My 2002 325i sedan has a cracked driver's side door speaker grill. Can I replace it and or if I upgrade to better speakers can I use the new grills provided with new speakers. And speaking of, what is the acutual size of door speaker I can put in the doors? I read 5.25 and 6.5 can fit, what is it? Are rear deck 6.5, read they were 4.
You should be able to find a new speaker grille. I'm not sure whether the dealer sells it separately, but you should check with them. Otherwise try eBay. Its doubtful that the grills supplied with a replacement speaker would fit.
The mid-bass speakers (the largest ones) in the doors have a very unusual mounting system with 3 screws. Fortunately Crutchfield makes an adapter that allows almost any 5 1/4 inch speaker to be used:
The front door speakers are 160 mm in diameter which works out to about 6.3 inches. The rear deck speakers are the same as these, again with the oddball 3-screw mounting system.
Also these speakers are 2 ohms, which is a bit unusual. I replaced the rear deck speakers with Infinity Reference 6030's. I removed the plastic "basket" that the factory speakers fit into, cut off the mounting tabs on the speakers and silicone glued the speakers into the basket. Since the basket has the 3 oddball screw tabs, the new speakers dropped right in. Here's a DIY that was helpful, if complicated:
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