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Saab 95 1967, Service Manual

The Saab 95 1967 Service Manual is your go-to manual for all maintenance and repair needs. Download it for free from manualshive.com and have access to detailed instructions, diagrams, and troubleshooting tips to keep your classic Saab running smoothly. Get your manual today and keep your Saab in top condition.

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Summary of Contents for 95 1967

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Page 6: ...526 Model 1968 470001 507018 Model 1969 520001 552859 Model 1970 560001 592844 Model 1971 96600001 96627413 Model 1972 96722000001 96722021567 Model 1973 96732000001 96732023028 Model 1974 96742000001...

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Page 8: ...in 1580 mm 4 ft 10 in 1470 mm 5 1 in 130 mm 4 ft 0 in 1220 mm 8 ft 2 in 2498 mm 17 ft 5 in 5 3 m 2080 lb 945 kg 3370 lb 1530 kg Front 57 Front 44 7 39 cu ft 1 1 m3 39 4 x 37 4 in 1000 x 950 mm 63 x 3...

Page 9: ...with driver 4 passengers Loading area with driver 1 passenger Trunk height Four 1077 Saab 95 Saab 96 14 ft in 13 ft 9 in 4300 mm 4200 mm 5 ft 2 in 5 ft 2 in 1580 mm 1580 mm 4 ft 10 in 4 ft 10 in 1470...

Page 10: ...space Loading area with driver 4 passengers Loading area with driver passenger Trunk height 010 6 3 9292 14 ft 1 in 4300 mm 5 ft 2 in 1580 mm 4 ft 10 5 in 1490 mm 5 1 in 130 mm 4 ft 0 in 1220 mm 8 ft...

Page 11: ...ing area with driver 1 passenger Trunk height 815 Saab 95 Saab 96 14ft 1 in 13ft 9in 4300 mm 4200 mm 5 ft 2 in 5 ft 2 in 1580 mm 1580 mm 4 ft 10 5 in 4 ft 10 in 1490 mm 1470 mm 5 1 in 5 1 in 130 mm 13...

Page 12: ...rea with driver 4 passengers Loading area with driver 1 passenger Trunk height Saab 95 14 ft in 4300 mm 5 ft 2 in 1590 mm 4 ft 10 5 in 1490 mm 5 1 in 130 MM 4 ft 0 in 1220 mm 8ft 2 in 2498 mm 17 ft 6...

Page 13: ...er 1 passenger Trunk height Marnh 1379 Saab 95 14 ft 1 in 4300 mm USA cars 14 ft 3 in 4350 mm 5 ft 2 in 1590 mm 4 ft 10 5 in 1490 mm 5 1 in 130 mm 4 ft 0 in 1220 mm 8 ft 2 in 2498 mm 17 ft 6 in 5 4 m...

Page 14: ...driver passenger Trunk height Saab 95 14 ft in 4300 mm 5 ft 2 in 1590 mm 4 ft 10 5 in 1490 mm 5 1 in 130 mm 4 ft 0 3 in 1228 mm 4 ft 1220 mm 8 ft 2 in 2498 mm 17 ft 6 in 5 6 m 2135 lb 980 kg 3395 lb 1...

Page 15: ...river 1 passenger Trunk height Saab 95 14 ft 5 6 in 4410 mm 5 ft 2 in 1590 mm 4 ft 10 5 in 1490 mm 6 in 150 mm 4 ft 0 3 in 1228 mm 4 ft 1220 mm 8 ft 2 in 2498 mm 17 ft 6 in 5 5 m 2150 lb 980 kg 3395 l...

Page 16: ...m model 1976 850 900 rev min Weight incl electric equipment and carburetor 265 lb 120 kg 265 lb 120 kg CYLINDER BLOCK Type 60 Vee formation cyl inder block and crank case casted in one piece Material...

Page 17: ...g 5 1267 As from engine No 59835 wmpress on 9 W Thickness 1978 1 990 mm Vllidth 0 15 in max max 3 76 mm PIStOI l ring clearance in groove 0 0394 0 077 mm Gap In posrtion 0250 0500 mm Lower compression...

Page 18: ...l bearing insert width BALANCE SHAFT Number of bearings Clearance in bushing Front Rear Balance shaft end float Inner diameter of bushings Front Rear Bearing diameter of balance shaft Front Rear Bachl...

Page 19: ...intake and exhaust Clearance between stem and guide Intake Exhaust Disc diameter Intake Exhaust Valve lift Valve clearance cold engine Intake Exhaust 020 4 3 41 516 41 542 mm 41 135 41 161 mm 40 754...

Page 20: ...thread Oil pump Clearance rotor to housing Clearance rotor to sealing surface Model 1967 1 78 in 45 2 mm 1 13 in 28 6 mm 175 211 N 39 47 lbs 17 8 21 5 kp WE 1 91 in 48 5 mm 1 13 in 28 6 mm 267 302 N 6...

Page 21: ...ation pump capacity Idling speed Fast idling Stage Stage Stage Float level when idling 020 6 29 39 Nm 3 4 kpm 98 Nm 10 kpm 34 Nm 3 5 kpm 49 Nm 5 0 kpm 69 Nm 7 0 kpm 20 Nm 2 0 kpm 49 Nm 5 0 kpm 54 Nm 5...

Page 22: ...35 2 0 0 33 0 45 cu in 5 5 7 5 cm3 10 strokes 800 900 rev min 1 800 2 000 rev min 1 08 in 27 5 mm 1 34 in 34 0 mm Model 1971 1975 FoMoCo 71 TW 9510 JB JC FoMoCo 71 TW 9510 JD FoMoCo 72 TF 9510 KGA FoM...

Page 23: ...designation Main jet Air jet main system Transition jet Air jet transition system Idling jet Acceleration jet Booster valve Fast idling speed Idling speed CO content Throttle valve damper delay time O...

Page 24: ...nter at permanent temperature below 50 F 1000 Position Summer Membrane pump driven by eccentric on the camshaft 3 4 4 3 lb sq in 0 24 0 30 bar kp cm2 at 4 000 crankshaft rev min Up to and incl model 1...

