BMW 735i 735iL 1988-1994 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 7 Series Model Variant: 735i, 735iL Model Years: 1988, 1989, 1990, 1991, 1992, 1993, 1994 Codes Chassis Code Primary: E32 Engine Code Primary: M30B35 👋 Introduction Market Position Positioning: Flagship luxury sedan of its era, representing BMW's engineering prowess and focus on performance and refinement. Competitive Analysis Competitors: Mercedes-Benz S-Class (W126/W140), Jaguar XJ, Audi V8 Quattro, Lexus LS 400 Key Features Design Philosophy: Classic BMW kidney grille, elegant lines, driver-focused interior, and superior handling for a large luxury car. Technological Advancements: Early adoption of electronic engine management, ABS, and sophisticated climate control for its time. Manual Value Proposition Value: Essential resource for owners and independent mechanics to maintain and repair these sophisticated vehicles accurately, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Primary Coverage: Complete Factory Service and Repair Diagnostic Coverage: Advanced diagnostics and troubleshooting Maintenance Coverage: Routine maintenance to major component overhaul Electrical Coverage: Comprehensive wiring diagrams and electrical system diagnosis Bodywork Coverage: Body repair, panel replacement, and alignment procedures Page Count Estimated Pages: Hundreds of pages (specific count not provided, implies substantial content) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, and repair (cylinder head, block, pistons, crankshaft, camshaft, valvetrain) Engine Management: Bosch Motronic fuel injection and ignition system (sensors, actuators, ECU diagnosis, troubleshooting) Cooling System: Radiator, fan, water pump, thermostat, coolant flow, and troubleshooting Exhaust System: Exhaust manifolds, catalytic converter, muffler, and emissions control Fuel System: Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, and fuel tank Transmission Automatic: ZF 4HP-22 EH automatic transmission: removal, installation, overhaul, and electronic control unit (EH) diagnostics Drivetrain: Driveshafts, differential, axle shafts, and wheel bearings Suspension Front: MacPherson struts, control arms, ball joints, bushings, and alignment specifications Suspension Rear: Independent rear suspension, trailing arms, shock absorbers, springs, and alignment specifications Steering System: Power steering system, steering rack, pump, hoses, and troubleshooting Brakes Front: Ventilated disc brakes, calipers, pads, rotors, and ABS system Brakes Rear: Solid disc brakes, calipers, pads, rotors, and ABS system Electrical System General: Battery, alternator, starter motor, lighting systems, and accessory power Climate Control: HVAC system, blower motor, heater core, A/C compressor, refrigerant system, and climate control module Interior Systems: Power seats, power windows, power mirrors, central locking, and interior trim removal Body Exterior: Doors, hood, trunk, bumpers, fenders, glass replacement, and seal maintenance Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid level checks, belt inspections Engine Repair: Timing belt/chain replacement (if applicable to M30), head gasket replacement, piston ring replacement, bearing replacement Transmission Overhaul: Complete rebuild procedures for the ZF 4HP-22 EH automatic transmission Brake Service: Brake pad and rotor replacement, brake caliper service, brake fluid flush and bleed, ABS sensor testing Suspension Repair: Ball joint replacement, bushing replacement, shock absorber/strut replacement, wheel alignment procedures Electrical Troubleshooting: Diagnosis of electrical faults using wiring diagrams, component testing procedures Climate Control Repair: A/C system recharge, leak detection, component replacement (compressor, evaporator, condenser), heater core replacement Diagnostic Codes: Identification and interpretation of diagnostic trouble codes (DTCs) from engine and transmission control units Technical Specifications: Torque specifications for all fasteners, engine clearances, fluid capacities, and diagnostic data Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Diagnostics: Detailed troubleshooting trees and diagnostic procedures for all major systems Rebuild Procedures: Step-by-step instructions for engine and transmission component overhauls Wiring Diagrams: Full set of accurate, high-quality electrical wiring diagrams 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF for easy information retrieval Print Quality Quality: High-resolution scans suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M30B35 Configuration: Inline 6-cylinder, DOHC (Dual Overhead Camshaft) Displacement: 3.430 cc (3.4 Liters) Performance Horsepower Approximate: 208 hp @ 5,700 rpm (E.U. spec), 197 hp (US spec) Torque Approximate: 225 lb-ft @ 4,000 rpm (E.U. spec), 211 lb-ft (US spec) Fuel System Type: Bosch Motronic ML/ME fuel injection and ignition system Fuel Type: Unleaded Gasoline (premium recommended) Cooling System Type: Water-cooled Lubrication System Oil Capacity Approximate: 6.5 Liters (approx. 6.9 US Quarts) Recommended Oil Viscosity: 10W-40 or 15W-50 depending on climate (refer to manual for exact specs) 🔧 Transmission Standard Type: ZF 4HP-22 EH Automatic Optional Type: 5-speed manual (less common in US market for 735i) Features Transmission Control: Electronic control for automatic transmission (EH - Electronic Hydraulic) Fluid Type Automatic: Dexron III (or equivalent - consult manual for exact BMW specification) Fluid Capacity Automatic Capacity Approximate: 1.7 Liters (for pan drop and refill) 📐 Dimensions Exterior Wheelbase 735I: 2,830 mm (111.4 in) Wheelbase 735Il: 3,000 mm (118.1 in) Length 735I: 4,920 mm (193.7 in) Length 735Il: 5,090 mm (200.4 in) Width: 1,800 mm (70.9 in)...
Flagship luxury sedan of its era, representing BMW's engineering prowess and focus on performance and refinement.
