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BMW 7 Series 735i 1988-1994 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 7 Series Model Variant: 735i Year: 1988-1994 Codes Chassis Code: E32 👋 Introduction Market Position Market Position: The BMW 7 Series (E32) represented...
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BMW 7 Series 735i 1988-1994 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
7 Series
Model Variant:
735i
Year:
1988-1994
Codes
Chassis Code:
E32
👋 Introduction
Market Position
Market Position:
The BMW 7 Series (E32) represented the pinnacle of luxury, technology, and performance in its era, directly competing with flagship sedans from Mercedes-Benz (W126 S-Class), Jaguar, and Lexus.
Competitive Analysis
Competitive Analysis:
The 735i offered a blend of smooth power, advanced (for the time) electronics, and superior driving dynamics compared to many contemporaries, establishing BMW's reputation for 'The Ultimate Driving Machine' even in the luxury segment.
Key Features
Key Features:
The E32 7 Series was known for its sophisticated independent suspension, powerful inline-six engines, advanced onboard computer, and optional features like the self-leveling suspension and power-adjustable rear seats.
Interior Features:
Luxurious leather upholstery, wood trim accents, power-adjustable seats with memory, heated seats (optional), dual-zone climate control, power sunroof, and automatic climate control were hallmarks of the E32's premium interior.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Drivetrain, Suspension, Steering, Brakes, Fuel System, Cooling System, Electrical System, Climate Control, Body, Interior, Diagnostics, Troubleshooting, Maintenance Procedures
Page Count
Page Count:
Extensive (Exact number not specified, but implies comprehensive coverage)
Manual Type
Manual Type:
Official Full Service Repair Manual
Language
Language:
English (assumed from product description and typical market)
Format
Format:
Digital (PDF implied, but may also refer to print availability)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, valve train, timing components, lubrication system, oil pump, oil filter housing
Engine Management:
Motronic engine management system, fuel injection (DME), ignition system, sensors (MAP, MAF, O2, coolant temp, crank position), actuators (injectors, ignition coils)
Drivetrain:
Transmission (automatic/manual), differential, driveshafts, CV joints, clutch system (if manual)
Suspension Steering:
Front and rear suspension components, shock absorbers, struts, control arms, bushings, steering rack, power steering system, hydraulic steering
Brakes:
Brake system components, hydraulic lines, master cylinder, brake boosters, ABS (Anti-lock Braking System), brake pad replacement, rotor resurfacing/replacement, caliper service
Fuel System:
Fuel pump, fuel filter, fuel injectors, fuel lines, fuel tank, evaporative emission control (EVAP)
Cooling System:
Radiator, water pump, thermostat, cooling fan, heater core, coolant hoses, pressure cap
Electrical System:
Battery, alternator, starter motor, lighting system, wiring diagrams, fuses, relays, electrical component testing, diagnostic trouble codes (DTCs)
Climate Control:
Air conditioning system (compressor, condenser, evaporator, refrigerant charging), heating system, blower motor, climate control module
Body Interior:
Body panels, doors, hood, trunk, interior trim, seats, dashboard, exterior lighting, windows, locks
Body And Chassis:
Body structural repair, panel replacement, door mechanisms, window regulators, trunk lid operation, chassis lubrication points.
Climate Control Diagnostics:
Troubleshooting HVAC system faults, refrigerant handling and charging procedures (EPA 609 certification may be required for refrigerant work).
Procedures Included
Maintenance:
Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid replacement, transmission fluid service, air filter replacement, belt inspection and replacement
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, electrical system troubleshooting, engine performance problems
Repair:
Detailed instructions for component removal, installation, and repair (e.g., engine rebuild, transmission overhaul, suspension component replacement, brake caliper overhaul)
Diagnostics:
Diagnostic procedures utilizing BMW's diagnostic tools (e.g., DIS, MoDiC - though specific tool names might not be in the manual, the principles apply), fault code reading and interpretation
Electrical Diagnostics:
Detailed troubleshooting of electrical faults using wiring diagrams, component testing procedures, and diagnostic charts. Coverage of Motronic system fault codes.
Suspension Alignment:
Specifications and procedures for front and rear wheel alignment, critical for handling and tire wear.
Body Panel Replacement:
Guidelines for removing and installing body panels, including door, fender, and hood adjustments.
Technical Depth
Technical Depth:
Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission rebuilds, including detailed torque specifications and diagnostic flowcharts.
Engine Rebuild Procedures:
Complete engine disassembly, inspection, measurement, and reassembly procedures, including critical clearances and tolerances.
Transmission Overhaul Procedures:
Detailed steps for the overhaul of the ZF automatic transmission, including torque converter, valve body, and clutch pack replacement.
Electrical Component Replacement:
Detailed instructions for replacing all major electrical components, including starter, alternator, fuel pump, window motors, and sensors.
📊 Manual Specifications
File Format
File Format:
PDF (Likely, for digital versions)
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of diagrams and text.
Binding Type
Binding Type:
N/A (For digital), Perfect Bound/Spiral Bound (If printed)
Paper Type
Paper Type:
N/A (For digital), High-quality paper stock (If printed)
Completeness
Completeness:
Official factory service manual, providing a complete and authorized guide to maintenance, repair, and diagnostics for the specified vehicle.
