BMW 735i 735iL 1992 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 735i, 735iL Year: 1992 Codes Chassis Code: E32 Engine Code: M30B35 👋 Introduction Market Position Segment: Full-size luxury sedan. Target Audience: Affluent individuals...

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Type: Car

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Sku: 432983

Tags: 1992 735i 735iL BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

735i, 735iL

Year:

Codes

Chassis Code:

Engine Code:

M30B35

👋 Introduction

Market Position

Segment:

Full-size luxury sedan.

Target Audience:

Affluent individuals seeking comfort, performance, and advanced engineering.

Competitive Analysis

Key Competitors:

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

Key Features

Platform:

E32 platform, known for its robust construction and advanced features for the era.

Distinction:

Blended luxury, performance, and cutting-edge technology, epitomizing BMW's 'Ultimate Driving Machine' philosophy in the luxury segment.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, repair, and diagnostics for all mechanical and electrical systems.

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Service And Overhaul:

Complete engine disassembly, inspection, repair, and reassembly for the M30B35 engine.

Fuel And Exhaust Systems:

Fuel injection system (Bosch Motronic), fuel pump, lines, injectors, exhaust manifold, catalytic converter, mufflers.

Cooling System:

Radiator, water pump, thermostat, hoses, coolant specifications, fan clutch.

Ignition System:

Spark plugs, ignition coils, distributor (if applicable), timing, ECU control.

Transmission Service And Repair:

Automatic transmission (e.g., ZF 4HP22) service, fluid changes, seal replacement, internal component repair, diagnostics.

Driveline And Axles:

Driveshaft, universal joints, rear axle differential, half-shafts.

Suspension And Steering:

Front and rear suspension components (struts, control arms, bushings), power steering system, steering rack, alignment specifications.

Brake System:

Front and rear disc brakes, ABS (Anti-lock Braking System) diagnostics and repair, brake fluid specifications, bleeding procedures.

Electrical System:

Battery, charging system (alternator), starter, lighting circuits, wiring diagrams, fuse box locations and functions.

Climate Control HVAC:

Air conditioning system service, heater core, blower motor, control panel diagnostics.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass replacement, chassis lubrication.

Interior Trim And Appointments:

Seat removal, dashboard disassembly, headliner, door panels.

Diagnostic Troubleshooting:

Component testing, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs) interpretation for Motronic and other systems.

Procedures Included

Routine Maintenance:

Oil change, filter replacement, spark plug replacement, fluid level checks, belt inspection and replacement.

Major Repairs:

Engine rebuild, transmission overhaul, suspension component replacement, brake caliper rebuild.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon issues.

Electrical Diagnostics:

Wiring diagram interpretation, voltage drop testing, circuit continuity checks.

Specifications And Tolerances:

Tightening torques, engine clearances, alignment angles, component specifications.

Special Tools:

Identification and usage of BMW-specific tools required for certain procedures.

Technical Depth

Depth Of Coverage:

Full workshop level, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete component rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if a scanned PDF with OCR, or natively searchable if a digital-native PDF.

Print Quality

Print Readability:

Designed for clarity, with detailed diagrams and text. Print quality depends on the source material.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-cylinder, SOHC

Engine Code:

M30B35

Displacement:

3.430 cc (3.4 L)

Bore X Stroke:

92 mm x 86 mm

Compression Ratio:

8.0:1

Performance

Horsepower At Rpm:

208 hp @ 5,700 rpm

Torque At Rpm:

225 lb-ft (305 Nm) @ 4,000 rpm

Fuel System

Fuel Delivery:

Bosch Motronic M3.3 electronic fuel injection

Fuel Type:

Unleaded gasoline, 91 octane (RON+MON)/2

Other

Engine Management:

Digital Engine Management (DME)

🔧 Transmission

Standard

Transmission Type:

4-speed automatic

Transmission Model:

ZF 4HP22

Optional

Transmission Type:

5-speed manual (less common in North America)

Features

Gear Ratios Auto:

1st: 2.48, 2nd: 1.48, 3rd: 1.00, 4th: 0.73, Reverse: 2.08

Transmission Fluid Type:

BMW ATF Dexron II or equivalent

📐 Dimensions

Exterior

Wheelbase 735I:

2,900 mm (114.2 in)

Wheelbase 735Il:

3,070 mm (120.9 in)

Length 735I:

4,958 mm (195.2 in)

Length 735Il:

5,125 mm (201.8 in)

Width:

1,800 mm (70.9 in)

Height:

1,400 mm (55.1 in)

Weights

Curb Weight 735I:

1,770 kg (3,900 lbs)

Curb Weight 735Il:

1,840 kg (4,057 lbs)

2,300 kg (5,070 lbs) approx.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated in modern standards, but known for robust construction.

IIHS Offset Crash:

Not tested by IIHS in this era.

Active Features

Standard (Bosch ABS III)

Traction Control:

Optional (ASC - Automatic Stability Control)

Passive Features

Airbags:

Driver airbag standard, passenger airbag optional.

Seatbelts:

3-point inertia-reel seatbelts with pretensioners.

Chassis Strength:

Reinforced safety cell, crumple zones.

💡 Technology Features

Infotainment

Audio System:

High-fidelity BMW sound system, often with cassette player and optional CD changer.

Navigation:

Optional early GPS navigation system, typically a bulky unit with a CRT display.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC) were introduced later in the E32's lifecycle, may not be on all 1992 models.

Connectivity

Communication:

Early cellular phone integration was available as an option.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 - 10,000 miles or 12 months, whichever comes first. (Refer to manual for specific conditions).

Spark Plug Replacement:

Approx. 30,000 miles (refer to manual for specific plug type and gap).

Transmission Fluid Change:

Every 30,000 - 60,000 miles. Crucial for longevity of the ZF automatic. (Consult manual for precise interval).

Coolant Flush:

Every 2 years or 30,000 miles.

Fluid Specifications

Engine Oil Type And Capacity:

SAE 5W-30 or 10W-40, approx. 6.5 liters (6.9 US quarts). Check dipstick.

Coolant Type:

BMW Blue Antifreeze/Coolant (G48) or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Head Gasket Failure:

M30 engines can be prone to head gasket failure if overheated. The manual will detail symptoms and repair procedures.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and front/rear main seals are common leak points.

Cooling System Components:

Plastic coolant reservoir can become brittle and crack; water pump seals can fail.

Electrical Gremlins:

Older E32s can experience issues with wiring harnesses, sensor failures, and module problems. Comprehensive wiring diagrams are essential.

Climate Control Issues:

Blend door actuators and blower motor resistor failures are common.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long-standing reputation for building driver-focused luxury vehicles with a focus on performance and engineering.

Model Evolution

E32 Generation:

The E32 chassis replaced the E23 7 Series and was produced from 1986 to 1994. It marked a significant advancement in technology and styling for BMW's flagship sedan.

735I Variant:

The 735i was the entry-level engine option for the E32 chassis in many markets, offering a balance of performance and luxury.

735Il Variant:

The 'iL' designation signifies the long-wheelbase version, providing increased rear-seat legroom and a more opulent experience.

Production

Manufacturing Location:

Germany

Production Years:

1986-1994 (E32 chassis)

🏆 Awards & Recognition

Recognitions

European Car Of The Year:

Not a winner, but consistently recognized for luxury and engineering.

Car And Driver 10Best:

Consistently praised by automotive journalists for its driving dynamics and refinement.

Ratings

Automobile Magazine Allstar:

Often featured in 'All-Star' lists for its category, highlighting its blend of performance and luxury.