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1991 BMW 525I CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
Import Compressor Service -> Keihin Compressors -> COMPRESSOR CLUTCH SERVICE -> COMPRESSOR CLUTCH, REPLACE
Vehicle: 1991 BMW 525I 2.5 L6 GAS
COMPRESSOR CLUTCH, REPLACE
- Retain pressure plate using tool No. 07923-PB8000, then remove center bolt, Fig. .
- Install clutch remover tool onto pressure plate, then remove pressure plate by screwing in center bolt, Fig. .
- Clean mating surfaces of pulley and pressure plate in a suitable solvent.
- Remove pulley snap ring, then the pulley using a suitable puller.
- Remove shims from compressor shaft, then the second snap ring.
- Remove clutch coi...
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BRAKE SERVICE PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
Disc Brakes -> TIGHTENING SPECIFICATIONS
Vehicle: 1991 BMW 525I 2.5 L6 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
BMW -> Component Locations -> 5 Series
Vehicle: 1991 BMW 525I 2.5 L6 GAS
Refer to Fig. ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assembly -> Disassembly
Vehicle: 1991 BMW 525I 2.5 L6 GAS
Disassembly
- Remove propeller shaft assembly.
- Remove hose straps.
- Lift out circlip.
- Pull off constant velocity joint complete with dust cover.
- Press knurled head bolts and washers out of constant velocity joint.
- Press off dust cover.
Assembly
- Pack new constant velocity joint with 60 grams of grease (HWB). Do not pack inner race with cage since the balls would tall out.
- Place gaske...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
Alternator, Replace
Vehicle: 1991 BMW 525I 2.5 L6 GAS
- Read fault memory with suitable scan tool.
- Disconnect battery ground wire.
- Remove complete suction filter with air-mass sensor.
- Remove fan.
- Disconnect plug connection on suction filter housing.
- Release screws.
- Loosen hose clamp on intake manifold.
- Unclip upper section of suction-filter housing and place ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
BMW -> Service Indicator Cluster ->
Vehicle: 1991 BMW 525I 2.5 L6 GAS
The service indicator cluster is used indicate when periodic maintenance is required. The service indicator consists of one yellow, five green and three red Light Emitting Diodes (LEDs), with the inscriptions "Oil Service" and "Inspection." When the ignition switch is turned to the On position, as many as five green LEDs will be illuminated.
The green LEDs will go out when the engine is started. If the yellow LED and one of the inscriptions illuminates with the ignition switch in the On position, and remain on after the engine has started, service the maintenance inscription indicated immediately. ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 BMW 525I 2.5 L6 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition hose clamp and remove hose from heater core.
- Reposition hose clamp and remove hose from engine.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 BMW 525I 2.5 L6 GAS
- Remove fan cowl by lifting out expansion rivets on both sides.
- Secure fan pulley with suitable securing tool, or equivalent, then remove fan. Fan has lefthand handed threads.
- Loosen tensioner lock bolts, then turn tensioner with suitable wrench to receive tens...
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COMPONENT LOCATION DIAGRAMS FOR 1991 BMW 525I AUTOMOBILES
Component location diagrams for most 1991 BMW 525I cars and light trucks sold in the U.S. from 1990+.
Passenger's Seat Power Seat Motor Diagram for 1991 BMW 525I 2.5 L6 GAS Components on diagram: |
Headrest Motors & Power Seat Connectors Diagram for 1991 BMW 525I 2.5 L6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 BMW 525I AUTOMOBILES
OEM drawn wiring diagrams for most 1991 BMW 525I cars and light trucks sold in the U.S.
1991 BMW 525I 2.5 L6 GAS Wiring Diagram Components on diagram: |
1991 BMW 525I 2.5 L6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 BMW 525I AUTOMOBILES
OEM TSB listings for most 1991 BMW 525I cars and light trucks sold in the U.S. from 1985+.
Document: Tools and Equipment Vehicle: 1991 BMW 525I 2.5 L6 GAS Auto Systems: |
Document: Tools and Equipment Vehicle: 1991 BMW 525I 2.5 L6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 BMW 525I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 BMW 525I cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 BMW 525I cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 BMW 525I cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 BMW 525I cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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