The 1991 BMW 525i has 4 NHTSA recall campaigns affecting an estimated 1,005,000 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 21 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
Recall campaigns
ENGINE AND ENGINE COOLING98V1780001998-08-04340,000 affected
Defect
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…
Consequence
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.
Remedy
DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERFLOW IN THE EVENT OF OVERHEATING.
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…
Consequence
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.
Remedy
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.
THE BRAKE LIGHT SWITCH CAN FAIL ALLOWING THE SWITCH TO REMAIN IN THE "BRAKE LIGHTS OFF" POSITION OR IN THE "BRAKE LIGHTS ON" POSITION.
Consequence
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.
Remedy
DEALERS WILL REPLACE THE EXISTING BRAKE LIGHT SWITCH WITH A NEWLY DESIGNED SWITCH.
AIR BAGS96V1100001996-07-0175,000 affected
Defect
THE AIR BAG CONTACT RING LOCKING TAB LOCATED IN THE STEERING WHEEL ASSEMBLY CAN BREAK WITHOUT WARNING.
Consequence
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.
Remedy
DEALERS WILL REPLACE THE LOCKING TAB WITH ONE OF A DIFFERENT DESIGN.
Complaints by component
ENGINE AND ENGINE COOLING:COOLING SYSTEM
3
1injuries
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
2
STRUCTURE:BODY:DOOR
2
AIR BAGS:FRONTAL
1
1injuries
AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE
1
ELECTRICAL SYSTEM
1
ELECTRICAL SYSTEM:12V/24V/48V BATTERY
1
ELECTRICAL SYSTEM:IGNITION
1
ENGINE AND ENGINE COOLING:ENGINE
1
EXTERIOR LIGHTING:HEADLIGHTS
1
Total complaints21
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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…”
“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…”
“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…”
“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…”
“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…”
“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 wheel had to be taped to be driven. *ak”
“The srs {a safety system} light keeps flashing. *ak”
“Fluid leaks since '11/95. Have had a total of 3 coils replaced; r/r lower timing cover, replaced gaskets/new drive belts - r/r oil pan and replaced gasket to the tune of $1,125.00 at 39,243 miles. Waranty is 4 yrs./50k miles. Asked for an adjustment due to low mileage and highly unusual problems.…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 BMW 525i as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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