BMW 735i 735iL 1990 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 735i / 735iL Year: 1990 Codes Chassis Code: E32 👋 Introduction Market Position Vehicle Segment: Full-size luxury sedan, representing the pinnacle of BMW's...

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UGS: 423424

Mots clés: 1990 735i 735iL BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

735i / 735iL

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Full-size luxury sedan, representing the pinnacle of BMW's engineering for its era.

Target Audience:

Affluent buyers seeking performance, comfort, and advanced technology, as well as independent repair shops and enthusiasts.

Competitive Analysis

Key Competitors:

Mercedes-Benz S-Class (W126), Audi V8 quattro, Jaguar XJ6.

Key Features

Long Wheelbase Option:

The 'iL' designation signifies the long-wheelbase version, offering enhanced rear passenger legroom and comfort.

Sophisticated Engineering:

Characterized by advanced powertrain, suspension, and electronics for its time.

Build Quality:

Renowned for BMW's typical high standards of materials and construction.

📋 Manual Details

Coverage Areas

Manual Type:

Full Service & Repair Manual

Language:

English

Format:

Digital (likely PDF, though not explicitly stated, common for this era's reproduction)

Page Count

Estimated Page Count:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed procedures for disassembly, inspection, repair, and reassembly of the M30B35 engine.

Engine Management:

Diagnosis and repair of the Bosch Motronic engine management system, including fuel injection and ignition timing.

Transmission Manual:

Service and repair for the Getrag 260 5-speed manual transmission, including clutch assembly.

Transmission Automatic:

Service and repair for the ZF 4HP-22 automatic transmission, including shift control and hydraulic system.

Suspension Front:

Repair and replacement of struts, control arms, bushings, and steering components.

Suspension Rear:

Service for trailing arms, shock absorbers, and associated linkages for the independent rear suspension.

Brakes Hydraulic:

Diagnosis and repair of the brake system, including ABS (Anti-lock Braking System) components and bleeding procedures.

Steering:

Service for the power steering system, including pump, rack, and hoses.

Electrical System:

Comprehensive wiring diagrams, component testing, and troubleshooting for the entire vehicle electrical system.

Climate Control:

Service for HVAC (Heating, Ventilation, and Air Conditioning) system, including refrigerant handling and component replacement.

Bodywork Interior:

Procedures for interior trim removal, seat adjustment, and body panel maintenance.

Bodywork Exterior:

Repair and adjustment of doors, hood, trunk lid, and associated hardware.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems across all vehicle systems.

Engine Rebuild:

Step-by-step instructions for complete engine overhaul, including torque specifications and clearances.

Transmission Overhaul:

Detailed steps for automatic and manual transmission disassembly, repair, and reassembly.

Brake System Repair:

Pad and rotor replacement, caliper servicing, brake line repair, and ABS diagnostics.

Suspension Alignment:

Specifications for wheel alignment and procedures for adjustment.

Electrical Diagnostics:

Testing of sensors, actuators, control modules, and wiring using multimeters and diagnostic tools.

Fuel System Service:

Fuel pump testing, injector cleaning, and fuel pressure diagnosis.

Cooling System Service:

Radiator, water pump, thermostat, and coolant hose replacement and flushing procedures.

Exhaust System Repair:

Replacement of muffler, catalytic converter, and exhaust pipes.

Body Panel Adjustment:

Alignment of doors, hood, trunk, and bumper covers.

Technical Depth

Diagnostics:

Advanced diagnostic procedures, including interpretation of fault codes and circuit analysis.

Rebuilds:

Comprehensive instructions for full engine and transmission rebuilds.

Specifications:

Includes detailed torque values, clearances, fluid capacities, and component tolerances.

📊 Manual Specifications

File Format

Digital Format:

PDF (presumed, typical for scanned manuals)

Searchability:

Likely OCR-enabled for text searching, crucial for efficient use.

Print Quality

Scan Quality:

Variable, depends on original source. High-quality scans are essential for legibility of diagrams.

Binding Type

Physical Format Analogue:

If printed, likely a bound volume or loose-leaf binder.

