2002 / 2002tii / 2002 Turbo

1968-1976 / Sedan / Germany

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

Minor Fuel System, Kugelfischer Injection (2002tii)

Injection Pump Wear and Calibration Drift

Symptoms

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

Cause

The Kugelfischer PL04 mechanical injection pump is a precision instrument with dozens of moving parts, cams, plungers, diaphragms, springs, and calibration shims. After 50 years, internal wear changes the fuel delivery curves. The pump's calibration drifts, and it can no longer meter fuel accurately across the full range of throttle positions and engine speeds.

Fix

The pump must be rebuilt by a Kugelfischer specialist.

This is not a DIY job, it requires specialised knowledge, calibration equipment, and test benches that exist in perhaps a handful of workshops worldwide.

In Australia, only a few specialists handle Kugelfischer work.

Cost: $2,000-4,000 for a full rebuild.

Replacement pumps (used, rebuilt): $3,000-6,000.

Cost mentioned in fix

Cost: $2,000-4,000 for a$3,000-6,000

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// More 2002 / 2002tii / 2002 Turbo problems

Other known issues

Common Fuel System, Kugelfischer Injection (2002tii)

Warm-Up Regulator Failure

Poor cold-start behaviour, the engine is hard to start when cold, runs roughly for several minutes, or stalls repeatedly during warm-up.

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.

Common Fuel System, Carburettor (Base 2002)

Carburettor Wear and Maladjustment

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

View all 17 2002 / 2002tii / 2002 Turbo problems