BMW 1500, 1502, 1600, 2000 Touring, 1602 and 2002 Repair and Service Manual 1959-1977

• BMW 1500 - 1499cc (91.4 cu. in.)
• BMW 1502 - 1573cc (95.9 cu. in.)
• BMW 1600 - 1573cc (95.9 cu. in.)
• BMW 1602 - 1573cc (95.9 cu. in.)
• BMW 2000 Touring - 1990cc (121.4 cu. in.)
• BMW 2002 - 1990cc (121.4 cu. in.)

STARTER MOTOR | DESCRIPTION, REMOVAL AND INSTALLATION

1. This type of starter motor incorporates a solenoid mounted on the starter motor body. When the ignition switch is operated, the solenoid moves the starter drive pinion, through the medium of the shift lever, into engagement with the flywheel starter ring gear.
   
   As the solenoid reaches the end of its stroke and with the pinion by now fully engaged with the flywheel ring gear, the fixed and moving contacts close and energize the starter motor to rotate the engine.



2. To remove the starter motor, first disconnect the lead from the battery negative terminal.



3. Disconnect the leads from the starter motor solenoid terminals. Release the starter motor front mounting (photos).



4. Unbolt the starter motor from the bellhousing and withdraw it (photo).



5. Installation is the reverse of removal.

STARTER MOTOR | OVERHAUL

1. Servicing operations should be limited to renewal of brushes.



2. The major components of the starter should normally last the life of the unit and in the event of failure, a factory exchange replacement should be obtained.



3. Disconnect the motor field winding lead from the solenoid terminal.



4. Remove the screws which secure the solenoid to the drive end cover and withdraw the solenoid at the same time unhooking it from drive engagement lever.

FRONT SUSPENSION STRUT | OVERHAUL

1. With the strut removed from the car, compress the coil spring using screw type compressors.



2. Pry off the cap from the top mounting and hold the piston rod quite still with a wrench and unscrew the self-locking nut. Withdraw the top mounting.



3. Withdraw the coil spring (still compressed) together with its upper mounting plate.



4. If the coil spring is to be replaced, release the compressors and fit them to the new spring and compress it ready for refitting. Always replace both front coil springs at the same time with ones of similar rating and color identification.



5. Replacement of the suspension hydraulic strut can be carried out in one of two ways, either replace the strut complete with a new or reconditioned unit or replace the internal components with a repair kit or cartridge.

• Introduction: Vehicle identification numbers. Buying parts. Safety. Maintenance techniques. Chemical and lubricants, and more.
• Tune-up and routine maintenance
• General engine overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Manual transmission
• Automatic transmission
• Clutch and driveline
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams