1992 BMW 525i Service and Repair Manual

This factory service and repair manual for the 1992 BMW 525i covers two bodies rather than one: a four-door sedan and a four-door wagon, both in Base trim and both using the 2.5L twin-cam inline-six of 152 cubic inches, naturally aspirated on gasoline. Mechanically the two are the same car, so engine, transmission and chassis coverage is shared; the wagon's tailgate, rear glass and load area are where the body sections have to part company.

Engines covered

• 2.5L inline-six (152 cu in) — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sedan
• 4-door wagon

Trims covered

• Base

Known issues on the 1992 525i. The federal record carries four recalls for this year. Two are throttle and brake related: a plastic bushing at the throttle housing that can break and leave the valve partly open, and a brake light switch that can stick so the lamps never come on or never go out. A third has the air bag contact ring's locking tab breaking until the wiring fails and the bag will not deploy. The fourth is the overheating cooling system that can crack the heater core end piece. Of 26 complaints, 11 concern engine and engine cooling and five the air bags.