1973 BMW 2002TII

Symptoms: hard starting when hot, erratic idle and stumbling, fuel leaking from injection pump seals, loss of power under load

Fix: The Kugelfischer pump is NLA from BMW and requires specialist rebuild (6-8 hours labor to remove, reinstall, and tune). Most shops send pumps out for rebuild which takes 2-4 weeks. Injectors often need ultrasonic cleaning or replacement. Complete system overhaul including pump rebuild, injector service, fuel lines, and tuning typically runs 12-16 hours total.

Estimated cost: $2,500-$4,500

Typical onset: 80,000-150,000 mi

Symptoms: heavy blowby and oil consumption over 1 qt per 500 miles, knocking or rattling from bottom end, low oil pressure below 20 psi hot at idle, metal shavings in oil filter

Fix: The M10 engine with original flat-tappet cam needs zinc additive or proper oil. Neglect leads to cam lobe wear and bearing failure. Full rebuild involves machine work on block and head, new pistons/rings, bearings, timing components, and seals. Engine-out rebuild takes 25-35 hours including R&R. Short block replacement if machining not needed: 20-25 hours.

Estimated cost: $4,500-$8,000

Typical onset: 70,000-120,000 mi

Symptoms: excessive shifter vibration, clunking when engaging clutch, difficult shifting especially into second gear, gear oil leaks from input shaft seal or tailshaft

Fix: The rubber transmission mount deteriorates and allows excessive movement. Replacement is 1.5-2 hours. Getrag 232 gearbox with worn synchros requires rebuild with new synchro rings, bearings, and seals (12-16 hours including R&R). Second gear synchro fails first from aggressive downshifting.

Estimated cost: $150-$300 for mount only; $2,000-$3,500 for full rebuild

Symptoms: rust particles clogging fuel filter repeatedly, fuel smell in trunk area, visible corrosion on tank exterior, fuel starvation under hard cornering

Fix: Steel fuel tanks rust from inside out, especially if car sat with old ethanol fuel. Tank removal is 3-4 hours; add coating/sealing service or replacement tank. All rubber fuel lines from 1973 are collapsed internally even if they look OK externally. Complete fuel system refresh including tank service, new hard and soft lines, filter, and pump check runs 8-12 hours.

Estimated cost: $800-$1,800

Symptoms: overheating in traffic or hot weather, weeping coolant from water pump or expansion tank, collapsed lower radiator hose, heater not working properly

Fix: Original radiators develop pin-hole leaks; most have been replaced by now but cheap replacements fail quickly. Water pump bearings wear and seals leak. All rubber hoses collapse internally. Complete cooling refresh with quality radiator, water pump, thermostat, hoses, and expansion tank takes 6-8 hours.

Estimated cost: $800-$1,500

Typical onset: 80,000-120,000 mi

Symptoms: clunking over bumps from rear, unstable handling and rear-end wander, uneven rear tire wear, visible cracking in rubber bushings

Fix: The semi-trailing arm rear suspension has large rubber bushings that crack and tear with age. Replacement requires pressing out old bushings and pressing in new ones, typically 4-6 hours for both sides. Subframe mounts also deteriorate. While back there, inspect shock mounts and differential mounts.

Estimated cost: $600-$1,200

Symptoms: intermittent gauge operation, lights flickering or dim, ignition system cutting out, mysterious electrical gremlins

Fix: The ceramic fusebox develops corroded connections and cracked fuse holders after decades. Ground straps corrode. Wiring insulation becomes brittle. Systematic diagnosis and repair of connections, ground cleaning, and fusebox rebuild or replacement typically takes 4-8 hours depending on severity. Ignition points and condenser if not converted to electronic ignition.

Estimated cost: $400-$1,000