Usability
Usability Features:
Clear chapter structure, exploded views of components, step-by-step instructions, torque specifications, special tool requirements, and diagnostic flowcharts enhance ease of use for both professional technicians and advanced DIY enthusiasts.
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30B35
Engine Type:
Inline 6-cylinder, naturally aspirated
Displacement:
3.5 Liters (3430 cc)
Bore X Stroke:
92.0 mm x 86.0 mm
Compression Ratio:
8.0:1 or 8.5:1 (depending on market/year)
Performance
Horsepower:
Approx. 208-211 hp (155-157 kW) @ 5700 rpm
Torque:
Approx. 220-224 lb-ft (298-304 Nm) @ 4000 rpm
Fuel System
Fuel System Type:
Bosch Motronic electronic fuel injection (DME)
Fuel Type:
Unleaded gasoline (RON 91 or higher recommended)
Cooling System
Coolant Capacity:
Approx. 9.5 Liters (with heater)
Engine Management
Emission Controls:
Catalytic converter, oxygen sensors, secondary air injection system (depending on market and year).
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (ZF 4HP22)
Optional
Transmission Type:
5-speed manual (Getrag 265 - rare in US market)
Features
Transmission Features:
Automatic transmission featured Sport and Economy modes. Manual transmission offered close-ratio gearing for spirited driving.
Fluid Specifications
Automatic Transmission Fluid:
BMW ATF Dexron II or equivalent (Check manual for specific part number recommendations)
Fluid Capacities
Automatic Transmission Fluid Capacity:
Approx. 1.5 Liters (dry fill), 4.0-4.5 Liters (total capacity)
📐 Dimensions
Exterior
Length:
Approx. 4970 mm (195.7 in)
Width:
Approx. 1800 mm (70.9 in)
Height:
Approx. 1400 mm (55.1 in)
Wheelbase:
Approx. 2900 mm (114.2 in)
Weights
Curb Weight:
Approx. 1700-1800 kg (3748-3968 lbs)
Gross Vehicle Weight:
Approx. 2200 kg (4850 lbs)
Cargo
Trunk Capacity:
Approx. 500 Liters (17.6 cu ft)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not subjected to modern standardized crash testing protocols like NHTSA/Euro NCAP. However, built with substantial safety cage and crumple zones for its era.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Servotronic power steering (speed-sensitive)
Passive Features
Passive Safety Features:
Driver and front passenger airbags (introduced later in the production run, check specific VIN), seatbelt pre-tensioners, reinforced chassis structure, energy-absorbing interior components.
💡 Technology Features
Infotainment
Infotainment Features:
Original Blaupunkt or BMW branded cassette/radio systems. Optional CD changer. On-Board Computer (OBC) displaying fuel economy, range, outside temperature, and basic system diagnostics.
Driver Assistance
Driver Assistance Features:
ABS, power steering, cruise control. Some models featured electronic suspension adjustment (EDC - Electronic Damper Control).
Connectivity
Connectivity Features:
Limited by modern standards. Basic telephone integration optional in later models. Diagnostic port for early OBD-I systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500-10,000 miles or 12 months, whichever comes first (depending on driving conditions; consult manual).
Spark Plug Replacement Interval:
Approx. 30,000 miles (for standard plugs); platinum/iridium plugs may extend this significantly.
Transmission Fluid Service Interval:
Every 30,000-50,000 miles (recommended for longevity, though BMW historically claimed 'lifetime' fluid).
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 15W-40 or 10W-40 (Check manual for specific viscosity recommendation based on ambient temperature).
Engine Coolant Specification:
BMW Blue Coolant (G48 ethylene glycol based) or equivalent with corrosion inhibitors. 50/50 mix with distilled water.
Power Steering Fluid:
BMW Power Steering Fluid (Pentosin CHF 11S or equivalent - **critical to use correct fluid to avoid pump damage**).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid (Consult manual for specific recommendation).
Known Issues
Known Issues:
Cooling system leaks (hose, radiator, water pump), head gasket issues (especially on high mileage M30 engines), subframe bushings, ABS sensor failures, door handle microswitches, blower motor resistor failure, OBC (On-Board Computer) pixelation.
Common Maintenance Items:
Regular replacement of cooling hoses, drive belts, and thermostat is crucial. Checking and cleaning the idle control valve (ICV) helps maintain smooth idle.
📚 Vehicle History
Brand Heritage
Brand Heritage:
BMW, established in 1916, has a long history of producing high-quality, performance-oriented vehicles, initially aircraft engines, then motorcycles, and finally automobiles. The brand is synonymous with engineering excellence and driving pleasure.
Model Evolution
Model Evolution:
The E32 generation represented a significant leap forward from its predecessor, the E23 7 Series. It introduced a more aerodynamic and modern design, advanced electronics, and improved chassis dynamics. It was succeeded by the E38 7 Series.
Chassis Code Significance:
E32 denotes the second generation of the BMW 7 Series, succeeding the E23. It was built on a new platform and introduced significant styling and technological advancements.
Production
Production Years:
1986-1994
Manufacturing Locations:
Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 1988-1994 735i model are not widely publicized as individual accolades, the E32 generation was consistently praised by automotive journalists for its blend of performance, luxury, and technological innovation, earning it a strong reputation as a class-leading luxury sedan.
Ratings
Ratings:
Consistently rated highly for build quality, ride comfort, and driving dynamics by contemporary automotive publications such as Car and Driver, MotorTrend, and Road & Track.
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