1967-1976 BMW 2002 OEM Service & Repair Manual
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)
)_
~
).
J
INTR-ODUCTION
..
This repair manual is intended to ensure tha'l: the maintenance and repair work required for BMW cars is done in
the correct manner. Therefore this manual shou·ld be used by inspectors and fitters as it helps to supplement the
practical and theoretical knowledge they have acquired at our service training school. -
The relevant specifications are always provided at the begihning of each main group.
The specifications apply to standard cars that have not been involved in an accident and have not been modified
after leaving the factory.
Basical~ speaking, the Touring models are identical with the saloons so that in the specifications and values
quoted reference is only made to points in which the Touring models differ from the other cars.
The group system applied in this manual is taken from our flat rate catalogue.
For example, page,32·21/6 means:
32
-21
/6
main group
sub group
page in sub-group
The spElcial tools required for good repair work are listed in our special tool catalogue - order
No. 01 99 9 099 420. Photographs have been provided to. show how the special tools must be applied for the
ltidrvlt~ual processes and operations.
Removal/disassembly is always described for each operation. If fitting/assembly is not possible in the opposite
order a "note when fitting" is pr-ovided.
. '• . .
The f.b"floli'liing 'supplements are both alterations and additions. If the word "alteration" has been printed on the
she3t, ·take o~t the sheet already provided and insert the new one in its place. Sheets marked "addition" must
si~·ply,J>e added to the existing manual without removing any old sheets.
, . ~
.. Gln tl]e f<?llowing page a list should be provided of the supplements inserted in the repair manual.
Af>artrrom the improvements ann9unced by regular circular notes, we recommend that the spare parts catalogues
- whtcb have clear' illustrations- are used as an additional source of information.
0 .... .
o,
..
' 0
BAYERISCHE MOTOREN WERKE AG
CUSTOMER SERVICE DEPARTME-NT
Published by Bayerische Motoren Werke AG, Miinchen 40, Vl!est Germany, Customer Se~vice Department.
All rights reserved. Reprints only allowed with the written._;Q.ns~nt of the publisher.
Printed in Germany
Alteration
List of $upp~lements inserted
Supplement/order No. inserted on signature
r1·"'
.
)
··.""
. .
•
.J>,
3.73 Addition
BMW N 600 02.0
)
Tightening torque values and preload forces
Applicable only for bolts to German standards DIN 912, 931, 933, 960, 961 and 6912, and nuts with height
0.8 x d to DIN 934, and exclusively for /).tot= 0.14.
(Bolts phosphated, nuts untreated or galvanised. Lubrication : unlubricated or lightly oiled.)
For cadmium plated nuts or bolts ( 11 tot f":j 0.08 to 0.09) the tightening torque must be f":j 30% less than the
value in the Tables for the equivalent degree of utilisation of the bolt material._
Not applicable for other surface treatments or methods of thread lubrication, or for different nut heights. In
such cases separate determination of values is necessary.
Not applicable either for bolts with tensile (expansion) shank, for self-locking bolt connections or for
threaded connections using components made of different materials.
The bolt utilisation factor for standard metric threads· is :
I
(j red - 0,09 . oo,2
I
)
1 mkp = 7.2 lb/ft 1 kp = 2.2 lb.f
. .
