BMW 735i 735iL 1988-1994 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 7 Series Model Variant: 735i, 735iL Model Years: 1988, 1989, 1990, 1991, 1992, 1993, 1994 Codes Chassis Code Primary: E32 Engine Code Primary:...

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Type: Car

Vendor:

Sku: 365384

Tags: 1988 1989 1990 1991 1992 1993 1994 735i 735iL BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

7 Series

Model Variant:

735i, 735iL

Model Years:

1988, 1989, 1990, 1991, 1992, 1993, 1994

Codes

Chassis Code Primary:

Engine Code Primary:

M30B35

👋 Introduction

Market Position

Positioning:

Flagship luxury sedan of its era, representing BMW's engineering prowess and focus on performance and refinement.

Competitive Analysis

Competitors:

Mercedes-Benz S-Class (W126/W140), Jaguar XJ, Audi V8 Quattro, Lexus LS 400

Key Features

Design Philosophy:

Classic BMW kidney grille, elegant lines, driver-focused interior, and superior handling for a large luxury car.

Technological Advancements:

Early adoption of electronic engine management, ABS, and sophisticated climate control for its time.

Manual Value Proposition

Value:

Essential resource for owners and independent mechanics to maintain and repair these sophisticated vehicles accurately, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Factory Service and Repair

Diagnostic Coverage:

Advanced diagnostics and troubleshooting

Maintenance Coverage:

Routine maintenance to major component overhaul

Electrical Coverage:

Comprehensive wiring diagrams and electrical system diagnosis

Bodywork Coverage:

Body repair, panel replacement, and alignment procedures

Page Count

Estimated Pages:

Hundreds of pages (specific count not provided, implies substantial content)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, and repair (cylinder head, block, pistons, crankshaft, camshaft, valvetrain)

Engine Management:

Bosch Motronic fuel injection and ignition system (sensors, actuators, ECU diagnosis, troubleshooting)

Cooling System:

Radiator, fan, water pump, thermostat, coolant flow, and troubleshooting

Exhaust System:

Exhaust manifolds, catalytic converter, muffler, and emissions control

Fuel System:

Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, and fuel tank

Transmission Automatic:

ZF 4HP-22 EH automatic transmission: removal, installation, overhaul, and electronic control unit (EH) diagnostics

Drivetrain:

Driveshafts, differential, axle shafts, and wheel bearings

Suspension Front:

MacPherson struts, control arms, ball joints, bushings, and alignment specifications

Suspension Rear:

Independent rear suspension, trailing arms, shock absorbers, springs, and alignment specifications

Steering System:

Power steering system, steering rack, pump, hoses, and troubleshooting

Brakes Front:

Ventilated disc brakes, calipers, pads, rotors, and ABS system

Brakes Rear:

Solid disc brakes, calipers, pads, rotors, and ABS system

Electrical System General:

Battery, alternator, starter motor, lighting systems, and accessory power

Climate Control:

HVAC system, blower motor, heater core, A/C compressor, refrigerant system, and climate control module

Interior Systems:

Power seats, power windows, power mirrors, central locking, and interior trim removal

Body Exterior:

Doors, hood, trunk, bumpers, fenders, glass replacement, and seal maintenance

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid level checks, belt inspections

Engine Repair:

Timing belt/chain replacement (if applicable to M30), head gasket replacement, piston ring replacement, bearing replacement

Transmission Overhaul:

Complete rebuild procedures for the ZF 4HP-22 EH automatic transmission

Brake Service:

Brake pad and rotor replacement, brake caliper service, brake fluid flush and bleed, ABS sensor testing

Suspension Repair:

Ball joint replacement, bushing replacement, shock absorber/strut replacement, wheel alignment procedures

Electrical Troubleshooting:

Diagnosis of electrical faults using wiring diagrams, component testing procedures

Climate Control Repair:

A/C system recharge, leak detection, component replacement (compressor, evaporator, condenser), heater core replacement

Diagnostic Codes:

Identification and interpretation of diagnostic trouble codes (DTCs) from engine and transmission control units

Technical Specifications:

Torque specifications for all fasteners, engine clearances, fluid capacities, and diagnostic data

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds

Diagnostics:

Detailed troubleshooting trees and diagnostic procedures for all major systems

Rebuild Procedures:

Step-by-step instructions for engine and transmission component overhauls

Wiring Diagrams:

Full set of accurate, high-quality electrical wiring diagrams

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable PDF for easy information retrieval

Print Quality

Quality:

High-resolution scans suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B35

Configuration:

Inline 6-cylinder, DOHC (Dual Overhead Camshaft)

Displacement:

3.430 cc (3.4 Liters)

Performance

Horsepower Approximate:

208 hp @ 5,700 rpm (E.U. spec), 197 hp (US spec)

Torque Approximate:

