BMW 735i 735iL 1992 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 7 Series Model Variant: 735i, 735iL Year: 1992 Codes Chassis Code: E32 👋 Introduction Market Position Segment: Full-size Luxury Sedan Competitive Analysis Competitors:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

7 Series

Model Variant:

735i, 735iL

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Full-size Luxury Sedan

Competitive Analysis

Competitors:

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

Key Features

Brand Philosophy:

Emphasis on driving dynamics, sophisticated engineering, and build quality.

Model Philosophy:

Blend of executive comfort and BMW's signature performance characteristics.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service and Repair

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Authorized Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

All aspects of the M30B35 engine including diagnosis, repair, and overhaul

Fuel System:

Fuel injection (Bosch Motronic), fuel pump, lines, injectors, EVAP system

Ignition System:

Ignition control module, coil packs, spark plugs, timing

Cooling System:

Radiator, water pump, thermostat, hoses, fan clutch, coolant types

Exhaust System:

Manifolds, catalytic converter, mufflers, pipework, oxygen sensors

Transmission:

4HP22 (Automatic): Diagnosis, repair, fluid change, rebuild

Drivetrain:

Driveshafts, CV joints, differential, rear axle assembly

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment

Steering:

Power steering system, steering rack, hydraulic pump, linkage

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), master cylinder, calipers, rotors, pads, fluid specifications

Electrical System:

Battery, charging system (alternator), starter motor, wiring diagrams, fuses, relays

Lighting:

Headlights, taillights, interior lights, fog lights, bulb types

HVAC:

Heating, Ventilation, and Air Conditioning system, refrigerant, blower motor, climate control

Body And Chassis:

Body panels, doors, windows, sunroof, bumpers, frame

Interior Trim:

Seats, dashboard, door panels, headliner, carpeting

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs) for various systems

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection

Component Repair:

Detailed step-by-step instructions for component removal, repair, and installation

Rebuild Procedures:

Comprehensive instructions for engine and transmission rebuilds

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon issues

Wiring Diagrams:

Full color, detailed electrical schematics for all vehicle systems

Special Tools:

Identification and usage of BMW-specific tools required for certain repairs

Technical Depth

Depth:

Expert Level: Covers everything from basic maintenance to complete engine and transmission overhauls, including in-depth diagnostics and troubleshooting.

📊 Manual Specifications

File Format

Digital Format:

PDF, often bookmarked and searchable

Print Quality

Quality:

High-resolution scans of original factory manuals

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B35

Configuration:

3.5L Inline-6 (SOHC, 12 valves)

Performance

Horsepower:

208 hp @ 5700 rpm

Torque:

224 lb-ft @ 4000 rpm

Fuel System

Injection Type:

Bosch Motronic Electronic Fuel Injection (EFI)

Fuel Type

Fuel Requirement:

Premium Unleaded Gasoline (91+ octane)

Cooling System

Capacity:

Approx. 10.5 Liters (11.1 US Quarts)

Maintenance

Spark Plug Type:

Bosch W8AC or equivalent

Ignition Timing:

Base timing typically 5 degrees BTDC (check manual for specifics and adjustment)

🔧 Transmission

Standard

Type:

4-Speed Automatic (ZF 4HP22)

Optional

Type:

5-Speed Manual (Rare in US Market)

Features

Control Mode:

Electronic control with Sport/Economy mode selection

Maintenance

Fluid Type:

Dexron III (or equivalent ATF)

Fluid Capacity:

Approx. 8.5 Liters (9 US Quarts) for complete fill (check dipstick for accurate level)

📐 Dimensions

Exterior

Wheelbase 735I:

117.1 inches (2974 mm)

Wheelbase 735Il:

123.6 inches (3140 mm)

Length 735I:

198.7 inches (5047 mm)

Length 735Il:

205.2 inches (5212 mm)

Width:

74.3 inches (1887 mm)

Height:

56.3 inches (1430 mm)

Weights

Curb Weight 735I:

Approx. 3800 lbs (1724 kg)

Curb Weight 735Il:

Approx. 3900 lbs (1769 kg)

Gross Vehicle Weight Rating:

Approx. 5000 lbs (2268 kg)

Wheels And Tires

Wheel Bolt Pattern:

5x120 mm

Standard Tire Size:

225/60VR15 (or 215/65VR15, check specific trim)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited public data available for this era, but designed to high German safety standards.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional (ASC - Automatic Stability Control)

Passive Features

Airbags:

Driver's airbag standard; passenger airbag optional/late availability

Seatbelts:

Three-point inertial reel seatbelts with pretensioners for front occupants

Body Structure:

Reinforced safety cage, crumple zones

💡 Technology Features

Infotainment

Audio System:

Premium Hi-Fi sound system, often with cassette player and optional CD changer.

Climate Control:

Automatic climate control with dual-zone functionality.

Onboard Computer:

On-Board Computer (OBC) displaying trip data, fuel economy, and basic system checks.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assistance:

Optional rear parking sensors (BMW Park Distance Control).

Connectivity

Phone Integration:

Optional factory cellular phone integration (older technology).

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 miles (12,000 km) or annually, whichever comes first.

Transmission Fluid Change:

Recommended every 30,000-50,000 miles (48,000-80,000 km), or as per manual recommendations. Lifelong fluid is generally not advised for this era.

Coolant Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Spark Plug Replacement:

Approx. 30,000 miles (48,000 km) for standard plugs.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Fluid Specifications

Engine Oil Viscosity:

SAE 15W-40 or 10W-40 (check owner's manual for specific climate recommendations and BMW approval).

Coolant Type:

BMW Blue Antifreeze/Coolant (G48) or equivalent ethylene glycol based coolant.

Brake Fluid Type:

DOT 4 brake fluid.

Known Issues

Cooling System:

Plastic coolant expansion tank can become brittle and crack; original water pump impellers can degrade.

Electrical:

Headlight switch recall, door seal water ingress leading to module issues (e.g., ABS, transmission control), OBC (On-Board Computer) pixelation.

Suspension:

Front control arm bushings, rear trailing arm bushings can wear, leading to steering looseness and tire wear.

Fuel System:

Older fuel pumps and fuel distributors can fail; injector O-rings can degrade.

HVAC:

Blower motor resistor failure, evaporator core leaks, climate control unit issues.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Bayerische Motoren Werke AG, known for performance, engineering, and the 'Ultimate Driving Machine' ethos.

Model Evolution

E32 Generation:

The E32 generation, launched in 1986, represented BMW's flagship luxury sedan, succeeding the E23 7 Series. It introduced a new, more aerodynamic design and advanced technology.

Production

Production Years:

1986-1994 (E32 generation)

Key Updates 1992:

Minor updates, potentially including interior trim refinements, sound deadening improvements, and electronic system enhancements.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Consistently ranked among the top luxury sedans of its era for comfort, performance, and build quality by automotive journalists and publications.

Ratings

Reliability Perception:

Perceived as a reliable vehicle when properly maintained, though complex systems can require specialized knowledge.