Tightening torque MA (mkp) Preload force Pv (kp)
Strength class to DIN 267 standard Strength class to DIN 267 standard
Thread 5.6 6.8 6.9 8.8 10.9 12.9 5.6 6.8 6.9 8.8 10.9 12.9
M6
0,4+0,1 0,6+0,1 0,7+0,] 0,9+0,1 1,2+0,2 1,5 +0,2
425 600 685 855 1210 1440
-
M8
1,0+0,1 1,6 +0,2 1,8 +0,2 2,2+0,2 3,0+0,3 3,6 +0,4
740 1190 1330 1570 2170 2630
-
M 10
2,0+0,2 3,2+0,4 3,6+0,4 4,3+0,5 6,0+0,7 7,3+0,8
1160 1880 2090 2500 3480 4200
M 8x1
1,0+0,1 1,0·+0,2 1,8+0,2 2,2+0,2 3,0+0,3 3,6 +0,4
740 1190 1330 1610 2200 2670
M 10x1 ,25
2,0+0,2 3,2+0,4 3,6+0,4 4,3+0,5 6,Q+0.7 7,3+0,8
1160 1900 2120 2520 3530 4250
M 12x1 ,25
3,4-10,
4
5,4 +0,6 6,1 +0,7 7,2+0,8
10,3+
1
12,0+1,5
1720 2710 3070 3610 5100 6090
M 12x1,5
3,4 +0,4 5,4 +0,6 6,1 +0,7 7,2+0,8
10,3+
1
12,0+
1
·
5
1690 2670 3030 3570 5040 6000
M 14x1,5 5,4 +0,
6
8,6+
1
9,8+
1
11,5+
1
·
5
16,0+
2
20,0+2 2330 3720 4180 5030 6970 8510
M 16x1 ,5 8,3+
1
13,5+
1
·
5
15,5+
1
·
5
18,0+
2
25,0+
3
30,0+4 3240 5190 5840 6920 9710 11770
)
M 18x1 ,5 11 ,o+
1
·
5
18,0+
2
20,0+2,5
24,0+
3
34,0+
4
40,0+5 3890 6240 7020 8380 11800 13960
M 20x1,5 16,0+
2
26,0+
3
29,0+3,5
34,0+
4
49,0+
5
59,0+
6
5070 8170 9180 10680 15200 18250
For a threaded connection conforming to the above conditions the values laid down in the Table are
applicable. The tightening torque including the tolerance will only be quoted on the engineering or
assembly drawing if :
a) a value differing from that shown in the Table is necessary for functional reasons
b) the strength class of the nut and bolt is not evident.
Warning: Special reference is made in the Technical Data to any deviation from
these Tables.
A BMW Standard concerning tightening and test torque values for threaded connections using self-
locking nuts to DIN 985 and BMW N 113 48.0 standards is in preparation.
9. 70
BMW N 600 02.0
Bolts
Head DIN Str. Head DIN I Str.
Description
patt . No. cat.
Description
patt. No. cat.
9311
Countersunk self-tapping
@
7982
1)
933 8.8
screw
0
960 10.9 Domed head self-tapping
~
7981
1)
Hex bolt
961 12.9
screw
70614
Domed head countersunk
@
7983
1)
self-tapping screw
561 8.8
@ 84
4.8
833
8.8
835
Cylindrical head bolt
@
912}
8.8
Stud bolt -
836
6912 10.9
838
8.8
@
939
Round head bolt 7986 4.8
940
Flat round head bolt
@
603
4.6
417
.
8.8
0
551 2) 4)
Threaded pin
553
@
63
4.8
438 4.8
4
)
8.8
Countersunk bolt
0
427 5.8
@ 7987
4.8 Shank bolt
8.8 ·· -
@
920
Wing bolt
<>
316 4.6
5.6
4
Domed head bolt
921 'JUO-
4.6
~
7985 4.8 Threaded plug
@
908
910
0
4.8
7604
5.6
4
)
Domed head counter-
91
8.8
@
7623
6.8
sunk bolt
~
7988 4.8
Hollow screw
71436
Cylindrical head self·
@ 7971
1)
Collar screw
0
3871 5.6
4
)
tapping screw
Hex head self-tapping
0
7976
1) Slotted plug
®
71022 5.6
4
}
screw
Nuts
~
I
Description
Pat- DIN Str.
Description
Pat- DIN Str.
tern
No. cat.
tern
No. cat.
439
5)
[QJ
557 5-2
Square nut
562 140-2 -
985
8
et}
986
84)
1 04)
Cap nut
1587 6-2
@
934
3)
Hex nut
@
70851
Slotted nut
6G
4
)
936
6G
~
70852
8G
m
3870
70615 8/1 0
4
)
Collar nut
7606
SD-2
4
)
70616
6G/8G4)
@
935
8/10 Knurled nut
cl
466
5-2
Castellated nut
937 6S/8G
467
?,)
315 GTS
Round shoulder nut
cm
74361 8/10 Wing nut
Flat shoulder nut
.