Page 25: ...0 Anti freeze coolant mixture Maximum anti freeze and rust protection is obtained at a dosage of 2 5 3 imp qt 3 3 5 l as from model 1977 2 2 5 imp qt 2 5 3 1 Saab original anti freeze should be used a...

Page 26: ...st pull in voltage for operating solenoid switch one I 12V 44Ah Bosch K1 14v35A20 Bosch Kl 14 V 2 000 rev min 14V55A20 35A 55 A Clockwise and cou nter clockwise 2 9 3 9 N 10 5 14 02 300 400 p As from...

Page 27: ...0 sparks minute 4 000 distributor revolutions Primary winding resistance between connections 1 and IS IGNITION CABLES Resistance in spark plug connection up to engine No 242000 Resistance in ignition...

Page 28: ...up 3 Febr 1017 Up to and incl engine No 59835 W W 225 T35 UL 82 Y B 7 HS 0 5 in 12 7 mm M 14 x 1 25 0 024 0 028 in 0 6 0 7 mm 22 29 ft b 29 39 Nm 0 18 0 22 uF As from engine No 59836 AGR resistor AG 2...

Page 29: ...ator light front Parking and direction indicator lights front USA Direction indicator light rear Tail light Stop light Number plate light Control and instrument lamps Control lamp hazard warning signa...

Page 30: ...971 As from model 1972 HEATER FAN MOTOR Type designation Output and speed at free blowing and a voltage of 13 V 1 2 speed 1 1 speed Febr 1977 Effect 932 50 40 W 60 55 W P 43 t 38 S W BA 15 S 21 W BA 1...

Page 31: ...cm 2 2 in lb and rev min A tension 13 V 46 i 5 1 5 2 Blockated motor e g frozen wiper blades 5 6 WINDSHIELD WASHER H EADLIGHT WASHER Type designation MEAB SCHURER Two jets o 0 7 mm Pressure bar kp cmz...

Page 32: ...9 mph 11 2 km h 3rd gear 11 5 mph 18 5 km h 11 3 mph 18 2 km h 11 2 mph 18 0 km h 4th gear 17 7 mph 28 4 km h 17 2 mph 27 8 km h 17 1 mph 27 9 km h Reverse 4 7 mph 7 5 km h 4 7 mph 7 4 km h 4 5 mph 7...

Page 33: ...935 lbs 340 425 kp Clutch operation Up to model 1968 Master cylinder Make Girling Girling Cylinder diameter 5 8 3 4 Max permissible stroke 1 38 in 35 mm Hose connection 3 8 UNF 24 3 8 UN F 24 Hose len...

Page 34: ...late to the lower part of the dash panel max stroke approx Wheel cylinder Diameter front Diameter rear Saab 96 Saab 95 up to model 1969 Saab 95 as from model 1970 Brake lines Brake hoses Length front...

Page 35: ...in toe out Both wheels together or measured rim to rim Toe in toe out per wheel must not exceed Max difference in wheelbase left and right front wheels pointing straight ahead 020 20 W 7 i 1 2 i 1 2...

Page 36: ...mm 5 7 in 145 mm 10 5 9 75 15 4 in 391 mm 16 0 in 405 mm 16 4 in 416 mm 14 5 in 368 mr 0 46 in 11 7 mm 0 47 in 12 mm Yellow Green Model 1972 Model certain export 1972 1975 markets 5 7 in 145 mm 5 7 in...

Page 37: ...Width across flats 3 4 in 19 05 mm Thread UNC 9 16 Tightening torques Castle nut front wheel hub 177 Nm 18 kpm 130 ft st Castle nut rear wheel hub 88 Nm 9 kpm 65 ft lbs Wheel bolts 79 98 Nm 8 19 kpm...

Page 38: ...etallic Silver crystal metallic White White Orchid white Light beige Savann beige Yellow Brillant yellow Indian yellow Topaz yellow Antilop brown Saab 95 13ft 7 in 4160 mm 5 ft 2 in 1 585 mm 4 ft 1 1...

Page 39: ...II III 1977 L E D O M L C m m A o T w III IIII IIII IIIIIIIll IIII IlluI Iull IIIII III a unuuuunuununnuannnnnunnnnn nnuun l u unnnnnare 2 v 7 low m III IIII Illllzllll IIII l III m m m Ill IIll Illll...

Page 40: ...0 Im m u IImu nu mum mu I III Im _ u n uunlln nu nu I n H II I I m Urn nmII III IIma In u III nIIIIII IIIIII II I ImII IIIIImm III 74 I II Inn I I I m Im nl IIII II I II I I M I II III u II IIIIIIIIII...

Page 41: ...25 0QO W 0 3 0 6 0 0 25 0 0 0 0 0 8 q m 3 2 26 6 3 1 0 00 m 5 0 0 9 25 5 8 1 2 0 3 8 2 0 0 3 8 0 3 0 so 0 5 0 6 0 0 5 2 20 30 3 30 8 3 8 8 9 0 8 0 0 2 0 2 8 3 8 0 3 3 0 8 3 3 8 20 01302 05 33 8 0 20 0...

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Page 84: ...ent to the valves via push s The tappets are accessible upon remov rectly by the c block and trans rods and rocker al of the cylinder heads CONNECTING RODS PISTONS AND PISTON RINGS The pistons are jou...

Page 85: ...assembly 3 Balance shaft 8 Gallery line 4 Crankshaft 9 Oil pressure switch 5 Camshaft Oil pump relief valve The oil pump is of the bi rotor type Its shaft is connected to the distributor shaft which...

Page 86: ...fuel up from the tank to the carburetor The pump is located on the left hand side of the engine and is driven by the camshaft by means of a push rod from a special cam on the shaft The withaniu g c _...

Page 87: ...s the valve thus providing a communication from the upper part of the tank to the surrounding air via the ventilation hose 6 which runs out under the rear fender The fuel which increases in volume whe...

Page 88: ...rolled booster syst rious carburetor function sections The illustr the functions described ref ations show carburetor 28 32 PDS T_7 but er to carburetor 32 PDSlT_4 as well Float system The fuel level...

