2002 / 2002tii / 2002 Turbo

1968-1976 / Sedan / Germany

All 2002 / 2002tii / 2002 Turbo problems All workshop issues

Common Fuel System, Carburettor (Base 2002)

Carburettor Wear and Maladjustment

Symptoms

Poor idle quality, hesitation on acceleration, rich running (black exhaust smoke, fuel smell), lean running (backfiring, overheating), poor fuel economy.

Cause

The Solex 40 PDSI or Weber 32/36 DGV carburettor has numerous wear points: throttle shaft bushings develop play (causing air leaks), jets wear, float valves stick, diaphragms perish, and gaskets shrink. Ethanol in modern fuel attacks old carburettor materials.

Fix

Rebuild the carburettor using a quality rebuild kit.

This replaces all gaskets, seals, needle valves, and accelerator pump diaphragms.

Inspect the throttle shaft bushings, if worn, the carburettor body needs bushing (specialist work).

Cost: $60-120 for a rebuild kit, $200-400 for a specialist rebuild.

Cost mentioned in fix

Cost: $60-120 for a$200-400 for a

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Other known issues

Common Fuel System, Carburettor (Base 2002)

Fuel Pump Failure

Engine stumbles or dies under load, particularly at high RPM or when the fuel tank is below half. Fuel starvation symptoms.

Critical Engine, M10 (All Models)

Timing Chain Tensioner Wear

A rattling or slapping noise from the front of the engine on cold start, which may quieten as oil pressure builds. In severe cases, the rattle persists when warm. If ignored, the chain can skip a tooth, altering valve timing and potentially causing valve-to-piston contact.

Critical Engine, M10 (All Models)

Oil Leaks, The M10 Weeps From Everywhere

Oil residue on the engine block, oil drips on the garage floor, burning oil smell from the exhaust manifold. Common leak points: rocker cover gasket, oil pan gasket, rear main seal, timing chain cover gasket, distributor shaft seal.

Minor Engine, M10 (All Models)

Overheating

Temperature gauge climbs into the red zone, particularly in slow traffic or on hot days. Coolant may boil over. Persistent overheating causes head gasket failure and head warping.

Common Engine, M10 (All Models)

Valve Clearance Drift

Ticking noise from the valve train that changes with engine temperature. Loss of power and rough running if clearances become too large or too small.

Minor Fuel System, Kugelfischer Injection (2002tii)

Injection Pump Wear and Calibration Drift

Flat spots in the throttle response, rough idle, poor cold starting, uneven fuel distribution between cylinders, black smoke, loss of power.

View all 17 2002 / 2002tii / 2002 Turbo problems