2002 BMW 525i Service and Repair Manual

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Covers all 2002 525i trims — Base Sedan 4-Door, Base Wagon 4-Door ·
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2002 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.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door
  • Base Wagon 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 #15V31800028/05/2015Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 325i, 325xi, 330i, and 330xi Sedans, and 325xi and 325i Sportswagons, 2002-2006 330Ci, 325Ci, and M3 Convertibles and 325i, 33

Consequence

In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could

Remedy

Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify

NHTSA #01V35200026/11/2001Component: TIRES:SIDEWALL

VEHICLE DESCRIPTION: DURING THE TIRE MOUNTING PROCESS ON CERTAIN PASSENGER VEHICLES BUILT WITH STANDARD (NON-SPORT) SUSPENSION AND EQUIPPED WITH CONTINENTAL CONTITOURINGCONTACT CH95 ECOPLUS TIRES, SI

Consequence

CONTINUED DRIVING WITH LOW INFLATION PRESSURE IN THE TIRE COULD ULTIMATELY RESULT IN DAMAGE TO THE T

Remedy

DEALERS WILL INSPECT ALL FIVE TIRES FOR A POSSIBLE CUT IN THE SIDEWALL, AND IF A CUT IS FOUND, THE T

NHTSA #02V05700019/02/2002Component: SUSPENSION

ON CERTAIN PASSENGER VEHICLES, DURING THE STRUT MOUNT MANUFACTURING PROCESS, THE THRUST BEARING WAS NOT PROPERLY POSITIONS AND SECURED. IF THE SUSPENSION IS FULLY UNLOADED, THE FRONT STRUT COULD SEPA

Consequence

THIS COULD AFFECT VEHICLE HANDLING AND CONTROL, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE BOTH FRONT SPRING STRUT UPPER MOUNTS. OWNER NOTIFICATION BEGAN MARCH 15, 2002

NHTSA #19V01500014/01/2019Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

BMW of North America, LLC (BMW) is recalling certain model year 2000-2003 525i Sedan, 530i Sedan, 540i Sedan, 2001-2003 525i Sports Wagon and 540i Sports Wagon vehicles, and 2000-2004 X5 SAV 3.0i, X5

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants res

Remedy

Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify

TSB #10249437

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

TSB #10247567

Engine will crank but not start. There is no communication with the integrated fuel module (TFE) whendiagnosing with ISTA. The following two fault codes will be stored in the DME: 032B43 - Low fuel pressure system, electric fuel pump: press

TSB #10245422

Customers may state that the alarm system (DWA) is not active after locking their unoccupied vehicle. Depending on the vehicles equipment and settings, no acoustic or optical confirmation (folding the mirrors/blinking confirmation) is notic

TSB #10037025

BMW: PROCEDURE FOR DETERMINING AND REPLACING INCANDESCENT AND HALOGEN LIGHT BULBS UNDER WARRANTY. *RM

TSB #10033130

BMW VEHICLES: FUEL LEVEL SENSOR REPAIRS. WHERE IT IS NECESSARY TO REPLACE THE RIGHT OR THE LEFT SIDE FUEL LEVEL SENSOR DUE TO A FAILURE, THE ENTIRE PUMP AND HOUSING OR DELIVERY UNIT (SUCTION JET ASSEMBLY) DO NOT NEED TO BE REPLACED AS WELL.

20041222Component: SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER1 injured

WHILE DRIVING, THE SEAT HEATER FAILED AND CONSEQUENTLY THE CONSUMER WAS BURNED. *JB

20210905Component: ELECTRICAL SYSTEMFire reported

The car was off and caught fire due too electrical malfunctioning. The a/c unit was staying on even after cutting the car off . Along with my steering wheel randomly adjusting at start of the car . Th

20171019Component: UNKNOWN OR OTHERFire reported

IT STARTED TO SMELL ELECTRICAL WHEN I WAS DRIVING THE CAR AND WHEN I STOPPED THE CAR PUT IT IN PARK AND TRYED TO TURN THE CAR OFF THE IGNITION WOULDNT TURN OFF AND MY ENTIRE CAR CAUGHT FIRE ..I SAW IT

Showing the 3 most serious of 41 complaints filed with NHTSA.

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