225 lb-ft @ 4,000 rpm (E.U. spec), 211 lb-ft (US spec)

Fuel System

Type:

Bosch Motronic ML/ME fuel injection and ignition system

Fuel Type:

Unleaded Gasoline (premium recommended)

Cooling System

Type:

Water-cooled

Lubrication System

Oil Capacity Approximate:

6.5 Liters (approx. 6.9 US Quarts)

Recommended Oil Viscosity:

10W-40 or 15W-50 depending on climate (refer to manual for exact specs)

🔧 Transmission

Standard

Type:

ZF 4HP-22 EH Automatic

Optional

Type:

5-speed manual (less common in US market for 735i)

Features

Transmission Control:

Electronic control for automatic transmission (EH - Electronic Hydraulic)

Fluid Type Automatic:

Dexron III (or equivalent - consult manual for exact BMW specification)

Fluid Capacity Automatic

Capacity Approximate:

1.7 Liters (for pan drop and refill)

📐 Dimensions

Exterior

Wheelbase 735I:

2,830 mm (111.4 in)

Wheelbase 735Il:

3,000 mm (118.1 in)

Length 735I:

4,920 mm (193.7 in)

Length 735Il:

5,090 mm (200.4 in)

Width:

1,800 mm (70.9 in)

Height:

1,400 mm (55.1 in)

Weights

Curb Weight Approximate:

1,690 - 1,800 kg (3,725 - 3,970 lbs) depending on configuration

Gross Vehicle Weight Rating Approximate:

2,250 kg (4,960 lbs)

Wheel Bolt Pattern:

5 x 120 mm

Wheel Size Standard:

15 x 7 inch or 15 x 7.5 inch (alloy wheels)

Tire Size Standard:

205/65R15 or 225/60R15 (depending on model and options)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited official crash test data available from regulatory bodies for this era and region; rely on inherent BMW safety design.

Active Features

Anti-lock Braking System (ABS) standard

Traction Control:

Optional, often referred to as ASC (Automatic Stability Control) or ASC+T (with traction control) on later models

Passive Features

Airbags:

Driver airbag standard from circa 1990/1991; passenger airbag optional or standard on later models.

Seatbelts:

Three-point inertia-reel seatbelts front and rear

Chassis Design:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Audio System:

Premium sound systems with cassette player; early generation CD changers available as options.

Climate Control:

Dual-zone automatic climate control with electronic sensors and servo-actuated vents.

Driver Assistance

Cruise Control:

Standard cruise control

Connectivity

Telematics:

OnStar or similar integrated telematics systems were not standard on these models.

Interior Features

Seat Adjustment:

Power adjustable front seats with memory functions

Lighting:

Interior courtesy lighting, map lights

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 - 10,000 miles or 1 year (depending on driving conditions and oil used; consult manual)

Transmission Fluid Change:

Every 50,000 - 100,000 miles (intervals can vary; critical for longevity)

Coolant Flush:

Every 2 years or 30,000 miles

Spark Plugs:

Every 30,000 - 60,000 miles (depending on plug type; Bosch Super Plus or platinum recommended)

Fluid Specifications

Engine Oil:

API SG or higher; consult manual for specific viscosity (e.g., 10W-40, 15W-50)

Coolant:

BMW Blue Antifreeze/Coolant concentrate (or equivalent HOAT type) mixed 50/50 with distilled water

Power Steering Fluid:

ATF Dexron III (or equivalent)

Brake Fluid:

DOT 4

Known Issues

Engine M30:

Oil leaks from valve cover gasket, oil pan gasket, and front crank seal. Potential for head gasket failure if overheated. Intake manifold vacuum leaks.

Cooling System:

Plastic coolant expansion tank can become brittle and crack. Water pump failure. Heater control valve issues.

Electrical:

Diaphragm in climate control servo motors can fail. Window regulators, central locking pump issues. Corrosion on electrical connectors.

Suspension:

Worn control arm bushings, ball joints, and rear subframe bushings are common, leading to vague steering and poor handling.

Transmission:

ZF transmissions are generally robust, but electronic solenoids can fail, and leaks from pan gaskets or cooler lines can occur.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's established reputation for building driver-oriented sedans with a strong emphasis on performance and luxury.

Model Evolution

E32 Introduction:

The E32 generation replaced the E23 7 Series and introduced a sleeker, more aerodynamic design, significantly updated technology, and a longer wheelbase option (iL).

Powertrain Updates:

While the M30 engine was carried over and refined, later E32 models saw the introduction of the larger V8 engines (740i, 750iL) and more advanced electronics.

Production

Production Years:

1986 - 1994

Manufacturing Location:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Consistently praised by automotive journalists for its blend of performance, luxury, and advanced engineering for its time.

Ratings

Reliability Perception:

While complex, the M30 engine is known for its durability when properly maintained. Ownership requires diligent attention to maintenance schedules.