Page 89: ...the adjustable control rod and the idling func tion of the throttle valve is now moved from the idling screw to the ratchet wheel Idling system When the engine is idling the throttle valve is almost...

Page 90: ...EEK Of th to the englnihese holes are located immediately abOVe carburetor sition of the throttle valve As the valve the closed Do increased from idling the mixture of opening IS SI 0V r W not only f...

Page 91: ...the of air determined by the emulsion jet is mixed with it engine through the main system of th fuel passes the main jet before re h e Carburetor The The obtained mixture of fuel and air then flows i...

Page 92: ...librated riser which is press hamber cover From the risgr a d er pipe which is also press fitted iUct g of the atomizer pipe is place In fitted in the float c leads to the atomiz the cover The openin...

Page 93: ...en injection ceases and the diaphragm returns to the normal position the ball closes the outlet duct and fuel fills the acceleration pump again through the open inlet valve The acceleration pump is co...

Page 94: ...the cooling water temperature Then fast idle works with three steps like the Solex carburetor previously used Adjustment of fast idle accelerating pump capacitY float chamber ventilation and float lev...

Page 95: ...l7 W 20 26 9 I I I I I I I 1 l I I I I I I I 27 71823 2221 CARBURETOR MODEL 1971 1975 1 Automatic choke housing 10 Thermostatic spring 2 Choke plate 11 Vacuum piston 3 Connection for float chamber ve...

Page 96: ...s cut off When the level sinks the course is repeated 24 F LOAT SYSTE M 1 Fuel inlet 2 Float needle valve 3 Float W Bush rod re a stable float level the needle valve is lumped ed ball ipped with a val...

Page 97: ...buretor 70 TW AA The choke flap is regulated in the same manner as before by a bimetal spring which reacts to the coolant tempera ture When the engine is started a vacuum actuated piston is drawn down...

Page 98: ...n air channel The fuel air mixture then passes anot er d receives more air 0m a pressure equalising strictlon an laced further down in the neck of the Car hole which I5 Prpose of this is to get the co...

Page 99: ...h a vacuum regulated full load enrichment system The system con sists of a piston which via a channel communicates with the carburetor neck The piston is actuated by the vacu um prevailing in the neck...

Page 100: ...t and om the fuel is forced past the ball in the outlet 9 into the carburetor neck via the acceleration n ceases and the cuapnragm returns to the n the ball closes the outlet duct and fuei p again thr...

Page 101: ...se by workshops are blue The carburetor has been designed in regard to th exhaust emlSS 0n regulations and is a d e mister FoMoCo carburetor As opposed to the FoMoCo carburetor the new carbu retor IS...

Page 102: ...ntilation 200 20 Choke To facilitate starting when the engine is cold the carbu retor is fitted with a choke valve In the Upper part of the carburetor throat As the valve closes the vacuum below it an...

Page 103: ...the engine To improve the transition from the idling system to the main system two holes connected to the idling passage are located above the idle mixture control screw in the throat of the carburet...

Page 104: ...Fuel stem to ensulc W V VVVVVV u WI yCluantity at full load The system comprises a which is connected to the carburetor throat be piston hrottle valv e by means of a passage The piste jow the t d by...

Page 105: ...e ball in the outlet duct through thieacsczlzcec j ration Jet into the throat of the carburetor When Injection ceases and the diaphragm returns to its ormal position the ball closes the outlet duct an...

Page 106: ...m a hole in the bottom cover acts from below 0 4 VI leration freewheel locked the vacu f the diaphragm is sufficiently high to the spring thus drawing the diaphragm ds This actuates the valve spindle...

Page 107: ...opens and the cycle is repeated Ventilation of the float chamber is by means of a valve in the carburetor housing Operation of the valve is governed by the position of the throttle valve lever When th...

Page 108: ...4 Diaphragm vacuum control 5 Dlephregm rod lant rises The automatic mechanism also in of the cm cam the function of which is to increase dudes stepeed during cold starting The step cam is re the dlmg...

Page 109: ...ansition to the main system several calibrated holes are situated above the idling mix ture adjusting screw and the fuel air mixture from the idling system flows through these when the throttle is ope...

Page 110: ...reby bringing the secondary stage into 0p eration Calibrated holes are prowded In the carburet0r throat at the same level as the throttle valve and the fuel air mixture is sucked through these holes f...

Page 111: ...EM TRANSITION SYSTEM SECONDARY STAGE Air jet transition system secondary stage Air jet main system Spray pipe 1 3 4 5 6 7 8 Fuel air passage transition system Fuel jet transition system secondary stag...

Page 112: ..._r _s I V IV Emulsion pipe Secondary stage Main jet Emulsion pipe Throttle valve Primary stage Spray pipe Throttle valve Main jet MAIN SYSTEM FULL LOAD 3 4 5 6 7 8 200 30...

Page 113: ...spray pipe into the throat of the carburetor When the injection ceases the outlet valve closes the diaphragm returns to its normal position and fuel from the open inlet valve once again throttle Fuel...

Page 114: ...through a calibrated ascending pipe Vacuum valve PVS valve A thermo regulated vacuum positive vacuum supply valve is located in the coolant pipe from the engine The VACUUM CONTROL DISTRIBUTOR 1 Carbu...

Page 115: ...n should be used at permanent temperature below 50 F 10 C In warmer weather when preheating is no lon gar necessary the upper part of the air cleaner is loosened and turned so that the snorkel inlet c...

Page 116: ...o the rear part Of the cylin I e Wa 1A blzgtgng passed the engine the water flows up by the er h a by pass line to the mostat and throug s de Of trig r fthe pump The cooling Jacket of the auto suc l o...

Page 117: ...lter insert and via a flame guard and a hose Is led into the righthand valve cover Through the crankcase the air is then led into the lefthand valve cover and on via a h an intermediate f retor If it...

Page 118: ...vapor from the tank The charcoal canister is placed in the engine com partment and it is connected to the vent hose from the fuel tank and via a hose to the air cleaner When the en gine runs fresh air...

