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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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- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 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 1991 BMW 525I AUTOMOBILES
BMW -> Wiring Diagrams -> A/C & Heater Blower Controls
Vehicle: 1991 BMW 525I 2.5 L6 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
Hydraulic Brakes -> BRAKE SYSTEM BLEEDING
Vehicle: 1991 BMW 525I 2.5 L6 GAS
The following procedure has been revised by BMW Technical Service Bulletin No. 34 06 90 (3134).
- Connect suitable pressure bleeder to brake fluid reservoir. Maximum charging pressure is 43.5 psi.
- Attach bleeder hose and container to right rear wheel. Bleed until no bubbles appear.
- Repeat step 2 for left rear, right front and left front wheels.
- Support rear suspension at wheel carriers and lower car so rear suspension compresses to its normal loaded position (to prevent damage to output shaft jo...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 BMW 525I AUTOMOBILES
BMW -> Fuel Shutoff Switch Location -> 1991-96 5 Series
Vehicle: 1991 BMW 525I 2.5 L6 GAS
The inertia switch is located below the ...
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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 Interval Indicator -> 1990-2003 5 Series Except M5 & X5 -> Interval Indicator -> Less Underhood Diagnostic Connector -> Oil Service -> With Underhood Diagnostic Connector
Vehicle: 1991 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 1991 BMW 525I AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 BMW 525I 2.5 L6 GAS
Lower
- Drain coolant into a suitable container.
- Reposition hose clamp and remove hose from radiator.
- Reposition hose clamp and remove hose from engine.
- Remove hose from vehicle.
- Reverse procedure to ins...
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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+.
 Rear LH Side Of Engine Compartment Diagram for 1991 BMW 525I 2.5 L6 GASComponents on diagram: |
 Vehicle Speed Sensor & Connector Diagram for 1991 BMW 525I 2.5 L6 GASComponents 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 DiagramComponents on diagram: |
 1991 BMW 525I 2.5 L6 GAS Wiring DiagramComponents 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+.
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Document: Tools and Equipment Vehicle: 1991 BMW 525I 2.5 L6 GAS Auto Systems: |
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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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