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BMW 325 325i 1991 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: BMW Model: 325i Year: 1991 Chassis Code: E30 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Era Context: The E30 generation represented a significant step...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Year:
1991
Chassis Code:
E30
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Era Context:
The E30 generation represented a significant step for BMW in refining its sport sedan formula.
Competitive Analysis
Key Competitors:
Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Volvo 240.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel-drive layout, and engaging driving experience.
Build Quality:
Typical BMW build quality for the era, emphasizing durability and a premium feel.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
All Models, Engines, Trim, Transmission Types
Page Count
Estimated Pages:
Varies by specific edition, typically 1000+ pages for comprehensive workshop manuals.
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing components.
Engine Management And Fuel:
Fuel injection system (Bosch Motronic), fuel pump, injectors, fuel lines, throttle body, air intake, emissions control.
Ignition System:
Ignition coil, spark plugs, distributor (if applicable), ignition timing, control module.
Cooling System:
Radiator, coolant pump, thermostat, hoses, fan, heater core, coolant specifications.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, lambda sensor (oxygen sensor).
Transmission Manual:
Clutch, gearbox internals, gear selection, driveshafts, fluid specifications, repair procedures.
Transmission Automatic:
Automatic transmission operation, valve body, torque converter, planetary gears, fluid specifications, overhaul.
Drivetrain:
Differential, rear axle, wheel bearings, CV joints.
Suspension:
Front and rear suspension components, struts, shock absorbers, control arms, bushings, springs, wheel alignment specifications.
Steering System:
Steering rack, power steering pump, steering column, tie rods, steering fluid specifications.
Brake System:
Front and rear brake pads and rotors, calipers, master cylinder, brake lines, ABS system (if equipped), brake fluid specifications.
Wheels And Tires:
Tire sizes, wheel specifications, bolt patterns, lug nut torque specifications.
Electrical System:
Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting systems.
Instrument Panel And Gauges:
Dashboard layout, gauge functions, warning lights, odometer, speedometer.
Body And Chassis:
Body panels, doors, hood, trunk, bumpers, frame components, rust prevention.
Interior Trim:
Seats, door panels, headliner, dashboard trim, carpet, seat belts.
Heating Ventilation And Air Conditioning HVAC:
Blower motor, evaporator, condenser, refrigerant, control panel, ducting.
Driver Information System Dis:
Onboard computer functions and diagnostics (if applicable).
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, tune-ups, fluid checks and changes, belt inspections.
Troubleshooting:
Diagnostic procedures for common and complex issues, symptom-based troubleshooting guides.
Repair And Overhaul:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly.
Component Replacement:
Detailed guides for replacing parts like alternators, starters, fuel pumps, brake pads, etc.
Diagnostic Codes:
Explanation of diagnostic trouble codes (DTCs) and their interpretation.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Tightening Torques:
Specific torque values for all critical fasteners.
Technical Specifications Data:
All necessary measurements, tolerances, and specifications for accurate repairs.
Technical Depth
Depth:
In-depth, professional-level coverage suitable for mechanics and experienced DIY enthusiasts. Includes detailed diagnostics and overhaul procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if professionally scanned and indexed.
Print Quality:
Depends on source; professional workshop manuals are typically clear and well-organized.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, naturally aspirated
Engine Code:
M20B25
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
8.8:1 or 9.1:1 (depending on specific model variant/market)
Performance
Horsepower:
168 hp @ 5800 rpm (approx.)
Torque:
164 lb-ft @ 4300 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (91 Octane or higher recommended)
Valvetrain
Configuration:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
🔧 Transmission
Standard
Type:
Getrag 260 5-speed manual transmission
Optional
Type:
ZF 4HP22 4-speed automatic transmission
Features
Final Drive Ratio:
Typically 3.25:1 or 3.46:1 (depending on transmission and differential options)
Fluid Specifications
Manual Transmission Fluid:
BMW Manual Gearbox Oil (e.g., BMW Part No. 83 22 9 408 236, typically a 75W-90 synthetic gear oil)
Automatic Transmission Fluid:
Dexron III or equivalent (e.g., BMW Part No. 83 22 0 025 091)
📐 Dimensions
Exterior
Length:
Approx. 170.5 inches (4330 mm)
Width:
Approx. 67.3 inches (1710 mm)
Height:
Approx. 54.7 inches (1390 mm)
Wheelbase
Wheelbase:
Approx. 101.2 inches (2570 mm)
Weights
Curb Weight:
Approx. 2800 - 3000 lbs (1270 - 1360 kg), varies by body style and options.
