Model year record

1991 BMW 525i recalls & problems

The 1991 BMW 525i has 4 safety recalls and 13 owner complaints on file with NHTSA. The most-reported problem area is engine and engine cooling (6 complaints).

Recalls4safety recalls

Complaints13filed by owners

Crashes · fires0 · 0reported in complaints

Injuries · deaths2 · 0reported in complaints

Safety recalls

Engine and engine coolingAug 4, 1998

Cooling system

Recall 98V178000340,000 vehicles

Problem: 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 TEMPERATURE AND SYSTEM PRESSURE. IF THE INDICATIONS OF A CRITICAL OVERHEATING CONDITION IS NOT NOTICED BY THE DRIVER, IT IS POSSIBLE THAT DAMAGE TO, OR FAILURE OF, A COOLANT SYSTEM COMPONENT COULD OCCUR.
Risk: IF A CRACK WERE TO FORM OR A SEAM WERE TO SEPARATE IN THE HEATER CORE END PIECE, HOT COOLANT COULD SUDDENLY BE EXPELLED, INCREASING THE RISK OF PERSONAL INJURY TO A VEHICLE OCCUPANT.
Fix: DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERFLOW IN THE EVENT OF OVERHEATING.

Vehicle speed controlAug 19, 1997

Vehicle speed control

Recall 97V131000410,000 vehicles

Problem: THE CRUISE CONTROL AND THROTTLE CABLES ARE ATTACHED TO THE SAME THROTTLE VALVE ACTUATING LEVER AT THE THROTTLE HOUSING. IT IS POSSIBLE THAT THE PLASTIC BUSHING ON EITHER CABLE COULD BREAK DUE TO ENVIRONMENTAL INFLUENCES COUPLED WITH VIBRATION. IF THE BUSHING BREAKS, THE OUTER CABLE HOUSING CAN SEPARATE FROM THE BUSHING. IN THIS CASE, DURING APPLICATION OF THE THROTTLE PEDAL WITHOUT CRUISE CONTROL BEING ENGAGED, THE OUTER TUBE COULD CATCH ON THE EDGE OF THE BROKEN BUSHING.
Risk: THIS COULD CAUSE THE THROTTLE VALVE TO REMAIN PARTIALLY OPEN. IT HIS WERE TO OCCUR, THE CAR MIGHT NOT DECELERATE AS EXPECTED INCREASING THE RISK OF A VEHICLE CRASH.
Fix: DEALERS WILL INSTALL A SPRING STEEL CLIP ON THE OUTER TUBE OF EACH CABLE IN THE AREA OF THE ADJUSTING SCREW AND PLASTIC BUSHING. THE CLIP IS DESIGNED TO PREVENT THE OUTER TUBE FROM DISLODGING FROM THE BUSHING.

Air bagsJul 1, 1996

Frontal

Recall 96V11000075,000 vehiclesopened after NHTSA action (ODI)

Problem: THE AIR BAG CONTACT RING LOCKING TAB LOCATED IN THE STEERING WHEEL ASSEMBLY CAN BREAK WITHOUT WARNING.
Risk: IF THIS HAPPENS, THE CONTACT RING WIRING COULD EVENTUALLY BREAK. THE AIR BAG READINESS INDICATOR LAMP (SRS OR AIRBAG) IN THE INSTRUMENT CLUSTER WILL ILLUMINATE, AND THE AIR BAG WOULD NOT DEPLOY IN THE EVENT OF A FRONTAL IMPACT VEHICLE COLLISION.
Fix: DEALERS WILL REPLACE THE LOCKING TAB WITH ONE OF A DIFFERENT DESIGN.

Exterior lightingJul 1, 1996

Brake lights › Switch

Recall 96V111000180,000 vehicles

Problem: THE BRAKE LIGHT SWITCH CAN FAIL ALLOWING THE SWITCH TO REMAIN IN THE "BRAKE LIGHTS OFF" POSITION OR IN THE "BRAKE LIGHTS ON" POSITION.
Risk: IF THIS HAPPENS, THE BRAKE LIGHTS EITHER WILL NOT OPERATE OR WILL BE CONTINUOUSLY ON, REGARDLESS OF BRAKE PEDAL POSITION. FOLLOWING DRIVERS WOULD NOT BE ABLE TO DETERMINE WHETHER THE VEHICLE IS STOPPING, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Fix: DEALERS WILL REPLACE THE EXISTING BRAKE LIGHT SWITCH WITH A NEWLY DESIGNED SWITCH.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

