1992 BMW 525i Starter replacement

[Scoobys92]

Can anyone give me some info on the easiest way to replace the starter on my 1992 525i , I've read up on this and some guys say that it can be done from underneath and others say that removing the intake manifold is the easiest way. HELP!!! also if the manifold needs to be removed how difficult is it?

[DrCharles]

Lots of threads on "M50 starter removal". It can be done from underneath but a considerable PITA.

Removing the intake manifold will give you much better access to the nuts on the engine side of the starter. (An insanely stupid design, which BMW later corrected by using threaded holes in the starter itself). Although they can still be reached from underneath with an S-wrench and a double-jointed arm ;)

I would pull the manifold, it's actually fairly simple, just seven nuts, the two fuel lines, the injector plug connections (leave the injector rail attached to the manifold), two bolts that hold the braces to the manifold, and the idle air hose and the odd vac hose/electrical connector or two. That will give you an opportunity to replace the intake gaskets which are probably cracked and hard by now, and clean your idle valve.

[Scoobys92]

I appreciate the information now I don't feel so lost doing this job.

[ross1]

I agree with removing the intake. It also allows access to a bunch of probably very old water, vacuum and idle air valve hoses that could stand to be replaced after 20 years and the idle valve that could be cleaned.

[DrCharles]

Yes, when I pulled my '93 525i manifold, I also changed all the coolant hoses and the heater valve assembly. MUCH easier with it out of the way.

Buy one of these too, in addition to six new intake gaskets and the hoses:
http://www.fcpeuro.com/products/bmw-breather-connector-intake-manifold-11611738629

You will break the 20+ year old brittle plastic connector trying to unclip it from underneath, no matter how careful you think you're being. DAMHIK :D

[whiskychaser]

This could be an age/experience related question. If you are under 25, you may not mind rolling around in the dirt and performing all sorts of contortions because a. You don't want to disturb what you don't need to b. It's a challenge to do it without removing the manifold. If you are over 25, you may think a. removing the manifold and doing other stuff while you are in there is a smart move. b. Your back is starting to give you trouble. I suggest that the deciding factor is the pin which projects from the bell housing into the starter flange. If that is seized tight - and I have yet to work on one that wasn't - you might want to go with the 'seasoned' man's approach :-)