Page 119: ...r the front panel and detach the two radiator supports from the car hwy Detach the clamping straps from the radiator and remove the hood lock and control Wire Model 1969 1970 4 Remove the headligh the...

Page 120: ...etr with the gearbox Use lifting eassem hookk7fvif a filtering arbor that the disc assembly 2 Choc c ntered in the clutch ls proper yn ine carefully towards the gearboX so 3 PUSh the jugch center enga...

Page 121: ...Mark the end of the pump push rod which rests against the camshaft as a guide for reassembly REMOVAL OF FUEL PUMP 1 Pump push rod 2 Gasket 3 Fuel pump 8 Take out the spark plugs 9 Remove the oil press...

Page 122: ...the correct order t wire and 22 Take the oil seal for the balance shaft out of the transmission cover with tool 78 62 147 new F TAPPETS REMOVAL OF TRANSMISSION COVER OIL SEAL REMOVAL 0 Tool 78 62147 1...

Page 123: ...29 Remove any redges or carbon deposits from the upper end of the cylinder bores 30 Make sure that all connecting rods and caps are marked so that they can be reinstalled in their origi nal positions...

Page 124: ...t drive the balance shaft rearwards until the sealing washer is out Care fully remove the balance shaft from the rear of the block REMOVAL OF BALANCE SHAFT 3 Ins beatzggt s r sm eanng caps Wlth insert...

Page 125: ...ly ready 0 bear WW i REAR CRANKSHAFT SEAL ASSEMBLY Tool 78 62 170 7 Fit new connecting rod bolts NOTE Fit new connecting rod bolts every time the crank shaft has been disassembled 8 Coat the pistons r...

Page 126: ...them into the rear main bearing PISTON ASSEMBLY cap with a blunt screwdriver Tool 78 62 287 10 If new bearings are installed check that the correct fitting clearance is obtained The measuring proce d...

Page 127: ...pping the gear as this may damage the axial bearings of the crankshaft 20 Apply a thin coat of sealing compound to the mounting surface of the intermediate plate on the front of the block and to the b...

Page 128: ...62 147 INSTALLATION MARKS TRANSMISSION GEAR 24 INSTALLATION OF TRANSMISSION COVER OIL SEAL Tool 78 62 I54 25 Install a new balance shaft pulley seal in the trans 26 Lubricate the inner diameter of the...

Page 129: ...e bolts and tighten them in the sequence indicated to the correct torque tightening in three stages as per the following table N_m kp_m Lib I 54 5 5 40 2 69 7 0 50 3 93 9 5 68 IMPORTANT To ensure effe...

Page 130: ...inal direction of the engine 41 Adjust the valve play See the section Valve adjust ment INSTALLATION OF ROCKER ASSEMBLY 42 Install a new oil filter Tighten it by hand until the 1 Rocker shaft with roc...

Page 131: ...r FITTING OF PISTONS For fitting of pistons in cylinder bores a feeler gauge with a width of 1 2 in is used In measuring the piston without rings should be placed in the bore in the way i which it wil...

Page 132: ...sition Measure the piston ring gap with a feeler gauge The cor rect figures are given in group 0 If the gap is too small the ring must be trimmed with a special file MATNING AV KOLVR l NGSGAP In a wor...

Page 133: ...2 Take away the cylinder head gasket REASSEMBLY 1 Remove all residual gasket material from the con tact surfaces 2 Place the cylinder head gasket over the two locat INSTALLATION OF CYLINDER ing sleeve...

Page 134: ...new gasket in the valve cover Press the f the gasket into the notches in the play See the section Valve adv clamp ends 0 cover I n as s s s _ INSTALLATION OF INDUCTION MANIFOLD GASKET 5 Fit the induct...

Page 135: ...cover er See fig page ket into the NOTE e Before the valve covers of the cYllnder heads are r st be fi tted the lubrication of the rocker shaft mu Checked with the engine running correct Posihm Reconn...

Page 136: ...y means of tool 78 62 279 depress the valve spring and remove the valve retainers rect position Remove tool 78 62 402 Screw in the spark plugs Install the rocker arm assembly Adjust the valve play Ins...

Page 137: ...n either be ground in a machine 3 the depending on its condition Insert the pilot in the valve guide from the valve seat side and Scribe valve clamping screw until the Guide is leeked 1 Guide The valv...

Page 138: ...e transmission cover If the crank shaft is turned slightly back and forth in this positiOn the rocker arms at the first or fourth cylinder will move in opposite directions will rock In this position a...

Page 139: ...ractically completely seals around the pistons the true cause of the leak can be established MEASURING COMPRESSION PRESSURE VALVE COVER Removal and installation 1 Remove the air cleaner Detach the ign...

Page 140: ......

Page 141: ...und to the two cor ner joints where the transmission cover the interme diate plate and the edges of the oil pan meet Posi Installation 1 If this job is done in the car it is nearly always neces sary t...

Page 142: ...8 62196 INSTALLATION OF OIL SEAL TRANSMISSION COVER Tool 78 62 154 REPLACEMENT OF FAN BEARING Transmission cover removed To press out the fan bearing use water pump tool 78 62 436 to hold up the trans...

Page 143: ...E NEW BEARING 1 Spacer for flange and radiator See also removal of transmission cover points 2 3 5 7 and for installation points and 2 When changing the crankshaft gear and balance shaft gear the engi...

Page 144: ...crankshaft Tighten the gear on the shaft with a bolt and washer to a torque of 49 Nm 36 ft Ib 5 0 kpm Avoid tapping the gear as this in volves a risk of damage to the crankshaft axial bearing CAMSHAF...

Page 145: ...ngs REMOVAL OF TAPPETS BY MEANS OF A BENT WIRE 15 16 Remove the balance shaft pulleY ump 17 Disconnect the water hoses from the water p 8 Remove the transmission cover er 19 Remove the bolt and washer...

Page 146: ...d Sim LATION OF TRANSMISSION COVER INSTAL 1 Transmission cover 2 Centering arbor 78 62 147 8 Connect the water hoses to the water pump 9 Lightlv oil the pu ey shaft Put on the pulley and tighten it wi...

