BMW 7 Series E32 1991 All Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: 7 Series Model Code: E32 Year: 1991 👋 Introduction Market Position Segment: Full-size Luxury Sedan Target Audience: Discerning luxury car owners, DIY mechanics,...

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Art.-Nr: 491066

Stichworte: 1991 7 Series E32 BMW Car Cars Misc

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

7 Series

Model Code:

Year:

👋 Introduction

Market Position

Segment:

Full-size Luxury Sedan

Target Audience:

Discerning luxury car owners, DIY mechanics, restoration enthusiasts

Competitive Analysis

Key Competitors:

Mercedes-Benz S-Class (W140), Lexus LS 400, Jaguar XJ

Key Features

Philosophy:

The E32 represented BMW's commitment to advanced engineering, driver engagement, and luxurious comfort in the flagship sedan segment.

Design Era:

Marked a significant evolution in BMW design, featuring cleaner lines and a more aerodynamic profile compared to its predecessor.

Innovation Focus:

Introduction of advanced features for its time, including electronic engine management, optional traction control, and sophisticated climate control systems.

📋 Manual Details

Coverage Areas

Engine Variants Covered:

All 1991 E32 variants

Regions Covered:

Global (specifications may vary slightly by market)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Comprehensive Service & Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, fuel injection, ignition, cooling, exhaust, lubrication, engine management (DME)

Transmission Systems:

Automatic transmission (Steptronic availability for later models, manual gearbox overhaul for applicable variants), clutch system, driveshafts, differentials

Suspension Steering:

Front and rear suspension, shock absorbers, springs, control arms, power steering system, steering column

Braking System:

Hydraulic brake system, ABS (Anti-lock Braking System), brake calipers, rotors, lines, master cylinder, parking brake

Electrical System:

Battery, charging system, starter motor, lighting systems, wipers, horn, instrumentation, body control modules, diagnostic connectors (OBD I)

Climate Control:

HVAC system, air conditioning, heating, ventilation, blower motor, controls

Body Interior:

Body panels, doors, windows, locks, seats, interior trim, convertible top mechanisms (if applicable to specific E32 models, though less common)

Safety Systems:

Airbag systems (SRS - Supplemental Restraint System), seatbelt mechanisms

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks and flushes, belt inspections, spark plug replacement, brake pad/rotor replacement, battery maintenance

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation (OBD I)

Repair Procedures:

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

Rebuild Instructions:

Detailed instructions for engine and transmission rebuilds, including torque specifications and assembly sequences

Wiring Diagrams:

Complete electrical schematics for all vehicle systems

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance and fluid checks to in-depth engine and transmission overhauls, electrical system diagnostics, and bodywork repairs.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Print Quality:

High-resolution, printable pages

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Codes 1991:

M30B35 (3.5L inline-6), M60B40 (4.0L V8 - introduced later in the E32 lifecycle, possibly late 1991/early 1992 model year depending on market)

Displacement 35:

3430 cc (3.5 Liters)

Bore Stroke 35:

92.0 mm x 86.0 mm

Compression Ratio 35:

8.0:1 or 8.5:1 (depending on market and fuel quality)

Horsepower 35:

208 hp @ 5700 rpm (approx.)

Torque 35:

228 lb-ft @ 4000 rpm (approx.)

Engine Codes V8:

M60B40

Displacement V8:

3982 cc (4.0 Liters)

Bore Stroke V8:

84.0 mm x 90.0 mm

Compression Ratio V8:

10.0:1

Horsepower V8:

296 hp @ 5800 rpm (approx.)

Torque V8:

295 lb-ft @ 4500 rpm (approx.)

Performance

0 60 Mph 35:

7.0 - 8.0 seconds (approx.)

0 60 Mph V8:

6.0 - 7.0 seconds (approx.)

