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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+
Air Bag System Precautions -> BMW -> Arming
Vehicle: 2004 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 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 -> Power Brake Unit Service -> 740 & 750 -> 745 -> Hydraulic Power Flow Regulator, Replace -> M3, 325 & 330 -> M3, M5, X5, Z3, Z8, 325, 330, 525, 530, 540, 740, 745, 750 & 760 -> M5, 525, 530 & 540 -> Mini Cooper -> Power Brake Booster, Replace -> X5 -> Z3 -> Z8
Vehicle: 2002 BMW 525I 2.5 L6 GAS
Hydraulic Power Flow Regulator, Replace
Mini Cooper
- Ensure ignition switch is in OFF position.
- Disconnect clip and air filter outlet hose.
- Remove air filter housing mounting bolts, then disconnect harness clip and connector.
- Remove air filter housing.
- With engine off, discharge hydraulic reservoir by operating brake pedal approximately 20 times with same force required for full stop braking action.
- Remove battery.
- Disconnect clips, lock and connectors, then remove Engine Control Module (ECM).
- Remove battery box mounting bolt and disconnect clips.
- Remove battery box.
- Disconnect val...
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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 -> Fuel Shutoff Switch Location -> 1991-96 5 Series
Vehicle: 1994 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 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 -> Front -> Rear
Vehicle: 2005 BMW 525I 2.5 L6 GAS
Front
Do not move vehicle with engine power once driveline shaft has been removed.
- Remove rear underbody protection from assemblies.
- Remove underbody protection at center.
- Remove bolts transmission companion flange.
- Remove bolts centering mount flange.
- Remove front driveline.
- Reverse procedure to install, noting...
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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+.
Wiring Diagrams -> Wire Color Code Identification
Vehicle: 2006 BMW 525I 3.0 L6 GAS
Refer to Figs. and for wir...
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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+.
Starter, Replace
Vehicle: 2003 BMW 525I 2.5 L6 GAS
- Disconnect Crankshaft Position (CKP) sensor electrical connector.
- Remove nuts and disconnect starter motor electrical connectors.
- Remove mounting bolts and starter mo...
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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: 1994 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 -> Anti-Lock Brake System Warning Lamp ->
Vehicle: 1991 BMW 525I 2.5 L6 GAS
The Anti-Lock 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. If the ...
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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+
Radiator, Replace
Vehicle: 1990 BMW 525I 2.5 L6 GAS
- Remove fan cowl, note engine variant.
- Drain coolant into a suitable container.
- Disconnect plug connection on level sensor.
- On models with air-conditioning, disconnect plug connection on temperature switch.
- On all models, disconnect upper water hose.
- Disconnect lower water hose.
- Disconnect expansion hose.
- On...
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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+.
 Top Center of Engine Compartment Diagram for 2002 BMW 525I Sport Wagon 2.5 L6 GASComponents on diagram: |
 Rear RH Side of Engine Compartment in E-Box Diagram for 2003 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.
 2002 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
 2002 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: TEILECLEARING (ENHANCED TECHNICAL SUPPORT) FOR DME Vehicle: 2003 BMW 525I 2.5 L6 GAS Auto Systems: |
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Document: BUSHING REMOVER KIT Vehicle: 1993 BMW 525I 2.5 L6 GAS Auto Systems: |
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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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