting:
Diagnostic procedures for common and intermittent faults, fault code interpretation
Repair:
Step-by-step repair instructions for all major systems, component replacement
Rebuilding:
Engine and transmission rebuilding procedures, specifications, and torque values
Adjustment:
Valve adjustments, idle speed adjustments, timing adjustments
Installation:
Component installation, accessory installation
Emissions Control:
Information on emission control systems and their maintenance/troubleshooting.
Chassis And Body:
Detailed procedures for bodywork, including door, hood, trunk panel alignment, and interior trim removal.
Technical Depth
Depth:
Comprehensive: Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics.
Wiring Diagrams:
Includes comprehensive electrical wiring diagrams for all major systems, crucial for electrical fault finding.
Torque Specifications:
Provides specific torque values for all critical fasteners during engine, transmission, suspension, and brake component replacement.
Manual Completeness
Scope:
Full workshop manual covering all aspects of repair and maintenance, not a condensed or partial guide.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, SOHC
Displacement:
2.7 Liters (2693 cc)
Bore X Stroke:
84.0 mm x 81.0 mm
Compression Ratio:
8.5:1 (approx.)
Performance
Horsepower:
168 hp @ 5,500 rpm (US Spec)
Torque:
223 lb-ft @ 3,250 rpm (US Spec)
Fuel System
Injection System:
Bosch Motronic L-Jetronic fuel injection
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Cooling System
Coolant Type:
BMW Blue Antifreeze/Coolant (or equivalent silicate-free coolant)
Coolant Capacity:
Approx. 8.5 Liters (8.9 US Quarts)
Lubrication System
Oil Type:
SAE 15W-40 or 20W-50 (depending on climate) - API SG or higher
Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change
Oil Filter Part Number:
Mann-Filter W 940/5 or equivalent
🔧 Transmission
Standard
Type:
Getrag 260 5-speed Manual Transmission
Optional
Type:
ZF 4HP22 4-speed Automatic Transmission
Features
Manual Fluid Type:
API GL-4 SAE 75W-90 Synthetic Gear Oil
Automatic Fluid Type:
ATF Dexron II or equivalent
Clutch:
Hydraulically actuated single dry plate clutch
📐 Dimensions
Exterior
Length:
170.5 inches (4331 mm)
Width:
65.7 inches (1669 mm)
Height:
55.1 inches (1400 mm)
Wheelbase:
104.7 inches (2660 mm)
Weights
Curb Weight:
2,950 - 3,100 lbs (1340 - 1406 kg) depending on transmission
Gross Vehicle Weight Rating:
Approx. 4,000 lbs (1814 kg)
🛡️ Safety Features
Ratings
Crash Test History:
E30 chassis received mixed results in contemporary crash testing. Manual provides information on safety systems and structural integrity.
Active Features
Brakes:
Front ventilated discs, rear solid discs. Optional ABS (Anti-lock Braking System).
Suspension:
Independent front strut suspension, semi-trailing arm rear suspension for excellent handling and stability.
Passive Features
Seatbelts:
3-point inertia-reel seatbelts front and rear.
Steering Column:
Energy-absorbing steering column.
💡 Technology Features
Infotainment
Audio System:
Factory cassette player with optional CD changer. Manual covers basic troubleshooting and speaker replacement.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) with dedicated diagnostic procedures in the manual.
Connectivity
Diagnostics:
On-board diagnostics system (OBD-I) with manual detailing connector locations and basic test procedures.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, whichever comes first. Monitor oil level frequently.
Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type. Manual specifies correct NGK or Bosch plugs and gap.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Transmission Fluid:
Manual: Inspect at 30,000 miles, change if necessary. Automatic: Change fluid and filter every 40,000 - 60,000 miles (64,000 - 96,000 km).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (check cap/reservoir for specific requirement).
Power Steering Fluid:
ATF Dexron II or equivalent.
Coolant Capacity Liters:
8.5 L
Known Issues
Cooling System:
Thermostat failure, radiator leaks, fan clutch failure, cracked expansion tanks are common. Manual provides detailed diagnostics for these.
Electrical:
Fuse box corrosion, headlamp switch failure, instrument cluster issues, wiring harness degradation.
Suspension:
Worn control arm bushings, worn subframe bushings, shock absorber degradation. Manual offers replacement procedures and torque specs.
Engine Management:
MAF sensor issues (if equipped), idle control valve problems, fuel injector clogging.
Body Corrosion:
Rust can be prevalent in common areas such as wheel wells, rocker panels, and jacking points. Manual offers guidance on repair.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long history of producing sporty, driver-oriented vehicles, a reputation significantly reinforced by the E30 generation.
Model Evolution
E30 Generation:
The E30 generation (1982-1991) was a critical success, solidifying BMW's market presence and introducing many innovations. The 325i was the performance flagship for much of this period.
Production
Manufacturing Locations:
Primarily Germany (Munich, Dingolfing) and South Africa.
Sales Figures Context:
Millions of E30s were produced worldwide, with the 325i being a popular choice for enthusiasts.
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
The E30 generation received numerous accolades from automotive journalists for its handling, performance, and build quality throughout its production run.
Ratings
Enthusiast Recognition:
Considered a modern classic and a benchmark for sport sedans, highly regarded by car enthusiasts and collectors.
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