1991 BMW 525i Service and Repair Manual

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Fits the 1991 525i — Base Sedan 4-Door ·
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1991 BMW 525i service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Sedan 4-Door

Engines covered

  • 2.5L 2494CC 152Cu. In. l6 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #98V17800004/08/1998Component: ENGINE AND ENGINE COOLING:COOLING SYSTEM

VEHICLE DESCRIPTION: PASSENGER VEHICLES. A MALFUNCTION OR FAILURE OF A COOLANT SYSTEM COMPONENT, SUCH AS A THERMOSTAT, WATER PUMP, OR FAN BELT, CAN RESULT IN SIGNIFICANTLY INCREASED COOLANT TEMPERAT

Consequence

IF A CRACK WERE TO FORM OR A SEAM WERE TO SEPARATE IN THE HEATER CORE END PIECE, HOT COOLANT COULD S

Remedy

DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERF

TSB #10249437

The basic conditions for initializing the power windows are not met.

TSB #50896

RECALL 96V110 - BMW OF NORTH AMERICA HAS INITIATED A RECALL CAMPAIGN WHICH INVOLVES THE AIRBAG CONTACT RING LOCKING TAB. *TW

TSB #50897

RECALL 96V111 - THIS RECALL CAMPAIGN INVOLVES THE BRAKE LIGHT SWITCH. *TW

TSB #50898

ANNOUNCEMENT THAT OWNERS OF VEHICLES INVOLVED IN RECALLS 96V110 AND 96V111 WILL BE COMBINED INTO ONE MAILING. *TW

19990203Component: ENGINE AND ENGINE COOLING:COOLING SYSTEM1 injured

ENGINE COOLING SYSTEM DESIGN CONTAINS A FLAW, WHEN REMOVING RADIATOR CAP CONSUMER SUSTAINED BURN INJURIES DUE TO CAP NOT HAVING A TWO-STAGE RELEASE, O-RINGS AT THE BASE OF THE CAP ENSURE THAT THE PRES

19981117Component: AIR BAGS:FRONTAL1 injured

TRAVELING 65MPH GOING AROUND A CURB WHEN SUDDENLY, THE DRIVER'S SIDE AIR BAG DEPLOYED FOR NO REASON. IT OBSTRUCTED THE DRIVER'S VIEW. HAD NOT HIT ANYTHING & NO OTHER VEHICLE HAD HIT BMW. STEERING WHE

20121020Component: STEERING

I PARKED MY CAR IN THE GARAGE AS USUAL. WHEN I WENT OUT TO LEAVE HOME THE STEERING WAS LOCKED. NOTHING OUT OF THE ORDINARY WAS DONE AFTER PARKING IT OR WHEN ATTEMPTING TO START IT. THE LIGHTS FOR THE

Showing the 3 most serious of 21 complaints filed with NHTSA.

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