BMW 735i 735iL 1991 Service Repair Workshop Manual

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

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Description

🏷️ Basic Information

Identification

Make:

Model:

735i / 735iL

Model Code:

Year:

Codes

Engine Code:

M30B35

👋 Introduction

Market Position

Segment:

Full-size Luxury Sedan

Target Audience:

Affluent buyers seeking advanced technology, comfort, and performance.

Competitive Analysis

Key Competitors:

Mercedes-Benz S-Class (W140), Lexus LS 400, Jaguar XJ6, Audi V8 Quattro.

Key Features

Design Philosophy:

Focus on driver engagement, sophisticated engineering, and understated luxury.

Technology Highlights:

Advanced engine management, optional ABS, early electronic climate control, power amenities.

📋 Manual Details

Coverage Areas

Coverage Description:

Comprehensive service and repair instructions for the 1991 BMW 735i and 735iL (E32 chassis).

Page Count

Estimated Page Count:

Approximately 500-700 pages (typical for this era and level of detail).

Manual Type

Manual Type:

Factory Authorized Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (likely PDF), printable pages, searchable text.

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, engine management, fuel injection, ignition, cooling, lubrication, exhaust systems.

Transmission:

Manual and Automatic transmission repair, overhaul, and maintenance.

Drivetrain:

Driveshafts, differentials, axles, clutch (manual).

Suspension:

Front and rear suspension systems, shock absorbers, springs, control arms, bushings.

Steering:

Power steering system, steering rack, tie rods, steering column.

Brakes:

Hydraulic brake system, ABS (Anti-lock Braking System), brake pads, rotors, calipers, lines, bleeding procedures.

Electrical:

Complete electrical schematics, wiring diagrams, battery, alternator, starter, lighting, fuses, relays, ECUs.

Body:

Body panels, doors, windows, locks, interior trim, climate control system, heating, ventilation, air conditioning (HVAC).

Chassis:

Frame, subframes, mounts, underbody protection.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes.

Troubleshooting:

Diagnostic procedures, fault code interpretation (where applicable), symptom-based troubleshooting guides.

Repair:

Step-by-step repair instructions for all major vehicle systems, including component removal and installation.

Rebuild:

Detailed instructions for engine and transmission overhauls, including specifications and tolerances.

Calibration:

Procedures for calibrating sensors, alignment, and electronic systems.

Technical Depth

Depth Level:

Comprehensive, covering basic owner maintenance to full engine and transmission rebuilds, including advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for efficient information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-cylinder, 24-valve (M30B35)

Displacement:

3.5 Liters (3430 cc)

Bore X Stroke:

92.0 mm x 86.0 mm

Compression Ratio:

8.0:1

Valvetrain:

SOHC (Single Overhead Camshaft)

Performance

Horsepower Hp:

208 hp @ 5700 rpm

Torque Lb Ft:

220 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Bosch Motronic L-Jetronic Fuel Injection

Fuel Type:

Unleaded Premium Gasoline (91+ Octane)

Cooling System

Coolant Capacity Liters:

12.0 Liters

Lubrication System

Oil Capacity Liters:

6.5 Liters (with filter)

Recommended Oil Viscosity:

SAE 15W-40 or 20W-50 (depending on climate, consult manual for specifics).

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic (ZF 4HP22)

Features

Automatic Transmission Features:

Sport/Comfort modes, electronically controlled.

Fluid Specifications

Automatic Transmission Fluid Type:

Dexron II (or equivalent specification as per BMW)

📐 Dimensions

Exterior

Length 735I Mm:

4970 mm

Length 735Il Mm:

5120 mm

Width Mm:

1800 mm

Height Mm:

1400 mm

Wheelbase 735I Mm:

2830 mm

Wheelbase 735Il Mm:

2980 mm

Weights

Curb Weight Kg Approx:

1700-1800 kg (varies by model and equipment)

🛡️ Safety Features

Ratings

Crash Test Data Availability:

Limited direct crash test data from independent bodies for this specific year/model, but BMW's reputation for robust construction.

Active Features

Standard on most models for 1991.

Traction Control:

Optional on some models (ASC - Automatic Stability Control).

Passive Features

Airbags:

Driver's side airbag standard for 1991 model year.

Seatbelts:

Front and rear three-point seatbelts.

Body Construction:

Reinforced safety cell, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Premium sound systems were available, often with cassette players and digital tuning radios.

Climate Control:

Automatic climate control with dual-zone functionality available, an advanced feature for its time.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Not available on this model year.

Connectivity

Cellular Phone:

Optional integrated car phone available on some models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions (refer to manual for exact recommendations).

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed.

Spark Plug Replacement:

Every 60,000 miles (96,000 km), typically copper core plugs for this era.

Coolant Flush:

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

Fluid Specifications

Coolant Type:

BMW Blue Long-Life Coolant (G48) or equivalent ethylene glycol based antifreeze with corrosion inhibitors.

Brake Fluid Type:

DOT 4

Power Steering Fluid:

CHF 11S (Pentosin) or BMW recommended equivalent.

Known Issues

Cooling System Reliability:

Aging plastic components (expansion tank, hoses) can become brittle and prone to leaks. Thermostat housing leaks are also common.

Electrical System:

Degradation of wiring insulation (especially in engine bay), failure of various sensors, power window regulators, and door lock actuators.

Engine Management:

Issues with the Motronic system, idle control valve (ICV), and fuel pump relays can cause drivability problems.

Suspension Wear:

Worn control arm bushings, ball joints, and tie rods are common due to age and mileage, affecting handling and ride comfort.

ABS Module:

ABS control modules can fail, leading to loss of ABS functionality.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long-standing reputation for performance, luxury, and engineering excellence in premium vehicles.

Model Evolution

E32 Introduction:

The E32 generation replaced the E23 7 Series and introduced significant advancements in technology and design. It was produced from 1986 to 1994.

E32 Facelift:

The 1991 model year falls within the initial production run before any major facelift changes were introduced in later years.

Production

Production Period:

1986-1994 (for E32 chassis)

Manufacturing Location:

Germany (primarily Dingolfing Plant)

🏆 Awards & Recognition

Recognitions

Automotive Press Reviews:

Consistently praised by automotive journalists for its refinement, ride comfort, and technological features upon release.

Ratings

Car And Driver 10Best:

While not a recurring 10Best winner, it was highly regarded in its class.