Page 147: ...e prescribed torque in the sequence indicated TIGHTENING SEQUENCE INDUCTION MANIFOLD BOLTS 18 Dip the push rod ends in engine oil and install the push rods in their original positions in the tappets 1...

Page 148: ...etor and gasket 25 Reconnect the fuel and vacuum lines 26 Install the distributor cap and attach the ignition cables 27 Install the air filter NOTE Retighten the cylinder head bolts and adjust the val...

Page 149: ...engine block Slide the oil seal off the crankshaft 14 Remove the bearing inserts and place them in the correct se uence for reinstallation 15 Remove rgsidual gasket fragments from all mount ing surfac...

Page 150: ...ghten the bolts for the center bearing cap NOTE Do not confuse the screw for cylinder heads and main bearings These have the same diameter but the screws for the main bearings are approx 0 4 in 10 mm...

Page 151: ...ges of the oil pan meet Position the oil pan gasket on the block and in sert the two tabs on the cork gasket under the re cesses in the rear bearing cap rubber seal Install and secure the oil pan Posi...

Page 152: ...rdened and loses its hardness if heated to temperatures above 5540 290 C PISTON WITH CONNECTING ROD Disassembly I 2 91 59 99 F 10 11 12 13 14 15 16 17 18 Install the engine on a work stand Drain the e...

Page 153: ...oves using a 2 of a worn piston ring Lubricate pistons SS and cylinder bores with engine oil Place the p St _ I 9 in the following manner Lhe 011 control ring center spring gap 180 from wiihnllk on th...

Page 154: ...ribed torque 7 Slide the oil pump onto its drive shaft and install it with the gasket Tighten the actual pump bolts first and then the suction line bolt 8 Insert the rubber seal in the groove in the r...

Page 155: ...scribed torque in the sequence indicated TORQUING THE INDUCTION MANIFOLD ASSEMBLED CYLINDER HEAD WITH MARKED SURFACES FOR APPLICATION OF SEALING COMPOUND 16 Dip the push rod ends in engine oil and ins...

Page 156: ...piston and on the outer edge of the piston pin The piston pin is shrunk into the small end of the con necting rod It is therefore of utmost importance to in stall the piston pin swiftly and correctly...

Page 157: ...to facilitate temperature checking When the correct temperature has been reached the paint will change colour in ac cordance with the tone of colour given on the package for the paint 4 Once the corre...

Page 158: ...the suction line bolt al in the groove in the rear main 5 Slide the oil pu with the gasket pump first and the 6 Insert the rubber se bearing cap 7 If a new crankshaft or new bearlng Inserts have been...

Page 159: ...ssed Plastigage strip by means of the scale printed on the Plastigage packing and read off the clearance One side of the packing gives the reading in mm and the other side in thousand of an inch Measu...

Page 160: ...sludge and ImpUrIties from enterin on the cork gasket under the recesses in the rear bear the engine the Oil pan must be removed downwargds 3 Ing cap rubber seal Install and secure the Oil pan Positi...

Page 161: ...3b 2 lt Wider the recesses in the rear bearing teagllnsumpgndoirt derg It 5 32p suction line Remove 4 Install and secure the oil pan Position the two bolts with the rubber washers at the rear balance...

Page 162: ...NTLED 1 Housing 5 Spring 3 Install the 78 valve and s rin n 2 Inner and Outer rotor 6 Cover plate With engine 0 p 9 a d coat them I thlY 3 Cover 7 Gasket 4 4 Relief valve 8 Suction line nstall a new c...

Page 163: ...e prescribed intervals everY 6 000 miles or 10 000 km Apply a little oil to the rubber gasket on the new cartridge Screw in the cartridge until the gasket makes contact with th 6 engine block and then...

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Page 165: ...IPLES 1 Throttle valve A Float chamber B Float chamber cover 12 Choke valve C Throttle body assembly 13 A cendlng pipe additional system Ieconostat D Housing automatic choke 14 Diaphragm acceleration...

Page 166: ...e same diameter To adjust the clearance slacken the nuts on the linkage rod for the fastidling system and then adjust the rod so that the valve takes up the correct position Then re tighten the rod an...

Page 167: ...s position and keep pressing it towards the ratchet wheel Open the throttle valve cautiously enough to allow the choke valve to move to the next position First release the throttle valve cautiosly and...

Page 168: ...float chamber cover and lift the cover off Collect the spring of the float chamber cover Remove gasket By holding the float chamber upside down remove the ball and the weight from the accelerating fu...

Page 169: ...thTOttle is kept closed Prior to tlg ed see to it that the valve centers In clos Mount the throttle valve shaft in the throttle body Fit the accelerating pump lever on the throttle ked O upwardS that...

Page 170: ...INSTALLAT ON A 1 08 in 27 5 mm B 1 34 in 34 mm 1 Fit new gaskets beneath the intermediate flange and carburetor NOTE Turn the face marked Chen upward ADJUSTMENT OF ACCELERATING PUMP 1 Fill the float...

Page 171: ...he center mark on the automatic choke housing The free end of the thermostatic spring to be fitted in the center slit of the thermostatic spring lever sane CONNECTING ROD LEVE R SETTING OF FLOAT CHAMB...

Page 172: ...dog of the throttle valve lever 2 Depress the vacuum piston fully Move the choke valve towards closed position until the tongue of the thermostatic spring lever contacts the vacuum PIStO lever in this...

Page 173: ...e step cam shall be exactly in front of the stop dog of the throttle valve lever SETTING OF CHOKE VALVE 3 The lower opening of the choke valve shall now be Standard carburetors 0 11 i 0 008 2 8 1 0 2...

Page 174: ...he air cleaner and depress the accelerator pedal Check that the choke valve closes completely CHECKING CHOKE VALVE OPENING and that the step cam engages the highest fourth catch 3 Start the engine and...

Page 175: ...position Warm up 9 control screw setting FAST IDLE ADJUSTMENT 1 R a un the engine until It reaches normal working tem 2 perature Remove the air cleaner Connect a tachometer 3 Hold the throttle valve...