Paper Type

Physical Format Analogue:

Typically durable paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B35

Engine Type:

Inline-6, SOHC

Displacement:

3.430 cc (3.4 Liters)

Performance

Horsepower:

Approx. 208 hp @ 5,700 rpm

Torque:

Approx. 224 lb-ft @ 4,000 rpm

Fuel System

Fuel Delivery:

Bosch Motronic M3.3 fuel injection and ignition control

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

🔧 Transmission

Standard

Transmission Type:

Getrag 260 5-speed manual

Optional

Transmission Type:

ZF 4HP-22 4-speed automatic

Features

Automatic Control:

Electronic control for smooth shifting and optimal performance (for automatic).

Manual Clutch:

Hydraulically actuated clutch system.

📐 Dimensions

Exterior

Length 735I:

4960 mm (195.3 in)

Length 735Il:

5124 mm (201.7 in)

Width:

1800 mm (70.9 in)

Height:

1400 mm (55.1 in)

Wheelbase 735I:

2830 mm (111.4 in)

Wheelbase 735Il:

2985 mm (117.5 in)

Weights

Curb Weight 735I:

Approx. 1700 kg (3748 lbs)

Curb Weight 735Il:

Approx. 1770 kg (3902 lbs)

Gross Weight Rating:

Typically around 2200-2300 kg.

🛡️ Safety Features

Ratings

Safety Standards:

Designed to meet contemporary safety standards of the late 1980s/early 1990s.

Active Features

Standard Anti-lock Braking System (ABS) on all four wheels.

Traction Control:

Optional ASC (Automatic Stability Control) system available on some models.

Passive Features

Airbags:

Driver's side airbag was optional and becoming more common.

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners (front).

Body Structure:

Reinforced safety cage, crumple zones designed for occupant protection.

💡 Technology Features

Infotainment

Audio System:

Original BMW Bavaria C or similar premium cassette/radio system, often with upgraded speakers.

Onboard Computer:

Optional check control system for vehicle status and basic diagnostics.

Driver Assistance

Cruise Control:

Standard or optional electronic cruise control.

Parking Sensors:

Not a standard feature for this model year; early ultrasonic parking assist systems were rare.

Connectivity

Telephone:

Optional factory fitted car phone systems were available, often bulky and integrated into the center console.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions.

Spark Plug Replacement:

Around 30,000 - 50,000 miles, depending on plug type used.

Coolant Flush:

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

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 5W-30 or 10W-40 (consult manual for specific ambient temperature recommendations).

Coolant Type:

BMW Blue or equivalent Ethylene Glycol based coolant (50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4.

Automatic Transmission Fluid:

ZF TE-ML 04D or equivalent (Dexron II/III may be acceptable, but consult manual for exact spec).

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90.

Known Issues

Cooling System Leaks:

Common leaks from plastic coolant expansion tanks and hose connections due to age and material degradation.

Head Gasket Failure:

While robust, the M30 engine can develop head gasket issues if consistently overheated.

Electrical Gremlins:

Aging wiring harnesses, corroded connectors, and failing relays or control modules can cause intermittent electrical faults.

Sunroof Drain Blockage:

Clogged sunroof drains can lead to water ingress into the cabin, affecting electronics and interior trim.

Automatic Transmission Harshness:

Valve body issues or low/degraded ATF can lead to rough shifting.

Suspension Bushings:

Worn control arm and sway bar bushings can lead to a less precise ride and clunking noises.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's reputation for 'The Ultimate Driving Machine' and engineering excellence.

Model Evolution

E32 Generation:

The E32 chassis marked a significant advancement for BMW's flagship sedan, introducing new technologies and a more aerodynamic design.

Predecessor:

Succeeded the E23 7 Series.

Production

Production Years:

1986-1994 (E32 generation)

Manufacturing Location:

Dingolfing Plant, Germany.

🏆 Awards & Recognition

Recognitions

Automotive Press:

Consistently praised by automotive journalists for its refined ride, potent engine, and luxurious appointments.

Industry Awards:

While specific awards are hard to pinpoint for this exact year, the E32 7 Series was a benchmark for luxury sedans in its time.