Competitive Analysis
Competitors:
Mercedes-Benz S-Class (W126/W140), Jaguar XJ, Audi V8 Quattro, Lexus LS 400
Key Features
Design Philosophy:
Classic BMW kidney grille, elegant lines, driver-focused interior, and superior handling for a large luxury car.
Technological Advancements:
Early adoption of electronic engine management, ABS, and sophisticated climate control for its time.
Manual Value Proposition
Value:
Essential resource for owners and independent mechanics to maintain and repair these sophisticated vehicles accurately, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Factory Service and Repair
Diagnostic Coverage:
Advanced diagnostics and troubleshooting
Maintenance Coverage:
Routine maintenance to major component overhaul
Electrical Coverage:
Comprehensive wiring diagrams and electrical system diagnosis
Bodywork Coverage:
Body repair, panel replacement, and alignment procedures
Page Count
Estimated Pages:
Hundreds of pages (specific count not provided, implies substantial content)
Bosch Motronic ML/ME fuel injection and ignition system
Fuel Type:
Unleaded Gasoline (premium recommended)
Cooling System
Type:
Water-cooled
Lubrication System
Oil Capacity Approximate:
6.5 Liters (approx. 6.9 US Quarts)
Recommended Oil Viscosity:
10W-40 or 15W-50 depending on climate (refer to manual for exact specs)
🔧 Transmission
Standard
Type:
ZF 4HP-22 EH Automatic
Optional
Type:
5-speed manual (less common in US market for 735i)
Features
Transmission Control:
Electronic control for automatic transmission (EH - Electronic Hydraulic)
Fluid Type Automatic:
Dexron III (or equivalent - consult manual for exact BMW specification)
Fluid Capacity Automatic
Capacity Approximate:
1.7 Liters (for pan drop and refill)
📐 Dimensions
Exterior
Wheelbase 735I:
2,830 mm (111.4 in)
Wheelbase 735Il:
3,000 mm (118.1 in)
Length 735I:
4,920 mm (193.7 in)
Length 735Il:
5,090 mm (200.4 in)
Width:
1,800 mm (70.9 in)
Height:
1,400 mm (55.1 in)
Weights
Curb Weight Approximate:
1,690 - 1,800 kg (3,725 - 3,970 lbs) depending on configuration
Gross Vehicle Weight Rating Approximate:
2,250 kg (4,960 lbs)
Wheel Bolt Pattern:
5 x 120 mm
Wheel Size Standard:
15 x 7 inch or 15 x 7.5 inch (alloy wheels)
Tire Size Standard:
205/65R15 or 225/60R15 (depending on model and options)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official crash test data available from regulatory bodies for this era and region; rely on inherent BMW safety design.
Active Features
ABS:
Anti-lock Braking System (ABS) standard
Traction Control:
Optional, often referred to as ASC (Automatic Stability Control) or ASC+T (with traction control) on later models
Passive Features
Airbags:
Driver airbag standard from circa 1990/1991; passenger airbag optional or standard on later models.
Seatbelts:
Three-point inertia-reel seatbelts front and rear
Chassis Design:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
Premium sound systems with cassette player; early generation CD changers available as options.
Climate Control:
Dual-zone automatic climate control with electronic sensors and servo-actuated vents.
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Telematics:
OnStar or similar integrated telematics systems were not standard on these models.
Interior Features
Seat Adjustment:
Power adjustable front seats with memory functions
Lighting:
Interior courtesy lighting, map lights
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 - 10,000 miles or 1 year (depending on driving conditions and oil used; consult manual)
Transmission Fluid Change:
Every 50,000 - 100,000 miles (intervals can vary; critical for longevity)
Coolant Flush:
Every 2 years or 30,000 miles
Spark Plugs:
Every 30,000 - 60,000 miles (depending on plug type; Bosch Super Plus or platinum recommended)
Fluid Specifications
Engine Oil:
API SG or higher; consult manual for specific viscosity (e.g., 10W-40, 15W-50)
Coolant:
BMW Blue Antifreeze/Coolant concentrate (or equivalent HOAT type) mixed 50/50 with distilled water
Power Steering Fluid:
ATF Dexron III (or equivalent)
Brake Fluid:
DOT 4
Known Issues
Engine M30:
Oil leaks from valve cover gasket, oil pan gasket, and front crank seal. Potential for head gasket failure if overheated. Intake manifold vacuum leaks.
Cooling System:
Plastic coolant expansion tank can become brittle and crack. Water pump failure. Heater control valve issues.
Electrical:
Diaphragm in climate control servo motors can fail. Window regulators, central locking pump issues. Corrosion on electrical connectors.
Suspension:
Worn control arm bushings, ball joints, and rear subframe bushings are common, leading to vague steering and poor handling.
Transmission:
ZF transmissions are generally robust, but electronic solenoids can fail, and leaks from pan gaskets or cooler lines can occur.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's established reputation for building driver-oriented sedans with a strong emphasis on performance and luxury.
Model Evolution
E32 Introduction:
The E32 generation replaced the E23 7 Series and introduced a sleeker, more aerodynamic design, significantly updated technology, and a longer wheelbase option (iL).
Powertrain Updates:
While the M30 engine was carried over and refined, later E32 models saw the introduction of the larger V8 engines (740i, 750iL) and more advanced electronics.
Production
Production Years:
1986 - 1994
Manufacturing Location:
Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Consistently praised by automotive journalists for its blend of performance, luxury, and advanced engineering for its time.
Ratings
Reliability Perception:
While complex, the M30 engine is known for its durability when properly maintained. Ownership requires diligent attention to maintenance schedules.