2002 / 2002tii / 2002 Turbo

1968-1976 / Sedan / Germany

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

Critical Rust

Sill and Jacking Point Corrosion

Symptoms

The sills (rocker panels) and integrated jacking points soften and crumble. The jacking point collapses when weight is applied.

Cause

Box-section sills trap moisture and rust from inside. The jacking point reinforcement corrodes similarly. Road spray from below and water entry from above (through door seal failures) accelerate the process.

Fix

Sill replacement panels are available.

The entire sill section must be cut out and new metal welded in.

This is a significant panel-beating job that affects body rigidity.

Cost: $1,000-2,500 per side.

Cost mentioned in fix

Cost: $1,000-2,500 per side

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Other known issues

Minor Rust

Front Strut Tower Corrosion

The sheet metal surrounding the front MacPherson strut mounting point thins and weakens. In extreme cases, the strut can push through the tower under load, the front wheel collapses into the guard.

Critical Rust

Floor Pan Corrosion

Soft or perforated floor pans, particularly under the driver's seat, in the footwells, and around the pedal box. Water entry through deteriorated seals accelerates the problem.

Critical Rust

Rear Wheel Arch Corrosion

Bubbling paint, perforation, and structural weakening of the inner and outer rear wheel arches.

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.

View all 17 2002 / 2002tii / 2002 Turbo problems