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 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: PDF 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 ABS: 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),...