1lcase hardening steel, file grade, hardening depth 0.1 - 0.2 mm
2)up to M 10 = 4.8, M 12 and beyond= 4.6
3)up to M 4 =5-2, M 5 and beyond = 8 and 10
4lprescribed strength categories not in accordance with DIN standard
5)up to M 8 = 4D-2, M 10 = 5S-2
9. 70
Index for Supplement 4 to BMW 1502-2002 Repair Manual Date of Issue 9.75
Order No. 01 50 9 699 589
Exchange alteration sheets Confirmed Exchange alteration sheets Confirmed
11- 0/1 to 4 34-0/1
0/3 to 13 0/3 to 5
00/1 00/1
00/21 to 24 11/1 to 5
I
00/26/1 to 4 21/3
i
12/3 31/1 to 3
12/7 33/1 to 3
14/1 to 4 41/5
21/1 to 4 35-0/3
26/1 36-0/3
31/1 to 7 41-0/1
33/1 0/5
34/1 35/1
41/1 51/1 to 2
64/11 51-0/1
12- 0/3 to 7 0/3
32/1 to 3 45/3
41/6 61-0/1
13- 0/1 0/3
0/3 to 5 13/1
11/3 31/3 to 5 I
11/13 to 16 62-0/1
31/1 0/3
32/1 11/1
16- 0/3 13/1
17- 0/3 63-0/1
21- 0/1 . 0/3
0/3 21/1
00/1 99/3
21/1 to 6 99/5 deleted
i
51/1 64- 11/19
52/1 65-11/1
23- 0/3 to 5 71- 0/3
00/3 to 8 60/3 to 5
00/13 to 16
24- 0/3 to 5 Insert additional sheet$ Confirmed
00/3 to 8
40/1 Tool number conversion list
25- 11/1 11- 0/17
26- 0/3 12- 0/9
31- 0/1 13- 0/7
0/3 to 5
.\
62/1
11/1 21- 0/5
12/1 to 5 23- 0/7
12/7 deleted 24- 0/5&
20/1 31- 0/7
21/1 . 21/3
31/1 to 3 32/1
33/1 33/3
32- 0/1 32-31/5
0/3 33- 0/11
. 11/1
34- 0/7
21/1 to 3 00/3
31/1 to 3 41- 51/3 to 10
32/1 61- 0/37
33/3 0/39
33- .0/3 to 9 13/3
31/7
62- 11 a
Insert -this sheet after the Introduction
Tightening torque values
for self-locking hex nuts
Applicable only to nuts to BMW N 113 48.0 and DIN 985 standards.
Surface treatment: phosphated or galvanized bolt. Nut galvanized, unwaxed.
Bolt lubrication : either unlubricated or lightly oiled.
BMWN
113 49.0
For cadmium plated nuts or bolts the torque value must be ~ 30% less than the value in the tables for
an equivalent utilisation factor of the bolt material.
Not applicable for other surface treatments or methods of lubrication, or a bolt strength classification
of less than 8.8 (e.g. 6.9) in conjunction with expansion bolts.
In such cases separate determination of values is necessary.
1 kpm = 7.2 lb/ft
Tightening torque MA (kpm)
Thread
Nuts to BMW N 113 48.0 std. Nuts to DIN 985 std.
Strength category Strength category
8 10 12 8 10 12
M6
1,1 +0,1 1,5+0,2 1,8+0,2 1,0+0,1 1,3 +0,2
I
1,6 +0,2
MS
\;
!
MS X 1
2,5+0,3 3,4+0,4 4,0+0,5 2,5+0,2 3,3+0,3 3,9 +0,4
M 10
4,9+0,5 6,8+0,8 8,0+0,9 4,7+0,5 6,4+0 ,7 7,7+0,8
M 10 X 1,25
M 12
8,1 +0,9
11,4 +
1
·
3
13,5+
1
·
5
7,8+0,6
1 0,9+
1
12,6+
1
·
5
M 12 X 1,5
M 14
13,0+
1
·
5
18,0+
2
22,0+
2
12,7+
1
·
5
17,0+
2
21,0+
2
M 14 X 1,5
M 16
22,5+
2
28,0+
3
33,0+
4
19,5+
2
26,0+
3
31,0+
4
M 16 X 1,5
M 18
27,0+
3
38,0+
4
44,0+
5
26,0+
3
36,0+
4
42,0+
5
M 18 X 1,5
The corresponding preload forces Pv (kp) relevant to the strength categories concerned are given in the
table 'Tightening torque values and preload forces', BMW N 600 02.0.