Gross Vehicle Weight Rating Gvwr:
Typically around 3800 lbs (1724 kg)
Wheels And Tires
Standard Tire Size:
195/65R14 or 205/55VR14
Wheel Bolt Pattern:
5x120 mm
Wheel Offset:
ET25 to ET30 (typical for 14-inch wheels)
🛡️ Safety Features
Ratings
Crash Test Performance:
As a 1991 vehicle, official NHTSA or IIHS ratings may not be readily available in modern formats. However, the E30 chassis was known for its solid safety structure for its time.
Active Features
Anti Lock Braking System ABS:
Optional on some models, standard on others.
Passive Features
Seat Belts:
Three-point inertia-reel seat belts (front and rear)
Head Restraints:
Adjustable front and rear head restraints
Child Seat Anchors:
Not standard in the modern ISOFIX sense; typically lap and shoulder belt restraints used.
💡 Technology Features
Infotainment
Radio System:
Typically a BMW Bavaria C or similar analog radio/cassette player, often with optional CD changer compatibility for later E30s.
Speaker System:
Factory speaker setup, often with door and rear deck speakers.
Driver Assistance
Cruise Control:
Available as an option.
Connectivity
Phone Integration:
None in the modern sense; optional provisions for early car phones might exist.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, depending on driving conditions. The manual will provide specific recommendations.
Engine Oil Filter Replacement:
With every oil change.
Spark Plug Replacement:
Approximately every 30,000 miles (48,000 km) for standard plugs, or as specified in manual.
Timing Belt Replacement:
The M20 engine uses a timing belt. Replacement is typically recommended every 50,000 - 60,000 miles (80,000 - 96,000 km) or 4-5 years. Critical to replace before failure to avoid engine damage.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Fluid Specifications
Engine Oil Viscosity:
10W-40 or 15W-50 synthetic or high-quality conventional oil (refer to manual for exact specs and temperature ranges).
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. BMW Blue Coolant or equivalent.
Brake Fluid:
DOT 4 synthetic brake fluid.
Power Steering Fluid:
ATF Dexron II or III, or CHF 11S for later models/specific systems (verify in manual).
Known Issues
Fuel Injector Leaks:
O-rings can degrade over time, leading to leaks.
Heater Control Valve:
Common failure point, leading to no heat or uneven cabin temperature.
Coolant Leaks:
Plastic coolant expansion tank can become brittle and crack. Hoses also degrade.
Idle Control Valve:
Can become clogged or fail, leading to rough idle.
Fuel Pump Relay:
Known to fail, preventing the car from starting.
Window Regulators:
Can fail, causing windows to not operate properly.
Rust:
Areas like wheel arches, rocker panels, and strut towers are prone to rust if not properly maintained.
Dashboard Cracking:
The vinyl dashboard material can degrade and crack from sun exposure.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's 'Ultimate Driving Machine' philosophy was firmly established by the E30 generation.
Model Evolution
E30 Generation:
The E30 (1982-1994 production) was a highly successful generation, popular for its engineering and driving characteristics. The 325i was a performance-oriented model within this range.
Production
Production Period:
The E30 325i was produced from 1987 to 1991 (with the 325i designation evolving from the earlier 325e/325es).
Manufacturing Locations:
Primarily Germany, but also assembled in other locations globally.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E30 chassis (including models like the 325i) was frequently recognized by publications like Car and Driver on its 10 Best lists during its production run, lauded for its sports sedan qualities.
Ratings
Enthusiast Following:
The E30 325i has a dedicated and passionate enthusiast following due to its classic BMW driving characteristics and timeless design.