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Tech Tips

100 Tips that will help keep your '02 happier (and safer):
   
ELECTRICAL:

• Seriously consider changing to an electronic ignition (Pertronix Ignitors are good, simple, and relatively cheap). The Pertronix "Flamethrower" coil is a great upgrade as well.
  
• Reversing wires on front turn signals can result in working turn indicators but no dash indicators.
• Erratic gauges can often be traced to a bad ground, either on the instrument cluster itself
  or on the engine to chassis strap.
• Belts tightened too much can cause excessive water pump bearing wear. Tighten only enough to run the alternator without slipping.
• Never install driving lights without using a relay. Wiring damage and fires can result.
• A failed cold-start relay on Tiis can be expensive to replace. Wiring the cold start injector to a small push-button switch on the dashboard can overcome the problem. The injector MUST operate for at least a
  second during cranking, and holding the switch for a second or two when starting works every time. It can also act as an anti-theft hurdle for those who don't know the switch is there.
• The early and late style fuel pumps are interchangeable on all non-Tii 02s; however, they use different length pushrods.
• A dead windshield washer pump can oftentimes be resurrected by carefully dismantling, cleaning and lubricating the motor. Failing that, the washer pump from an older VW or Audi is a perfect replacement.
• Erratic electrical accessory problems can be caused by a deteriorated or broken battery-to-body strap.
• A group 26R battery fits an 02 just fine and usually has a higher CCA rating than an equivalent group 42 battery.
• Any reluctant or non-working electrical item should have its fuse checked first. The German cartridge fuses wear out and should be replaced every few years.
• If the turn signal flasher bulb on the dashboard flashes intermittently but both front and rear turn signals
  are OK and flash properly, clean or replace the fuse and all grounds before suspecting the flasher unit itself.
• There are several different seemingly identical bulbs which will fit 2002 taillights. Make sure you use the correct ones to avoid melting the lens (too big) and for best visibility (not too small).
• '72 and later cars with a stalk-mounted wiper switch can be retrofitted with interval wiper controls from a 320i.
• Early 2002s with 6-position fuse boxes have non-fuse headlights. Using the wiring diagram in the owners manual, install a fused relay in both the low beam and high beam circuits. It will save molten wires, and make the lights brighter. Until 1974, even the 12-fuse cars didn't have a fuse for high beam.
• Dim taillights can be caused by corroded reflectors. Some silver spray paint applied to the inside housing to brighten them up
• A 530i (or equivalent) starter will give you a lot more starting torque.
• If radio reception is poor, try replacing the antenna. They deteriorate with age.
• The adapter kit for a late Chrysler New Yorker will allow the mounting of a DIN-style radio in a 2002 console.