Target Audience:
Owners and independent mechanics specializing in classic BMW vehicles, particularly those seeking to maintain or restore the 1600 and 2002 series.
Market Niche:
The BMW 1600 and 2002 series represent a pivotal era for BMW, marking the birth of the modern sport sedan. This manual caters to a passionate enthusiast market preserving these iconic vehicles.
Manual Value Proposition:
FORESTMAN solutions emphasizes customer satisfaction and post-purchase support, suggesting a commitment to providing a high-quality, valuable resource for owners of these classic BMWs.
Manual Coverage Scope:
Comprehensive service and repair for BMW 1600 and 2002 series vehicles.
Number Of Pages:
Detailed page count not specified in product information, but described as comprehensive.
Type Of Manual:
Service Repair Manual
Language Of Manual:
English
Manual Format:
Likely printed format, given the seller's description implying physical product handling. Could also be available as a digital reproduction (PDF).
Engine Systems:
Engine mechanicals (cylinder head, block, pistons, crankshaft, camshaft), fuel system (carburetors, fuel pump, lines), ignition system (distributor, coils, spark plugs), cooling system (radiator, water pump, thermostat), exhaust system.
Drivetrain Systems:
Clutch, transmission (manual), driveshaft, differential, axles.
Chassis Systems:
Suspension (front struts, rear independent suspension), steering (steering box, linkage), braking system (disc and drum brakes, master cylinder, wheel cylinders, brake lines), wheels and tires.
Electrical Systems:
Wiring diagrams, lighting system, starter motor, alternator, battery, dashboard instruments, gauges, horn, wipers, heater blower.
Bodywork And Interior:
Body panel removal and installation, door mechanisms, window regulators, seat adjustment, interior trim, bumpers, glass replacement.
Routine Maintenance:
Oil changes, filter replacements, spark plug tuning, fluid level checks and top-offs, lubrication points, valve adjustments.
Troubleshooting:
Diagnostic procedures for common problems related to engine performance, starting issues, electrical faults, and braking systems.
Repair And Rebuild:
Detailed step-by-step instructions for component removal, repair, and reassembly for major vehicle systems.
Specifications And Data:
Torque specifications, clearances, timing settings, fluid capacities, and electrical resistance values.
Depth Of Coverage:
Comprehensive, covering everything from basic preventative maintenance to detailed engine and transmission rebuilds, including electrical system diagnostics and bodywork repairs.
Digital Format:
If digital, likely PDF. Quality of scanned pages or original digital files is a key factor. Searchable text is a significant advantage for digital formats.
Print And Paper Quality:
For printed versions, expect typical 1970s manual paper quality. Clarity of diagrams and text is paramount. Binding type affects usability.
Binding:
Likely perfect bound or saddle-stitched for printed versions, common for service manuals. Durability for workshop use is important.
Paper Quality:
Standard paper, potentially not high-gloss. Focus is on legibility of text and line drawings.
Bmw M10 Engine Variants:
The M10 engine family powered both series. Key variants include: M10B16 (1573cc), M10B18 (1770cc - used in some late 1600/early 2002 models), M10B20 (1990cc).
1600 Engine Power:
1600-2: Approx. 85 hp (SAE Gross) @ 5700 rpm.
2002 Engine Power:
2002: Approx. 100 hp (SAE Gross) @ 5500 rpm. 2002tii: Approx. 130 hp (SAE Gross) @ 5800 rpm.
2002 Engine Torque:
2002: Approx. 116 lb-ft (SAE Gross) @ 3500 rpm. 2002tii: Approx. 130 lb-ft (SAE Gross) @ 3800 rpm.
Carburetion:
Solex or Zenith downdraft carburetors. Typically single Solex 40/45 DDH for 1600-2 and base 2002. 2002tii featured Kugelfischer mechanical fuel injection.
Fuel Type:
Unleaded gasoline (as mandated over time). Early models were designed for leaded fuel.
Engine Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
Valve Train:
Single Overhead Camshaft (SOHC), driven by a duplex timing chain.
Wheelbase:
Approx. 2500 mm (98.4 inches)
Length:
Approx. 4000 mm (157.5 inches) for 1600-2, and around 4005 mm (157.7 inches) for 2002.
