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BMW 525I CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about BMW 525I car and truck
repair procedures including BMW engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your BMW 525I automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR BMW 525I AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported BMW 525I cars and light trucks from 1990+
BMW -> Component Replacement & Adjustment -> Thermostat, Replace -> 325 & 330 -> 750 -> M Coupe, M Roadster & Z3 -> M3 -> M5, X5 4.4i, X5 4.6i, 540 & 740 -> X5 3.0i, 525 & 530 -> Z3
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
M Coupe, M Roadster & Z3
- Remove fan pulley and clutch as outlined under "Water Pump, Replace."
- Drain cooling system into suitable container.
- Remove water hoses.
- Remove mounting nut and engine suspension eye.
- Remove cable channel.
- Remove mounting bolts and thermostat housing.
- Remove thermostat.
- Reverse procedure to install, noting the following:
- Ensure vent arrow points upward.
- Install new gasket.
M3
- Remove fan as outlined under "Radiator, Replace."
- Drain coolant into suitable container. ...
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BRAKE SERVICE PROCEDURES FOR BMW 525I AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported BMW 525I cars and light trucks from 1990+.
Power Brake Units -> Description -> Hydraulic Booster System -> Vacuum Booster System
Vehicle: 2001 BMW 525I 2.5 L6 GAS
Hydraulic Booster System
The hydraulic system incorporates a power flow regulator which diverts a small flow of fluid from the power steering operating circuit for the power assisted brake system, Fig. . It charges the hydraulic reservoir in a high pressure range without impairing the function of power steering. The pressurized hydraulic oil volume is supplied to the booster for the sake of power assistance and is applied by operating the connected standard tandem master cylinder. Should the power steering pump fail, the hydraulic reservoir has sufficient reserve pressure to permit m...
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FUEL FILTER REPLACEMENT PROCEDURES FOR BMW 525I AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported BMW 525I cars and light trucks sold in the U.S. for 1980+.
BMW -> Component Locations -> 5 Series
Vehicle: 1993 BMW 525I 2.5 L6 GAS
Refer to Fig. ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR BMW 525I AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported BMW 525I cars and light trucks from 1990+.
DRIVESHAFT, Replace
Vehicle: 1993 BMW 525I 2.5 L6 GAS
The propeller shaft is adapted to pertinent requirements in reverence to the transmission version, power flow and vibration behavior, so that removal and installation will differ and depend on the version. Only tighten nuts or bolts on the flange end whenever possible to avoid tension in the joint disc.
- Raise and support vehicle.
- Remove exhaust assembly.
- Unscrew heat shield.
- On models with front joint disc, unscrew propeller shaft on transmission.
- On models with front universal Joint, support transmission with special tools 24 0 120 and 00 2 020.
- Unscrew transmission suspension...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR BMW 525I AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported BMW 525I cars and light trucks sold in the U.S. from mid 1990's+.
Description
Vehicle: 2001 BMW 525I 2.5 L6 GAS
The Tire Pressure Monitor System (TPMS) monitors the tire inflation pressure while the vehicle is being driven. To achieve this, the tire inflation pressure and tire air temperature are measured at certain intervals by sensors located on each wheel at t...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR BMW 525I AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported BMW 525I cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1993 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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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR BMW 525I AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported BMW 525I cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> BMW -> 1992-95 5 Series
Vehicle: 1995 BMW 525I 2.5 L6 GAS
Service interval is determined by the service indicator.
- Obtain the radio anti-theft code prior to disconnecting the battery ground cable.
- Disconnect the battery ground cable.
- Lift out the glove compartment clips, then pull off the retaining straps.
- Detach the tabs located at the righthand and lefthand sides of the glove compartment.
- Remove the glove compartment.
- Remove the screws retaining the lefthand and righthand side carpeted console trim panels.
- Remove the trim panel from above the glove compartment.
- Remove the two air duct attaching screws, then the air duct.
- Remove the cabin air...
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MAINTENANCE LAMP RESET PROCEDURES FOR BMW 525I AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported BMW 525I cars and light trucks sold in the U.S. from 1990+.
BMW -> Service Interval Indicator -> 1990-2003 5 Series Except M5 & X5 -> Interval Indicator -> Less Underhood Diagnostic Connector -> Oil Service -> With Underhood Diagnostic Connector
Vehicle: 1990 BMW 525I 2.5 L6 GAS
Less Underhood Diagnostic Connector
On these models the SII reset tool cannot be used. Resetting is possible using the instrument cluster trip odometer reset button. Proceed as follows:
- Turn ignition Off.
- Press and hold trip odometer reset button, then turn ignition to "1" (Accessory).
- Keep odometer reset button depressed for approximately five more seconds until any of following words appear in display: "Oil Service" or "Inspection" with "Reset" or "Re."
- On models equipped with high cluster, remaining amount of fuel in liters until next service is displayed should appear.
- On ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR BMW 525I AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported BMW 525I cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition hose clamp at heater core and remove hose.
- Reposition hose clamp at heater control valve and remove hose.
- Remove hose from vehicle.
- Reverse procedure ...
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SERPENTINE BELT SERVICE PROCEDURES FOR BMW 525I AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported BMW 525I cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 1992 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 BMW 525I AUTOMOBILES
Component location diagrams for most BMW 525I cars and light trucks sold in the U.S. from 1990+.
 In Rear RH Side of Luggage Compartment behind Trim Panel Diagram for 2005 BMW 525I 2.5 L6 GASComponents on diagram: |
 In RH Side of Luggage Compartment Diagram for 2002 BMW 525I 2.5 L6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR BMW 525I AUTOMOBILES
OEM drawn wiring diagrams for most BMW 525I cars and light trucks sold in the U.S.
 2004 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
 2005 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR BMW 525I AUTOMOBILES
OEM TSB listings for most BMW 525I cars and light trucks sold in the U.S. from 1985+.
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Document: CUSTOMER CONTACT SYSTEM - SURVEY GENERATED Vehicle: 1990 BMW 525I 2.5 L6 GAS Auto Systems: |
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Document: AIR CONDITIONING SYSTEM POOR PERFORMANCE - REVISED Vehicle: 2005 BMW 525I 2.5 L6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR BMW 525I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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