BMW 735i 735iL 1991 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 735i / 735iL Year: 1991 Generation Chassis Code: E32 Codes Engine Code Primary: M30B35 👋 Introduction Market Position Segment: Full-size Luxury Sedan Competitors...

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Description

🏷️ Basic Information

Identification

Make:

Model:

735i / 735iL

Year:

Generation

Chassis Code:

Codes

Engine Code Primary:

M30B35

👋 Introduction

Market Position

Segment:

Full-size Luxury Sedan

Competitors 1991:

Mercedes-Benz S-Class (W126), Lexus LS 400 (XF10), Cadillac DeVille, Lincoln Town Car.

Competitive Analysis

Strengths:

Renowned BMW driving dynamics, robust M30 engine, advanced features for its era, comfortable ride, high-quality interior materials.

Key Features

Standard Features:

Leather upholstery, automatic climate control, power-adjustable front seats with memory, cruise control, power moonroof, power windows and mirrors.

Optional Features:

Heated front and rear seats, premium sound system, self-leveling rear suspension (on some models), cellular telephone.

📋 Manual Details

Coverage Areas

Diagnostic Coverage:

Comprehensive diagnostic procedures for all major systems.

Repair Coverage:

Detailed step-by-step repair instructions for mechanical and electrical components.

Maintenance Coverage:

Complete maintenance schedules, fluid specifications, and interval guidelines.

Wiring Diagrams Coverage:

Includes detailed electrical wiring diagrams for all vehicle circuits.

Page Count

Estimated Page Count:

Hundreds of pages (exact count not specified, but indicates a comprehensive volume).

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

3.5L Inline-6 (M30B35): Engine mechanical, lubrication, cooling, fuel, emissions, ignition, starting, charging.

Transmission:

Automatic Transmission (ZF 4HP22): Operation, diagnosis, repair, fluid specifications.

Drivetrain:

Driveshafts, differential, rear axle assembly.

Suspension:

Front and rear suspension systems, shock absorbers, springs, bushings, alignment.

Steering:

Power steering system, steering gear, steering column, linkages.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), brake fluid, hydraulic system.

Electrical System:

Battery, alternator, starter, lighting, horn, wipers, power windows, mirrors, seats, central locking.

Body:

Body panels, doors, hood, trunk, bumpers, glass, seals, interior trim, sound deadening.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.

Chassis Electrical:

Instrument cluster, warning lights, on-board computer diagnostics.

Procedures Included

Engine Repair:

Engine overhaul, cylinder head removal/installation, piston/ring replacement, bearing service.

Transmission Repair:

Transmission fluid and filter change, torque converter service, internal transmission component repair.

Brake System Service:

Brake pad and rotor replacement, brake caliper service, brake fluid flush, ABS bleeding.

Suspension And Steering Repair:

Shock absorber replacement, ball joint and tie rod end replacement, steering rack service.

Electrical Troubleshooting:

Systematic diagnosis of electrical faults using wiring diagrams and test procedures.

Body Panel Repair:

Door adjustment, panel replacement, rust repair, weatherstrip replacement.

Diagnostic Troubleshooting:

Step-by-step diagnostic flowcharts for common and uncommon problems.

Maintenance Procedures:

Oil changes, filter replacements, spark plug service, belt replacement, coolant flush.

Technical Depth

Depth:

Full factory specifications, diagnostic codes, component testing, disassembly/assembly procedures.

Torque Specifications:

Detailed torque specifications for all critical fasteners.

Tolerance Data:

Specific measurement tolerances for engine and chassis components.

Diagnostic Tools:

Information on necessary special tools and diagnostic equipment.

📊 Manual Specifications

File Format

Format Type:

Searchability:

Likely text-searchable if scanned from original factory document.

Print Quality

Quality:

High-resolution, suitable for printing.

Reproducibility:

Allows printing of selected pages or the entire manual.

Binding Type

Binding Type For Printed:

Not applicable for PDF download, but original would be bound.