Page 176: ...ttle shaft REMOV NG THE CARBURETOR 3 Remove the mixture screw and the idling screw and save the springs On 1977 model cars first remove the seal from above the mixture adjusting screw 5 Blank off the...

Page 177: ...two punche down_ Ensure that the valve is corr t the closed position before tightemng Check that the shaft moves freely INSTALLING THE THROTTLE VALVE 3 Qch u sm Install the idling screw and mixture s...

Page 178: ...oking the link onto the driver on the choke valve INSTALLATION 1 Fit new gaskets between the intermediate flange and the carburetor 2 Mount the carburetor 3 Connect the throttle cable and choke cable...

Page 179: ...f fast idling 1 Remove the air cleaner 2 Run the engine until hot and check the idling setting 3 Hold the choke valve in the fully open POSitiO With one hand at the same time turning the choke into th...

Page 180: ...se REMOVING THE PLASTIC PLUG ADJUSTING THE CHOKE FLAP STOP After the adjustment fit a new blue plug by means of Idling adjustment engine speed and C0 value a drift and hammer NB Adjustment should be c...

Page 181: ...BOTTOM COVER REMOVED 2 Undo the top cover retaining bolts and remove the cover complete with adjusting screw gasket spring and spring seat and valve REMOVAL OF DECELERATION VALVE 3 Unscrew the valve...

Page 182: ...le Let down the throttle rapidly and measure the time as require to drop the engine speed from 3 000 r min to idle An engine fitted with a correctly adjusted decelera tion valve should drop from 3 000...

Page 183: ...18 19 20 Z CARBURETOR 11 Adjusting screw 1 Air jet main system 2 Ventilation pipe float sham 3 Air jet transition system ber ventilation 4 Fuel jet transition system 15 Throat ring 16 Throttle valve 1...

Page 184: ...for the choke valve Remove the cover Spring and diaphragm with thrust rod Assembly Clean the carburetor and flush all passages and fixed jets with compressed air On reassembly fit new gaskets and sea...

Page 185: ...FITTING BI METALL HOUSING 7 Bolt the choke housing to the carburetor housing Note the O ring for the vacuum passage Fit the vacuum control for the choke valve Screw in the float valve and fit the flo...

Page 186: ...17 19 mm and equal on both sides Carburetor design 79 TF 9510 LA FLOAT CHAMBER VENTILATION The distance between the lowest part of the float in normal position and the flat surface of the carburetor c...

Page 187: ...tely when the temperature of the coolant exceeds 178 187 F 60 6500 Rotation clockwise away from the basic setting will cause the choke to open later It is essential that the choke valve spindles move...

Page 188: ...screw to achieve the correct setting 1 i 0 5 I 5 fit a new plastic plug for sealing to the mixture ad justing screw om ADJUSTING SCREWS 1 Idling setting screw 2 Mixture adjusting screw 231 24 HECKING...

Page 189: ...f the valve 1 With the engine switched off and cold and an am bient temperature of less than 68 F 25 C the valve should shut off the cold air intake 2 When the engine is running and the ambient air te...

Page 190: ...t go the flap valve a minute and it will remain in the same position 3 Let the temperature of the water rise to 87 90 F 31 32 C The flap valve will now move to the central position L THE FLAP VALVE HA...

Page 191: ...ner and remove the lock ring from its groove in the diaphragm rod Re move the spring lock washer and the spring Replace the lock ring on the diaphragm rod NOTE A small shaft seal is provided to afford...

Page 192: ...e diaphragm is not under tension In this position insert the screws and join the upper and lower parts of the pump together 5 Install a new strainer and a new gasket Screw on the cover LATER VERSION T...

Page 193: ...st be connected to G and the brown cable to 9 Refit the trunk floor or sheathing as applicable Re place seats and cushions N Checking fuel tank ventilation as from model 1970 or the ventilation hose n...

Page 194: ...ot collect at one corner To flush the system more thoroughly remove the fuel gage sender unlt and direct the stream of liquid through the hole towards different parts of the tank An extremely dirtY ta...

Page 195: ...uction manifold gasket The protruding part of the righthand cylinder head gasket shall enter the aper ture in the induction manifold gasket ASSEMBLED CYLINDER HEADS WITH MARKED SURFACES FOR APPLICATIO...

Page 196: ...w gaskets if neces sary Tighten the bolts evenly to the prescribed tor qua _ 6 Install the distributor cap and attach the ignitlon cables 7 Install the carburetor 8 Reconnect the fuel and vacuum lines...

Page 197: ...e the nuts at the engine connections and the clamps and brackets at the engine mountings Remove the spacers at the engine Withdraw the clamps and sleeves through the hole in the engine compartment flo...

Page 198: ...n bolts 1 Insert the left h inse 2 Raise the muffler for co the spacers position the mu and screw on the nuts 3 Fit the exhaust pipe to the muffler and tighten the clamp 4 Loosely fit the hr pipe and...

Page 199: ...rear wheel and lower the car nto EXHAUST PIPE Removal Jack up the right side of the car before starting work 1 Take off the right rear wheel and release the clamp joining the exhaust pipe to the rear...

Page 200: ...sh ions to the exhaust pipe 3 Back off and remove the up muffler rubber cushions to t the wheel house 4 Back off and remove the nuts holding the rubber cush ions to the muffler It may possibly be nece...

Page 201: ...rmostat valve 6 Thermostat 13 Defroster jet 20 Drain plugs one on each side 7 By pass 14 Collector box _ _ _ 9 Warm air Cold air COOLING AND HEATING SYSTEM MODEL 1969 1 Water pump 9 By pass 17 Cold ai...

Page 202: ...13 Fan motor 21 Thermostat valve 6 Fan 14 Side defroster hose 22 Drain valve 7 Temperature transmitter 15 Defroster jet 23 Drain plugs one on each side 8 Thermostat 16 Collector box 1 II Warm air Cold...