525i

18mpg combined

City / highway	15 / 23 mpg
Fuel	Premium Gasoline

2.5 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,550/year to fuel

525i

18mpg combined

City / highway	15 / 23 mpg
Fuel	Premium Gasoline

2.5 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $4,550/year to fuel

525i

15mpg combined

City / highway	15 / 17 mpg
Fuel	Premium Gasoline

2.5 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,500/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Injuries	Typical mileage*
Engine and engine coolingCooling system; Cooling system › Radiator assembly	6	1	—
Electrical systemIgnition; 12v/24v/48v battery	3	0	—
Air bagsFrontal; Frontal › Sensor/control module	2	1	—
StructureBody › Door	2	0	—
Exterior lightingHeadlights; Tail lights	2	0	—
Vehicle speed controlCables	1	0	—
Fuel system, gasolineFuel injection system	1	0	—
Power train	1	0	—
Latches/locks/linkagesTrunk lid › Lock	1	0	—
SeatsFront assembly › Recliner	1	0	—
Steering	1	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

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 RADIO CAME ON, THE WINDSHIELD WIPER WORKS, THE LIGHTS ON THE CONSOLE LIGHT UP, BUT THE STEERING WHEEL IS LOCKED AND THE KEY WILL NOT TURN MORE THAN A FEW CENTIMETERS. *TR
Oct 20, 2012 · 167,446 miles
Seats › Front assembly › Recliner
WHILE SITTING IN MY 1991 BMW 525I THE SEAT SUDDENLY FELL BACKWARD,AND SIDEWAYS. AFTER REMOVING THE SEAT, AND ALMOST COMPLETELY DISSASSEMBLING IT SO I COULD TRY TO REALIGN THE THING LONG ENOGH TO MAKE IT HOME,I WAS ABLE TO THROUGH BRUTE FORCE PUT IT BACK IN PLACE. LATER AFTER SEVERAL SUBSEQUENT FAILURES I WAS ABLE TO PINPOINT THE PROBLEM.THE CABLES THAT GO BETWEEN THE ELECTRIC DRIVE MOTORS AND THE SEAT ADJUSTMENT GEARBOXES WERE SHEATHED IN A FAILURE-PRONE PLASTIC! THE PLASTIC THROUGH TIME WEARS AND STRETCHES UNTILL THE DRIVE CABLE SLIPS OUT OF GEARBOX ALLOWING CATASTROPHIC FAILURE. I JUST CHECKED TO SEE IF THIS ITEM HAD BEEN RECALLED WITH NO LUCK. *AK
Jul 17, 2004 · 108,000 miles
Exterior lighting › Tail lights
TAIL LIGHTS DO NOT STAY ON DUE TO DEFECTIVE SOCKETS. THE PLASTIC SOCKETS HAVE MELTED FROM THE HEAT OF THE TAIL LIGHT BULBS AND NO LONGER HOLD THE BULBS IN PROPERLY. THEY BLINK ON AND OFF AND SOMETIMES STAY OFF ALL TOGETHER. DEALER ADVISED ME TO BUY NEW ONES @ $320 EACH TO SOLVE THE PROBLEM. SINCE THIS IS A SAFETY DEFECT, BMW SHOULD REPLACE THEM. DT
Mar 22, 2002
Engine and engine cooling › Cooling system
THE COOLING SYSTEM FAN CLUTCH FAILED WITHIN 45,000 MILES. NLM
Jul 11, 2000
Engine and engine cooling › Cooling system
UPPER RADIATOR "PLASTIC MALE" OUTLET CONNECTING TO UPPER RUBBER HOSE EXPLODED CAUSING EXTRIME ENGINE OVERHEATING AND ENGINE FAILURE WITH NO WARNING EVEN AFTER DEALER INSTALLED NEW RADIATOR CAP RECALL IN AUGUST 1999. ALMOST CAUSED A HIGHWAY ACCIDENT. CAR HAS EXCELLENT MAINTENANCE RECORD AT DEALERSHIP. REPORTED PROBLEM TO BMW OF NORTH AMERICA. REPRESENTATIVE TOLD ME THAT WAS NOT THE RESPONSIBILITY OF BMW OF NORTH AMERICA.
Sep 7, 1999
Engine and engine cooling › Cooling system › Radiator assembly
REPLACED THE RADIATOR CAP BUT THE NEW CAP CAUSED A HOLE IN THE RADIATOR. *AK
Jul 30, 1999
Engine and engine cooling › Cooling system1 injury
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 PRESSURE IS MAINTAINED WITHIN THE RADIATOR UNTIL THE CAP IS FULLY UNSCREWED.
Feb 3, 1999
Air bags › Frontal › Sensor/control module
THE SRS {A SAFETY SYSTEM} LIGHT KEEPS FLASHING. *AK
Jun 1, 1998

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.