Paper Type

Paper Type For Printed:

Not applicable for PDF download, but original would be on durable paper.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Inline-6 Cylinder

Engine Code:

M30B35

Displacement:

3.430 cc (3.4 Liters)

Bore X Stroke:

92.0 mm x 86.0 mm

Compression Ratio:

8.0:1

Valvetrain:

SOHC (Single Overhead Camshaft), 2 Valves per Cylinder

Performance

Horsepower Net SAE:

208 hp @ 5,700 rpm

Torque Net SAE:

224 lb-ft @ 4,000 rpm

Fuel System

Fuel Delivery:

Bosch Motronic M1.3 Fuel Injection

Fuel Type:

Unleaded Premium Gasoline (91 Octane or higher)

Emissions

Catalytic Converter:

Standard

Engine Management

Ignition System:

Distributorless Electronic Ignition (EDIS)

🔧 Transmission

Standard

Type:

ZF 4HP22 4-Speed Automatic Transmission

Optional

Type:

5-Speed Manual Transmission (Less Common)

Features

Sport Mode:

Yes (for automatic transmission)

Fluid Specifications

Automatic Transmission Fluid:

BMW ATF Dextron III (or equivalent)

📐 Dimensions

Exterior

Wheelbase 735I:

2,945 mm (115.9 inches)

Wheelbase 735Il:

3,070 mm (120.9 inches)

Length 735I:

4,970 mm (195.7 inches)

Length 735Il:

5,105 mm (201.0 inches)

Width:

1,800 mm (70.9 inches)

Height:

1,400 mm (55.1 inches)

Weights

Curb Weight 735I:

~1,770 kg (3,902 lbs)

Curb Weight 735Il:

~1,860 kg (4,100 lbs)

Wheels Tires

Standard Tire Size:

205/65R15

Wheel Bolt Pattern:

5x120

🛡️ Safety Features

Ratings

NHTSA Rating:

Not officially rated by NHTSA for this era, but designed with advanced safety features for its time.

Active Features

Standard (Bosch ABS II)

Passive Features

Airbags:

Driver's side airbag standard, passenger airbag optional.

Seat Belts:

Front seat pretensioners, all seating positions equipped with three-point belts.

โครงสร้าง:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory premium stereo system, often with cassette player and amplifier. Optional CD changer.

Display:

Central information display (CID) for vehicle status, climate control, and diagnostics.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assistance:

Rear parking sensors were an option on later models.

Connectivity

Phone Integration:

Optional factory cellular telephone system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles or 12 months, depending on driving conditions (consult manual for specific recommendations).

Coolant Flush Interval:

Every 2-3 years or 30,000 miles.

Transmission Service Interval:

Fluid and filter change every 50,000-60,000 miles.

Fluid Specifications

Engine Oil Type:

API SG or higher, viscosity 5W-30 or 10W-40 (check manual for specific BMW approval).

Engine Oil Capacity:

6.5 Liters (6.9 US Quarts) with filter change.

Coolant Type:

BMW Blue Antifreeze (G48 ethylene glycol based) or compatible, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Common Problems Engine:

Oil leaks from valve cover gasket and oil pan gasket, potential for head gasket failure if overheated, idle control valve issues.

Common Problems Cooling:

Plastic coolant expansion tank can become brittle and crack, water pump failure, thermostat issues.

Common Problems Electrical:

Dashboard illumination issues, SRS warning light, door lock actuator failures, EML (Engine Management Light) issues.

Common Problems Suspension:

Worn control arm bushings, sagging rear self-leveling suspension (if equipped).

📚 Vehicle History

Brand Heritage

Brand Focus:

BMW is renowned for its 'Ultimate Driving Machine' philosophy, focusing on performance, engineering, and driver engagement.

Model Evolution

E32 Introduction:

The E32 generation was introduced in 1986 and replaced the E23 7 Series.

735I Positioning:

The 735i was the entry-level engine option for the E32, offering a balance of performance and comfort.

735Il Positioning:

The 735iL (Lang) offered an extended wheelbase for increased rear passenger legroom and a more luxurious experience.

Production

Production Years E32:

1986-1994

Manufacturing Location:

Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

While specific awards for the 1991 735i are not prominent, the E32 generation was highly regarded and consistently appeared on '10Best' lists in the luxury segment for its era.

Ratings

User Satisfaction:

Owner reviews and long-term reliability studies often highlight the robust nature of the M30 engine and the solid build quality of the E32 chassis.