Page 203: ...d water if the engine is hot or the cylinder block may crack Check the level in the expansion tank after driving for a few days as a complete bleeding is achieved only when the system has been warmed...

Page 204: ...of the pressure cap can also be checked with the pressure tester Concerning opening pressures see specifications in group O I SZIIQ CHECKING THE OPENING PRESSURE OF THE PRESSURE CAP to avoid damage an...

Page 205: ...lamp which h0 ds the water pipes togeth er 4 Remove the water distribution tube from the engine together with the hoses WATER DISTRIBUTION PIPE Installation 1 Moisten the hoses and pass them onto the...

Page 206: ......

Page 207: ...er leaks OVERHAULING WITH A REPAIR KIT Ema REPAIR KIT WATER PUMP 1 Tool 78 62 204 2 Tool 78 62 196 Disassembly Using a drift press the pump shaft with bearing and im Feller simultaneously out of the p...

Page 208: ...that it protrudes small edge of tool 78 62 204 NOTE gainst the pump shaft and not against the im Press a pel ler 786219 8 2424 INSTALLATION OF PULLEY Tool 78 62 196 INSERTION OF PUMP SEAL Tools 78 62...

Page 209: ...screw on the upper part 3 Reconnect the water hoses 4 Reinstall the air filter and the carburetor 5 Fill the system with coolant and bleed the system TH E RMOSTAT REMOVAL INSPECTION OF REMOVED THERMO...

Page 210: ......

Page 211: ...plastic plug See the Spare parts catalogue The cover must be mounted with its cupped side facing downwards Press the cover in about 0 049 0 089 in 1 25 2 25 mm under the face of the cylinder block Us...

Page 212: ...AL BATTERY GENERATOR STARTER IGNITION COIL DISTRIBUTOR SPARK PLUGS SUPPRESSION OF INTERFERENCE LIGHTING DIRECTION INDICATORS HORNS SIGNALING DEVIC WINDSHIELD WIPERS AND ELECTRICAL CONTROLS A WIRING AN...

Page 213: ...hed on with the ignition key The suppressors which eliminate radio interference are mounted in the rotor and in the ignition cable terminals For further suppression see section 346 Interference suppre...

Page 214: ...H D Saab 96 L are equipped with electrically heated rear window The switch for which is placed in the instrument panel A control lamp in the switch lights with green light when the current is on 1 Exc...

Page 215: ...t When the battery is in place again coat the posts and terminals with acidfree vaseline BATTERY MAINTENANCE The condition of the battery determines the ease of start ing and regular testing and atten...

Page 216: ...ltage is 2 volts and the differ ce In voltage between any two cells should not exceed 0 2 volts CAUTION e battery Reversing the pole mentarily will damage the al ternator rectifier Connect the positiv...

Page 217: ...ring gear side 3 Stator 4 Slip ring and bracket 5 Protective ring 6 Rotor 7 Voltage regulator The alte Carbon ggaSEJSVTSIres very little maintenance because Output Current I commutators are not needed...

Page 218: ...r is fitted insulated To consumers Battery 12 V Exciter winding nnected to a ground contact re from ground or direct co carriers is located insulated spectively Between these two the carrier of the ex...

Page 219: ...2 rod to D l6l 4 73 voliow to or DISASSEMBLY 1 Hold the belt pulley with a suitable tool and loosen the nut with a 0 87 in 22 mm open end wrench Loosen the belt pulley 2 On the drive end plate mark ou...

Page 220: ...he carbon brush connections on e a earmg to the slip ring end it is necessary to make sure that the tin does not flow into the cable Minimum length of the carbon brushes to be approx 0 34 in 9 mm SOLD...

Page 221: ...o f a s exciting properties after long Storage The 0 rs can lose their charge indicator light of 12 V and minimum 2 W must be FOnnected between terminals 61 and 8 according to wir 9 diagram The pre ex...

Page 222: ...due to excessive cur rent and too much heat or conducting in both directions in most cases due to excessive voltages during operation f diodes with OHM meter Mn an Ohmmeter be Similarly diodes can res...

Page 223: ...intervals is therefore not prescribed for this alternator Repair of the A C generator should be carried out by a specialized service garage as it is vital that disassembly and testing are carried out...

Page 224: ...ngs to re ceive the exciter current To consumers Exciter winding a indicator DESCRIPTION When the ignition key is turned to ignition position the circuit is closed The current goes from the ignition l...

Page 225: ...nt increase is not possible DESIGNATION The Bosch designation of the alternator is 14 V 35 A 20 The meaning of the type designation is K1 H K 1 14V35A 20 x 100 2 000 r min r min for 2 3 of max current...

Page 226: ...g screw 5 If the lamp still glows after checking in this way the cause can be determined in the following manner Remove the connector from the charging regulator Connect a cable between the red cable...

Page 227: ...and belt pulley The large spacer is to be placed between the fan and the belt pulley The small spacer is to be placed between the belt pulley and the spring washer Tighten the nut to a torque of 23 29...

Page 228: ...on DISCONNECT NG THE BRUSH UNIT ASSEMBLY M the brushes can then be removed When resoldering the wire connections make sure that no solder flows into the wires 4 Undo the brush unit assembly retaining...

Page 229: ...is approx 50V Excitation Contrary to D C generators alter citing properties after long storage nators lose their selfex Therefore a charge in dicator light of 12 V and minimum 1 2 2 0 W must be COnne...

Page 230: ...small in the conducting di rection e g a few Ohms whereas the resistance in the insulating direction is considerably higher e g a few kilo Ohms Testing of stator windings Short Circuit to Ground diod...

Page 231: ...Disconnect the solenoid feeder cable Remove the solenoid retaining screws Unhook and remove the solenoid Undo the two retaining screws from the capsule bracket Remove the capsule bracket U washer spac...

Page 232: ...ove the Wk ring With me ring pliers 16 Inspect the spiral splines on the rotor shaft for burrs Remove the pinion and the gasket ring If there are any file them off 17 Check the gear ring starter drive...

Page 233: ...ect with shims if neces sary 16 Hook the solenoid to the engaging lever arm and secure with the two screws 17 Connect the feeder cable 18 Test the starter see group 9 for specifications and test value...

