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2002 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
- Tire Pressure Monitoring System
- 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 2002 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 2002 BMW 525I AUTOMOBILES
BMW -> Automatic Temperature Control System Diagnosis & Testing -> Description
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
The electronically controlled automatic temperature control system uses a microcomputer to contro...
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BRAKE SERVICE PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
Hydraulic Brake Systems -> Brake System Bleed
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
The following procedure has been revised by a Technical Service Bulletin.
Ensure traction control systems are turned Off prior to bleeding brake system.
- Connect suitable pressure bleeder to brake fluid reservoir. Maximum charging pressure is 43.5 psi.
- Attach bleeder hose and container to righthand rear wheel. Bleed until no bubbles appear.
- Repeat previous step for lefthand rear, righthand front and lefthand front wheels.
- Support rear suspension at wheel carriers and lower vehicle so rear suspension compresses to its normal loaded position (to prevent...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
BMW -> Component Locations -> 5 Series
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
Refer to Fig. ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
CV AXLE SHAFT, Replace -> REAR
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
REAR
- On models equipped with air suspension, proceed as follows:
- Remove air supply system fuse.
- Disconnect distributor block lines.
- On all models, raise and support vehicle, then remove rear tire and wheel assembly.
- Remove rear axle carrier.
- Remove output shaft to transmission ...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
Reset Procedures -> Less iDrive -> With iDrive
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
The reset procedure needs to be performed anytime the tire pressure is adjusted or the tires are rotated.
Less iDrive
- Turn ignition switch to On with vehicle in a stationary position.
- Press the Tire Pressure Warning/RDC button, located at front console or on the instrument panel, until the indicator lamp on the instrument panel is illuminate...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
Alternator, Replace
Vehicle: 2002 BMW 525I 2.5 L6 GAS
- Remove intake air filter housing.
- Lock belt pulley in position using suitable holding tool, then remove water pump fan clutch mounting nut using suitable wrench tool. Nut has lefthand threads.
- Remove fan wheel with coupling.
- Remove drive belt.
- Remove mounting bolt...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
Cabin Air Filter Service -> BMW -> 1996-2005 5 Series
Vehicle: 2002 BMW 525I Sport Wagon 2.5 L6 GAS
Service interval is determined by the service indicator.
- Open the hood.
- Turn quick-release fastener approximately, 90° counterclockwise. Unlatch the cabin air filter cover retainers.
- Remove the cabin air fi...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
BMW -> Service Indicator Cluster ->
Vehicle: 2002 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 2002 BMW 525I AUTOMOBILES
Radiator, Replace
Vehicle: 2002 BMW 525I 2.5 L6 GAS
- Open coolant expansion tank cap and loosen vent plug.
- Raise and support vehicle, then remove mounting bolts and front splash shield.
- Open radiator plug and drain coolant into suitable container.
- Open plug on righthand side of engine block near cylinder No. 2 and drain coolant into suitable container.
- Lock belt pulley in position using holding tool No. 11 5 030, or equivalent, then remove water pump fan clutch mounting nut using wrench tool No. 11 5 040, or equivalent. Nut has lefthand threads.
- Remove fan wheel with coupling.
- Disconnect level sensor connector, then disconnect clamp a...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 BMW 525I AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 BMW 525I 2.5 L6 GAS
- If reusing belt, mark belt with rotational direction for installation alignment.
- Lock belt pulley in position using suitable holding tool, then remove water pump fan clutch mounting nut using suitable wrench. Nut has lefthan...
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COMPONENT LOCATION DIAGRAMS FOR 2002 BMW 525I AUTOMOBILES
Component location diagrams for most 2002 BMW 525I cars and light trucks sold in the U.S. from 1990+.
 Top Center of Engine Diagram for 2002 BMW 525I Sport Wagon 2.5 L6 GASComponents on diagram: |
 LH Side of Engine Compartment, Bottom Diagram for 2002 BMW 525I 2.5 L6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 BMW 525I AUTOMOBILES
OEM drawn wiring diagrams for most 2002 BMW 525I cars and light trucks sold in the U.S.
 2002 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
 2002 BMW 525I Sport Wagon 2.5 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 BMW 525I AUTOMOBILES
OEM TSB listings for most 2002 BMW 525I cars and light trucks sold in the U.S. from 1985+.
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Document: Tools and Equipment Vehicle: 2002 BMW 525I 2.5 L6 GAS Auto Systems: |
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Document: Tools and Equipment Vehicle: 2002 BMW 525I 2.5 L6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 BMW 525I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 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 2002 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 2002 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 2002 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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