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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),...
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BMW 735i 735iL 1991 Service Repair Workshop Manual
🏷️ 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), 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.
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