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1992 BMW 525I CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- 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
- Cabin Air Filter Locations & 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 1992 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 1992 BMW 525I AUTOMOBILES
Air Bag System Precautions -> BMW -> Arming
Vehicle: 1992 BMW 525I 2.5 L6 GAS
- Ensure nobody is in vehicle, then connect battery positive cable, then ground cable.
- From a safe position to the side of or below air bag modules, turn ignition On and observe air bag indicator lamp. Lamp s...
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BRAKE SERVICE PROCEDURES FOR 1992 BMW 525I AUTOMOBILES
Power Brake Units -> POWER BRAKE UNIT SERVICE -> 318, 325, 525 & 535 -> 735, 750 & 850 -> POWER BRAKE BOOSTER, REPLACE
Vehicle: 1992 BMW 525I 2.5 L6 GAS
POWER BRAKE BOOSTER, REPLACE
318, 325, 525 & 535
- Remove master cylinder from booster.
- Remove lower left trim panel.
- Disconnect bayonet pin and clip from booster pushrod, below instrument panel. Fig.
- Detach booster from pedal base. Remove booster from engine compartment.
- Reverse procedure to install.
735, 750 & 850
- With engine off, discharge hydraulic reservoir by operating brake pedal approximately 20 times with same force required for fu...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1992 BMW 525I AUTOMOBILES
BMW -> Fuel Filter Replacement -> Except X3 & Z4 -> Fuel System Pressure Relief -> Models w/Fitting Or Union Bolt Connection -> Models w/Fuel Hose Connection -> Removal & Installation
Vehicle: 1992 BMW 525I 2.5 L6 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while it relearns its adaptive strategy.
Fuel System Pressure Relief
- Obtain the vehicle owner's radio theft protection code.
- Remove the fuel pump relay(s).
- Start the engine and allow it to stall.
- Crank engine for 10 seconds to ensure the fuel pressure has been...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1992 BMW 525I AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assembly -> Disassembly
Vehicle: 1992 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 1992 BMW 525I AUTOMOBILES
Starter, Replace
Vehicle: 1992 BMW 525I 2.5 L6 GAS
- Disconnect battery ground cable and drain cooling system.
- Mark position of starter leads, remove retaining nut and disconnect electrical connectors from starter.
- Disconnect coolant hose shrouding start...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 1992 BMW 525I AUTOMOBILES
Cabin Air Filter Service -> BMW -> 1992-95 5 Series
Vehicle: 1992 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 1992 BMW 525I AUTOMOBILES
BMW -> Automatic Stability Control (ASC, ASC+) & Dynamic Stability Control (DSC) Warning Lamp ->
Vehicle: 1992 BMW 525I 2.5 L6 GAS
The warning lamp is used to warn of a system fault. It will be lit during engine start-up, but should go out when the self-diagnostic system determines that the system is functioning properly. The warning lamp will also flash when the syst...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1992 BMW 525I AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1992 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 1992 BMW 525I AUTOMOBILES
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 1992 BMW 525I AUTOMOBILES
Component location diagrams for most 1992 BMW 525I cars and light trucks sold in the U.S. from 1990+.
 Bottom Of Steering Column Diagram for 1992 BMW 525I 2.5 L6 GASComponents on diagram: |
 Bottom Of Driver's Seat Diagram for 1992 BMW 525I 2.5 L6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1992 BMW 525I AUTOMOBILES
OEM drawn wiring diagrams for most 1992 BMW 525I cars and light trucks sold in the U.S.
 1992 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
 1992 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1992 BMW 525I AUTOMOBILES
OEM TSB listings for most 1992 BMW 525I cars and light trucks sold in the U.S. from 1985+.
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Document: Turbocharger Installation Tool Vehicle: 1992 BMW 525I 2.5 L6 GAS Auto Systems: |
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Document: Tools and Equipment Vehicle: 1992 BMW 525I 2.5 L6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1992 BMW 525I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1992 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 1992 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 1992 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 1992 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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