For a threaded connection conforming to the above mentioned conditions the values laid down in the
tables areaapplicable. The tightening torque including tolerance will only be quoted on the engineering
or assembly drawing if for functional reasons a value other than that given in the standard is necessary.
An accurate theoretical and experimental investigation is always necessary for
a threaded connection subjected to high dynamic stress.
0
n
0
Conversion list for special tool numbers
(new to old)
New Order No. Old Order No. New Order No • . Old Order No.
00 1 500 6000 13 5 240 6078
00 2 000 CARTOOL 13 5 260 '7028
Friction Meter Friction Meter 16 1 000 6067
00 2 050 7035 16 1 010 6068
00 2 500 5104 17 0 000 Manual tester
00 2 510 5104A 21 2 060. 7061
00250 6027 21 2 100 603
00 5 000 7051 23 0 000 7060
00 5 500 5129 23 0 010 7060/1
00 5 650 5079 23 0 040 6002
00 7 500 Kukko 17/K 23 0 05Q
.60()2~2
00 8 500 Kukko 204/2 '23 0 150 7002
00 8 510 Kukko 21/1 and '22/1 23 0 160 7024
00 8 650 Kukko 21/5 and 22/2 23 1 000 611
11 0 ooor 600 23 1 140 6039
11 0 020 7000 23 1 150 604
11 0 100 6001 23 1 200 607
11 0 120 7001 23 1 210 SW 30/83
11 t 000 6017 23 1 300 7026
11 1 040 6025-1 23 1 400 7010
11 1 060 7003-1 23 2 000 6206
11 1 100 609 23 2 010 6206E
11 1 120 610 23 2 040 6304
11 1 240 6060 23 2 050 6305
11 2 000 7006 23 2 060 6306
11 2 040 6018 23 2 100 6044
11 2 100 6069 23 2 150 7026/1
11 2 120 6069-1 23 2 200 1846c/3
11 2 140 6013 . 23 2 210 1846a/3
11 2 160 7007 23 2 240 6055
11 2 180 7013 24 0 000 6042
11 2 200 7026 24 0 010 6085
11 2 260 7006 24 0 100 7044
11 2 290 6020 24 0 150 6002-1
11 3 000 6019 34 0 160 7030
11 3 040 6012 24 1 000 6041
11 3 060 7004 24 1 040 6030
11 3 100 . 7008-1 24 1 050 7052
11 4 000 6065-1 24 1 060 7043
11 '.5 000 608 24 1 100 7053
12 1 040 6083/1 24 1 160 7039
12 1 050 6083 24 2 000 6050/1-4
12 1 060 7068 24 2 001 6050/1
12 1 100 6066 .24 2 002 6050/2
13 0 020 7062 24 2 003 6050/3
·13 0 040 011 24 2 004 6050/4
13 0 050 022 24 2 040 6032
13 0 060 010 24 2 050 6034
13 0 600 Unitast synchronizer 24 2 140 6031
13 1 000 6023 24 2 160 7032
13 1 010 6023-1 24 2 180 7038
13 1 030 7020 24 2 190 7037
13 3 000 5125 24 2 250 7035/2
13 3 050 6070 24 2 260 7035/1
13 6 040 6071 24 2 270 7040
13 6 050 6075 24 3 040 7056
13 6 070 6072 24 3 060 7033
13 6 080 6077 24 3 140 6033
13 6 140 6073 24 3 150 7064
13 6 150 6076 24 3 160 7031
Insert after bolt and nut table
. -1-
ew Order No.
J 3 260
J 3 460
J 4 000
' 4 040
'4 042
'4 043
!l4050
' 4 061
'4 062
5 1 000
6 1 000
6 1 050
1 1 000
1 1 007
1 2 000
1 2 040
1 3 000
1 3 100
1 3 140
1 3 160
2 1 000
2 2 000
2 2 020
2 2 050
·2 2 070
2 2 090
;2 3 000
:2 3 050
:2 3 100
12 4 000
12 4 050
13 1 000
13 1 040
13 1 060
13 1 100
13 1 150
13 1 180
13 1 250
13 1 270
13 1 300
33 1 350
33 1 400
33 1 420
33 1 450
33 2 000
33 3 000
34 1 000
34 1 010
34 1 050
34 1 060
34 1 100
34 1 120
34 1 150
34 1 170
34 1 200
34 1 250
34 2 000
34 3 000
34 4 000
35 3 000
36 1 000
36 1 050
Old Order No.
