BMW 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 2002 Model Code: BMW Neue Klasse / Generation 1 Generation Production Years: 1968-1977 Codes Chassis Codes: 114, 115, 120, 121 👋 Introduction Market...

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标签: 2002 BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Code:

BMW Neue Klasse / Generation 1

Generation

Production Years:

1968-1977

Codes

Chassis Codes:

114, 115, 120, 121

👋 Introduction

Market Position

Market Segment:

Compact executive sedan and coupe, influential in establishing BMW's reputation for sporty driving and reliable engineering.

Competitive Analysis

Key Competitors:

Mercedes-Benz 200-230 series, Alfa Romeo Giulia, Ford Taunus, Opel Rekord.

Key Features

Vehicle Strengths:

Agile handling, responsive steering, peppy engines, robust build quality, sporting image, driver-focused cockpit.

Seller Value Proposition

Forestman Solutions Advantage:

Commitment to customer satisfaction, post-purchase support, comprehensive product information.

📋 Manual Details

Coverage Areas

Manual Type:

Comprehensive Service & Repair Manual

Language:

English

Format:

Digital (Likely PDF, though exact format may vary)

Page Count

Page Count:

Est. 500-800+ pages (typical for comprehensive manuals of this era)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, fuel injection ( Kugelfischer), carburetors, cooling system, lubrication system, ignition system, exhaust system

Transmission Drivetrain:

Manual transmissions (4-speed, 5-speed Getrag), automatic transmissions (optional), clutch system, driveshaft, differential, axles

Suspension Steering:

Front and rear suspension components, shock absorbers, springs, bushings, steering gearbox, steering linkage

Brakes Wheels:

Front disc brakes, rear drum brakes, brake hydraulics, parking brake, wheel bearings, wheel bolt patterns

Electrical Systems:

12V electrical system, alternator, starter motor, battery, lighting system, instrumentation, wiring diagrams, fuses, relays

Body Chassis:

Body repair, rust prevention, door mechanisms, window regulators, interior trim, chassis lubrication points

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, spark plug service, brake fluid flush, cooling system service

Diagnostics:

Troubleshooting guides for common engine, electrical, and mechanical problems; diagnostic charts

Repair Rebuild:

Detailed step-by-step instructions for engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement

Technical Data:

Torque specifications, clearances, timing adjustments, fluid capacities, electrical resistance values

Technical Depth

Depth Level:

Professional Level: Covers everything from basic maintenance to full engine and drivetrain rebuilds, including detailed troubleshooting and diagnostic procedures.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF for easy searching and printing, potentially with high-resolution scans of original diagrams.

Print Quality

Print Quality Notes:

Assumed to be high quality if digital, preserving original technical drawings and schematics.

Binding Type

Binding Type:

Not Applicable (Digital Format)

Paper Type

Paper Type:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

BMW M10 Inline-4

Engine Variants

Engine Displacement Range:

1.6L, 1.8L, 2.0L

Notable Engine Codes:

M10B16, M10B18, M10B20, M10B20/S (Ti)

Performance

Horsepower Range:

Approximately 85 hp (1600) to 130 hp (2002 Ti/Tii)

Torque Range:

Approximately 130 Nm (1600) to 170 Nm (2002 Ti/Tii)

Fuel System

Fuel Delivery:

Solex carburetors (twin choke), Zenith carburetors, Bosch D-Jetronic fuel injection (Ti models)

Engine Construction

Block Material:

Cast Iron

Head Material:

Aluminum Alloy

Cooling System

Cooling Type:

Water-cooled, pressurized system

Lubrication System

Oil Capacity:

Approx. 4.5 liters (with filter change)

🔧 Transmission

Standard

Standard Transmission:

4-speed manual (ZF or Getrag)

Optional

Optional Transmission:

3-speed automatic (optional on some models)

Features

Clutch Type:

Single dry plate, hydraulically operated

Drivetrain

Drive Layout:

Rear-wheel drive (RWD)

Gear Ratios

Gear Ratios Note:

Varies by specific gearbox and engine, detailed in manual.

📐 Dimensions

Exterior

Wheelbase:

Approx. 2565 mm (101 in)

Length:

Approx. 4200 mm (165.4 in)

Width:

Approx. 1630 mm (64.2 in)

Height:

Approx. 1410 mm (55.5 in)

Weights

Curb Weight:

Approx. 1000-1150 kg (2200-2535 lbs) depending on model

Gross Vehicle Weight:

Not explicitly specified, but typically around 1450 kg.

Cargo

Trunk Volume:

Approx. 450 liters (15.9 cu ft)

🛡️ Safety Features

Ratings

Safety Ratings Note:

Modern safety rating systems were not prevalent during its production. Relied on robust construction.

Active Features

Braking System Type:

Front: Disc, Rear: Drum

Passive Features

Seatbelts:

Standard 3-point front seatbelts, optional rear lap belts

Body Structure:

Reinforced safety cage, crumple zones (early implementation)

Steering Column:

Collapsible steering column

💡 Technology Features

Infotainment

Infotainment System:

Basic analog radio with optional power antenna. Focus on mechanicals over electronics.

Driver Assistance

Driver Assistance Features:

None (standard for the era)

Instrumentation

Dashboard Layout:

Driver-centric, analog gauges: speedometer, tachometer, fuel gauge, coolant temperature, oil pressure warning light.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 8,000 km (3,000 - 5,000 miles) or 6-12 months, depending on usage and oil type.

Tune Up Interval:

Spark plugs, points, and condenser checked/replaced every 15,000 - 20,000 km (9,000 - 12,000 miles).

Timing Belt Chain:

Engine M10 uses a timing chain, designed for the life of the engine, but inspection for stretch is recommended.

Fluid Specifications

Engine Oil Grade:

SAE 20W-50 or 10W-40 (API SF or SG rated) recommended, check manual for specific ambient temperature grades.

Coolant Type:

Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 (always use fresh fluid).

Transmission Fluid:

GL-4 gear oil (e.g., 75W-90) for manual transmissions, Dexron II for automatic transmissions.

Known Issues

Rust Prone Areas:

Wheel arches, rocker panels, floor pans, battery tray, strut towers, trunk floor.

Engine Wear:

Valve stem seals, oil pump wear, timing chain stretch over high mileage.

Fuel System Issues:

Kugelfischer injection pump leaks/calibration issues, carburetor tuning difficulties, fuel line deterioration.

Electrical Gremlins:

Degraded wiring insulation, faulty grounds, distributor issues, alternator voltage regulator.

Common Repairs

Suspension Bushings:

Replacement of worn control arm bushings, sway bar bushings, and shock mounts.

Exhaust System:

Periodic replacement due to corrosion and age.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure – the 2002 was a key vehicle in solidifying this brand identity.

Model Evolution

Predecessor:

BMW 1500/1600 (Neue Klasse)

Successor:

BMW 3 Series (E21)

Key Variants:

1602, 1802, 2000, 2002, 2002tii, 2002 Turbo (rare), touring models

Production

Manufacturing Location:

Munich, Germany

Production Volume:

Over 800,000 units produced across all variants.

🏆 Awards & Recognition

Recognitions

Automotive Icon Status:

Widely considered an automotive icon and a pioneer in the compact sports sedan class. Contributed significantly to BMW's 'Ultimate Driving Machine' reputation.

Ratings

Historical Reviews:

Consistently praised by automotive journalists of the time for its handling, performance, and driver engagement.

Certifications

Historical Market Impact:

Credited with revitalizing BMW's sales and brand image in North America, paving the way for future success.