Fuel System

Fuel Delivery:

Bosch Motronic electronic fuel injection (DME for M30, DME 3.3/3.3.1 for M60)

Fuel Type:

Unleaded premium gasoline

Engine Management

Bosch Motronic

🔧 Transmission

Standard

Transmission Type 35:

4-speed automatic (ZF 4HP22)

Optional

Transmission Type V8:

5-speed manual (Getrag 260/5 - rare option), 4-speed automatic (ZF 4HP24)

Features

Automatic Features:

Sport/Economy modes (depending on variant)

Fluid Specifications

Automatic Transmission Fluid:

Dexron II or III (check manual for exact specification, e.g., Esso LT 71141 may be specified for later ZF boxes)

📐 Dimensions

Exterior

Length:

Approx. 4960 mm (195.3 in)

Width:

Approx. 1800 mm (70.9 in)

Height:

Approx. 1400 mm (55.1 in)

Wheelbase:

Approx. 2830 mm (111.4 in)

Weights

Curb Weight 35:

Approx. 1700 kg (3750 lbs)

Curb Weight V8:

Approx. 1850 kg (4080 lbs)

Gross Vehicle Weight Rating:

Refer to VIN plate or manual for exact specification

Cargo

Trunk Volume:

Approx. 500 liters (17.7 cu ft)

🛡️ Safety Features

Ratings

NHTSA Rating:

Not specifically rated by NHTSA using modern standards; safety was focused on passive restraints and chassis design for its era.

Active Features

Standard on most models, optional on earlier variants.

Traction Control:

Optional on some later E32 models (ASC - Automatic Stability Control)

Passive Features

Airbags:

Driver's side airbag standard for 1991 model year.

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette stereo system, often with premium sound options (e.g., Hi-Fi system).

Navigation:

Optional early navigation system available on some models, often rudimentary by modern standards.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assist:

Optional rear parking sensors on some late E32 models.

Connectivity

Diagnostic Port:

OBD I (On-Board Diagnostics I) utilizing a 15-pin connector, located under the hood or dashboard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 - 10,000 miles or annually (depending on driving conditions and oil used).

Transmission Fluid Change:

Recommended every 30,000 - 50,000 miles for automatic transmissions.

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles.

Spark Plug Replacement:

Approx. 30,000 miles for standard plugs, longer for platinum/iridium.

Fluid Specifications

Engine Oil Type:

API SG or higher; viscosity typically 10W-40 or 15W-40 (check manual for specific recommendations based on climate).

Engine Oil Capacity 35:

Approx. 5.5 Liters (5.8 US Quarts)

Engine Oil Capacity V8:

Approx. 6.5 Liters (6.9 US Quarts)

Coolant Type:

Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. BMW Blue or Green coolant compatible.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tank cracking, thermostat housing leaks, heater core issues.

Electrical System:

Instrument cluster illumination issues, door lock actuator failures, intermittent ABS warning lights, wiring harness degradation.

Engine M30:

Oil leaks from valve cover gasket, oil pan gasket, rear main seal. Timing chain guide wear on high mileage examples.

Engine M60:

Timing chain tensioner and guide wear (critical failure point if neglected), Nikasil cylinder liner wear (in early M60B40 engines, replaced by Alusil later).

Suspension:

Wear in control arm bushings, ball joints, and rear subframe bushings. Self-leveling rear suspension issues (if equipped).

Interior:

Cracking dashboard, sagging headliner, worn leather upholstery.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long history of producing driver-focused luxury sedans known for their engineering and performance.

Model Evolution

E32 Predecessor:

Succeeded the E23 7 Series.

E32 Successor:

Succeeded by the E38 7 Series.

Introduction Year:

Facelift Details:

The 1991 model year represents the pre-facelift E32, with updates occurring around 1992/1993.

Production

Production Period:

1986-1994

Manufacturing Location:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

While the E32 specifically may not have made the list for 1991, the 7 Series lineage consistently received accolades for its engineering and luxury.

Model Reputation:

Widely regarded as a benchmark for automotive engineering and driver involvement in the luxury sedan segment of its era.