7041
7036
6028-1
6062
6062/2
6062/1
7055
7034
6062/3
6043
6006-4
538
6011
6011-1
6014-1
6080
6037
6035
6047
6016
7015
7027
6059
6056
6082
7009
6024
7021/1-4
6087
7017
7016
6003
6003-3
6003-1
6081-1
7019
5103
7011-2
6046
Rollex puller with cups
HM 89 449, LM 503 349
and pressure pad 6058
6053
6054
5104/1
7023
6045
6007-2
7029
3.9314-1400.2
3.9314-1800.2
3.9314-1500.2
3.9314-0900.1
3.9314-0600.1
3.4314-1901.2
3.9315-1900.2
7807
3.9314-1300.2
6038
6063
7014
6021
Wheel runout tester
6036
New Order No.
41 5 000
41 6 000
51 1 000
51 1 050
51 1 060
51 2 000
51 2 020
51 2 050
51 2 100
51 3 050
51 3 100
51 3 101
51 3 102
51 3 103
51 3 150
64 1 000
64 5 000
Old Order No.
7057
6048
6009
6049
6064
6052
6079
7018
7022
Happich insertion tool
6084/1-4
6084/1
6084/2
6084/3
6084/4
6086
6074
0
()
0
Conversion list for special tool numbers
""\
(old to new)
Old Order No. New Order No. Old Order No. New Order No.
010 13 0 060 6042 24 0 000
011 13 0 040 6043 25 1 000
022 13 0 050 6044 23 2 100
538 26 1 050 6045 33 2 000
600 11 0 000 6046 33 1 270
603 21 2 100 6047 31 3 140
604 23 1 150 6048 41 6 000
607 34 1 200 6049 51 1 050
608 11 5 000 6050/1-4 24 2 000
609 11 1 100 6050/1 24 2 001
610 11 1 120 "6050/2 24 2 002
611 23 1 000 6050/3 "24 2 003
1846c/3 23 2 200 6060/4 24 2 004
1846a/3 23 2 210 6052 51 2 000
5079 00 5 550 6053 33 1 350
5103 33 1 180 6054 33 1 400
5104 00 2 500 6055 23 2 240
5104/1 33 1 420 6056 32 2 050
5104A 00 2 510 6059 32 2 020
5120 00 5 500 6060 11 1 240
5125 13 3 000 6062 24 4 040
6000 00 1 500 6062/1 24 4 043
~
6001 11 0 100 6062/2 24 4 042
6002 23 0 040 6062/3 24 4 062
6002-1 24 0 150 6063 34 3 000
6002-2 23 0 050 6064 51 1 060
6003 33 1 000 6065-1 11 4 000
6003-1 33 1 060 6066 12 1 100
6003-3 33 1 040 6067 16 1 000
6006-4 26 1 000 6068 16 1 010
6007-2 33 3 000 6069 11 2 100
6009 51 1 000 6069-1 11 2 120
6011 31 1 000 6070 13 3 050
6011-1 31 1 007 6071 13 5 040
6012 11 3 040 '6072 13 5 070
6013 11 2 140 6073 13 5 140
6014-1 31 2 000 6074 64 5 000
6016 31 3 160 6075 13 5 050
6017 11 1 000 6075 13 5 150
6018 11 2 040 6077 13 5 080
6019 11 3 000 6078 13 5 240
6020 11 2 290 6079 51 2 020
6021 35 3 000 6080 31 2 040
6023 13 1 000 6081-1 33 1 100
6023-1 13 1 010 6082 32 2 070
6024 32 3 000 6083 12 1 050
6025-1 11 1 040 6083/1 12 1 040
~
6027 00 2 550 6084/1-4 51 3 100
6028-1 24 4 000 6084/1 51 3 101
I
6030 24 1 040 6084/2 51 3 102 )
~-
6031 24 2 140 6084/3 51 3 103
6032 24 2 040 6084/4 51 3 150
6033 24 3 .140 6085 24 0 010
6034 24 2 050 6086 64 1 000
6035 313 100 6087 32 3 100
6036 36 1 050 6206 23 2 000
6037 31 3 000 6206E 23 2 010
6038 34 2 000 6304 23 2 040
6039 23 1 140 6305 23 2 050
6041 24 1 000 6306 23 2 060
7000 11 0 020
Insert after bolt and nut table
-3-
Id Order No. New Order No. Old Order No. New Order No. ()
J01 11 0 120 7041 24 3 260
J02 23 0 150 7043 24 1 060
J03-1 11 1 060 7044 24 0 100
004 11 3 060 7051 00 5 000
006 11 2 260 7052 24 1 050
006 11 2 000 7053 24 1 100
007 11 2 160 7054 24 3 150
008-1 11 3 100 7055 24 4 050
009 32 2 090 7056 24 3 040
010 23 1 400 7057 41 5 000
011-2 33 1 250 7058 12 1 060
013 11 2 1fl> 7060 23 0 000
014 34 4 000 7060-1 23 0 010
01!5 32 1 000 7061 21 2 060
016 32 4 060 7062 13 0 020
017 32 4 000 7807 34 1 200
018 61 2 060 SW 30/83 23 1 210