Width:
Approx. 1620 mm (63.8 inches)
Height:
Approx. 1390 mm (54.7 inches)
Curb Weight:
Approx. 900-1000 kg (1980-2200 lbs) depending on model and equipment.
Gross Vehicle Weight Rating:
Estimated around 1300-1400 kg (2866-3086 lbs).
Crash Test Ratings:
No official standardized crash test ratings (like NHTSA or Euro NCAP) were conducted for vehicles of this era. Safety features were basic by modern standards.
Braking System:
Front disc brakes and rear drum brakes were standard on most models. The 2002tii and later 2002 models often featured larger front discs.
Suspension Design:
Independent front suspension (MacPherson struts) and independent rear suspension (semi-trailing arms) provided a balance of ride and handling.
Seat Belts:
Lap belts were standard initially; inertia-reel or three-point belts became optional or standard on later models and as safety regulations evolved.
Body Structure:
Unibody construction with integrated safety cage elements for its time. Crumple zones were rudimentary compared to modern vehicles.
Original Infotainment:
Basic analog radio, often with a single speaker. Cassette player was a rare dealer-installed option later in the production run.
Driver Assistance Features:
None by modern standards. Features like power steering were not typically available on base models.
Connectivity Options:
No digital connectivity features. Basic electrical systems for lighting, ignition, and instruments.
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months. Consult manual for specific intervals based on driving conditions.
Tune Up Interval:
Points, condenser, spark plugs, and timing checks usually every 10,000-15,000 miles or annually.
Valve Adjustment:
Recommended every 15,000-20,000 miles. Requires checking clearances when the engine is cold.
Engine Oil Specification:
API SG or SH category oil, viscosity typically 10W-40 or 20W-50 depending on climate. Early models may specify leaded fuel compatible oils or require additives.
Coolant Specification:
A 50/50 mix of antifreeze (ethylene glycol based) and distilled water. Specific BMW coolant compatibility is ideal.
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Specification:
For manual transmissions, GL-4 rated gear oil, typically SAE 75W-90 or 80W-90. For automatic, ATF Dexron II or equivalent.
Rust And Corrosion:
Common issue in floor pans, rocker panels, wheel arches, and battery trays due to age and environmental exposure. Requires diligent inspection and treatment.
Cooling System Leaks:
Rubber hoses, radiator, and water pump seals can degrade over time, leading to leaks. Regular inspection is crucial.
Carburetor Issues:
Wear in carburetor components, vacuum leaks, and clogging can affect fuel delivery and engine performance. Rebuilding or replacing is often necessary.
Electrical Component Failure:
Older wiring harnesses can become brittle, and components like regulators, alternators, and ignition switches can fail with age.
Suspension Wear:
Bushings, ball joints, tie rod ends, and shocks are common wear items contributing to poor handling and alignment issues.
Bmw Engineering Philosophy:
BMW established its reputation for building driver-focused, sporting sedans with the Neue Klasse platform, which the 1600 and 2002 series evolved from.
1600 Series Introduction:
Introduced in 1966 (as the 1600-2, meaning '2-door'), it was a more affordable and compact offering than the larger 2000 series, but shared the same M10 engine concept.
2002 Series Introduction:
Launched in 1968, the 2002 featured the larger 2.0-liter engine, significantly boosting performance and establishing the 'Ultimate Driving Machine' ethos for smaller sedans. The 2002tii (Touring International injection) variant, introduced in 1971, was a performance benchmark.
Production Period:
1966-1977 for the 1600/2002 family, with the manual covering the 1967-1976 production years of the core models.
Manufacturing Locations:
Primarily manufactured in Munich, Germany.
Market Impact:
The 2002 is widely credited with popularizing the concept of the sporty compact sedan and laying the groundwork for future BMW success in this segment, including the 3 Series.
Historical Recognition:
The 2002 is consistently recognized by automotive publications as one of the most significant cars of the 20th century, lauded for its blend of performance, practicality, and affordability.
Enthusiast Acclaim:
Highly regarded by car enthusiasts and collectors, often featured in 'best affordable classics' lists.
