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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 -> Control Module, Replace -> 740, 745, 750 & 760 -> M Coupe, M Roadster & Z4 -> M3, X5, 325 & 330 -> M5, 525, 530 & 540
Vehicle: 2003 BMW 525I 2.5 L6 GAS
M Coupe, M Roadster & Z4
- Remove center console as outlined under "Console, Replace."
- Disconnect Bowden cables, connector and micro-switch.
- Remove control module.
- Reverse procedure to install.
M3, X5, 325 & 330
- Pull heater control out using unlock and fitting tools No. 64-1-010, or equivalent.
- Disconnect connectors and remove controls.
- Reverse procedure to install.
M5, 525, 530 & 540
- On models equipped with MID or IRIS, remove mounting screws and radio. Disconnect connectors.
- On models less MIS or...
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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: 2001 BMW 525I Sport Wagon 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 Filter Scheduled Maintenance -> 1999-06
Vehicle: 2006 BMW 525I 3.0 L6 GAS
Inspection interval is determ...
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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+.
CV AXLE SHAFT, Replace -> REAR
Vehicle: 2003 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 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+.
Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification
Vehicle: 2002 BMW 525I 2.5 L6 GAS
Accessing Diagnostic Trouble Codes
Connect a suitable scan tool the DLC (Data Link Connector). Follow the scan tool manufacturers instructions.
Diagnostic Trouble Code Identificati...
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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: 2002 BMW 525I Sport Wagon 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 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 -> 2004-05 645 & 2006-07 525, 530 & 2006-09 550, 650, M5, M6 & 2008-09 528 & 535
Vehicle: 2007 BMW 525I 3.0 L6 GAS
The service interval is determined by the service indicator.
- Open the hood.
- Rotate the quick release fastener 90° counterclockwise, Fig. .
- Release the retainer located at the side of the cabin air filter cover, the r...
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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 -> Tire Pressure Monitoring System (TPMS) Warning Indicator -> 1997-2009 5 Series Except X5 -> Less iDrive -> Reset -> With iDrive
Vehicle: 2004 BMW 525I 2.5 L6 GAS
Reset
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 il...
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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: 1995 BMW 525I 2.5 L6 GAS
- Raise and support vehicle.
- Remove engine cooling fan using pulley holding tool No. 11 5 030, or equivalent. Fan nut has lefthand thread.
- Remove engine splash guard and heat shields.
- Drain coolant into suitable container.
- Remove mounting bolts and upper air duct.
- Disconnect coolant level sender electrical connector.
- Disconnect lower coolant, expansion and bleed hos...
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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: 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 BMW 525I AUTOMOBILES
Component location diagrams for most BMW 525I cars and light trucks sold in the U.S. from 1990+.
 In Upper LH Rear Door Diagram for 2003 BMW 525I 2.5 L6 GASComponents on diagram: |
 Center Top of Engine, Left 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.
 2005 BMW 525I 2.5 L6 GAS Wiring DiagramComponents on diagram: |
 2003 BMW 525I Sport Wagon 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: DSC/DXC WARNING LAMP, FAULT CODE 5EBA - REVISED Vehicle: 2005 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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