019 33 1 160 3.9314-0600.1 34 1 120
020 13 1 030 3.9314-0900.1 34 1 100
021/1-4 32 3 050 3.9314-1300.2 34 1 250
022 51 2 100 3.9314-1400.2 34 1 010
' 023 33 1 . 460 3.9314-1500.2 34 1 060
'024 23 0 160 3.9314-1800.2 34 1 050
0
'026 11 2 200 3.9314-1900.2 34 1 170
' 026. 23 1 300 3.9314-1901.2 34 1 150
'021/1 23 2 150 Kukko 17/K 00 7 500
'027 32 2 000 Kukko 204/2 00 8 500
1028 13 5 260 Kukko 21/1 and 22/1 00 8 510
1028 34 1 000 Kukko 21/5 and 22/2 oo a 550
J030 24 0 160 CARTOOL
J031 24 3 160 Friction Meter 00 2 000
1032 24 2 160 UNITEST synchroniser 13 0 500
1033 24 3 060 Manual tester 17 0 000
1034 24 4 061 Happich insertion tool 51 3 060
IQ31 00 2 060 Wheel runout tester 36 1 000
1113!{1 24 2 260 Rollex puller with cups 33 1 300._
'.J
~
103!112 24 2 250 HM 89449,
JOC36 24 3 460 LM 503349
1037 24 2 190 and pressure pad
1038 24 2 1~ 6058
7039 24 1 100
7040 24 2 270
0
-0
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- This workshop repair and service manual is designed for the BMW 2002, covering production years 1967 to 1976, and encompasses all styles, models, and engines.
- It is a comprehensive OEM manual with a total of 742 pages, available in a cross-platform document format for Windows, Mac, and Linux, in English.
- Upon purchase, the manual is instantly accessible via a download link on the checkout page and is also sent via email after payment. It is DRM‑free and printable.
- The manual includes detailed sub-steps, notes, cautions, and warnings throughout each chapter, with numbered instructions and bold figure numbers for easy reference.
- It features detailed illustrations, drawings, and photos to guide users through every procedure, along with an enlarged inset for more detailed part examination.
- A numbered table of contents is provided for quick information retrieval, with troubleshooting procedures and detailed wiring diagrams that assist in diagnosing and repairing electrical system issues.
- Furthermore, it ensures there are no missing pages, contains official service information, and guarantees customer satisfaction.
EXCERPT (1967-1976 BMW 2002 OEM Service & Repair Manual):
This repair manual serves as a comprehensive guide for the proper maintenance and repair of BMW cars. It is intended for inspectors and fitters to supplement the practical and theoretical knowledge acquired from service training.
Each main group in the manual begins with detailed specifications applicable to standard cars that have not been involved in accidents or modified after leaving the factory. The grouping system is derived from the flat rate catalogue.
Special tools required for effective repair work are listed in the special tool catalogue, alongside accompanying photographs that demonstrate their use in individual operations.
The manual provides detailed guidelines on the manual gearbox, including the subsequent fitting of the five-speed gearbox, removal and reinstallation procedures, stripping and reassembling operations, and the replacement of radial seals and guide sleeves.
Additionally, it includes alteration procedures such as the installation of the five-speed gearbox, removal of existing support blocks, and exchange of both the propeller shaft and speedometer shaft.