Page 234: ...the stop ring and the pinion Check the spiral splines on the rotor shaft for burrs If there are any file them off 999 9914 Remove the commutator bearing housing screws Assembly 55 11 12 nes on the rot...

Page 235: ...Specifications NOTE Check that distributor gap and dwell angle are INSTALLATION correct 1 Disconnect leads from coil n ter 2_ Back off retaining screws and remove coil_ 1_ Secure coil with the retaini...

Page 236: ...etaining spring CaDlCItor Gear FIbr 1977 i REMOVAL Remove ignition cables from spark plugs Release retaining springs and remove cap Remove primary cable Remove vacuum hose Crank engine until the mark...

Page 237: ...ker pornt Remove the breaker point breaker unit distributor O 231 146 033 If necessary remove bearing bushing by the aid of a mandrel During this operation the distributor housing should be turned ups...

Page 238: ...ack off the capacitor retaining screw and remove the capacitor together with the connection 4 Remove the lock ring from the pivot for the vacuum regulator control rod 5 Back off the two retaining scre...

Page 239: ...ve retaining screw that secures fixed breaker point 9 5 Remove breaker point breaker unit on distributor 4 3 5 2 O 231 146 033 Assembly NOTE Do not get any oil or grease on contact surfaces may cause...

Page 240: ...4 Fit shims and clip on the pivot applies to distri butors O 231 146 044 and O 231 146 024 5 Smear the breaker cam and fiber peg with Bosch Ft v 22 grease Connect breaker arm lead Adjust gap and dwell...

Page 241: ...Remove capacitor retaining screw Remove capacitor together with terminal Installation 1 Insert capacitor terminal in distributor housing and screw capacitor in place 2 Connect up breaker arm lead 3 C...

Page 242: ...llation 1 Position cap Note that its position is determined by the rear retaining spring Secure cap with springs 2 Connect up ignition cables in correct firing order CHECKING AND ADJUSTING THE IGNITIO...

Page 243: ...speed readings shall be when compared with those valid whe bench Moreover engine vibrations may cause a amount of deviation from these values I 590 1090 1s oo 20loo 2500 r min o 100 200 300 400 560 m...

Page 244: ...H Underpraaaura Degrees on distributor shaft IIIIIIIIIIIIHIIIIIIIIIIII annual ulaaaalegg Elli won Ilaalnqaaalual ill ll anaaaaaaaaaan aza III all Ill maana cal Ill ll III Illuulaanalll ill IIIIIDIIAIZ...

Page 245: ...3 Contact pressure 4 9 6 2 N 500 630 p I Centrifugal advance r min Distributor rev min ll Vacuum advance mmHg Underpressure III I I I E III IIV I l H I i5 II E 7 Inn rum EEiEg mluilnm 0 L ll 5 U m n...

Page 246: ...00 630 p Centrifugal advance r min Distributor rev min II Vacuum advance mmHg Underpressure Degrees on distributor shaft cinnumLmunmu murmurs mun we 5 e III IIIIIIIII I VAIWAL rmocoeneuns o s rmeum In...

Page 247: ...hat is present under the throttle and gives ignition advance when the throttle is closed The hose is connected to the carburetor interme diate flange The membran surface is bigger on the side which is...

Page 248: ...SETTING It is very important that the ignition setting is correCt when both vacuum hoses are disconnected Testing mm connected vacuum hoses shall be done to check that vacu urn advance works properly...

Page 249: ...STALLATION 1 Screw in spark plug by hand 2_ Tighten the plug with a torque wrench 29 39 Mm 3 4 kpm 22 28 ft b 3 Connect ignition cable TEST Spark plug removed 1 Clean spark plug by sandblasting 2 Chec...

Page 250: ...stor spark plugs are not nec essary but can in certain cases give better results Extra suppression can be made on the ignition coil con nection capacitor 2 2 4JF ALTERNATOR INTERFERENCE If alternator...

Page 251: ...nsert with glass 7 Bulb 3 Adjusting ring 8 Fastening spring 9 Rubber seal 4 Adjusting screw 5 Adjusting nut Fm 1977 Beam headlights are mounted As from model 1969 all cars have a for dimming and for h...

Page 252: ...incorrectly located in the reflector a faulty light pattern will result and it will therefore be impossible to get a correct setting Alignment of right dipping and left dipping asymmetric lights 1 Ch...

Page 253: ...T Place the left hand wheels of the car along the line A maximum deviation of 1 2 in 3 cm in the dis tance of the front and rear wheels from the line is permitted b When the beam aligning apparatus is...

Page 254: ...lines 2 2 and 3 3 The tolerance limits which may not be exceeded by the center of the beam under any circumstances are marked by the black area on the screen The transver sal limits are 6 in 150 mm t...

Page 255: ...rkets left dimming asymmetric or Sealed Beam units To modify the asymmetric lights so that they produce ordinary symmetric light for instance when travelling by car abroad the asymmetric section can b...

Page 256: ...minals have good contact 1 Open the hood and remove the contact housing and rubber sealing cap from the headlight 2 Push in the bulb retainer and twist it counterclock wise The bulb can then be withdr...

Page 257: ...IGHTS UP TO AND INCL MODEL 1975 RIGHT ASYMMETRIC LIGHT S 2 Switch on the headlight at low beam a Adjust the height relative to the left hand left asym metric light the right hand horizontal line Adjus...

Page 258: ...left for a left asymmetric beam and should thus meet the horizontal part imme diately below the dead center ALIGNMENT TOWARDS SCREEN H a Height of headlight center above ground A 11 3 in 288 mm B 2 0l...

Page 259: ...As from model 1969 the Saab 95 has a new light arrange merit at the rear It comprises a stop and tail light and a flashing and back up light The stop light switch which is mechanical is located on a b...

Page 260: ...ake sure that it is firmly seated and that good contact is obtained 4 Refit the housing and tighten the retaining screws Check that sealing is effective between the rubber gas ket and the housing NUMB...

Page 261: ...te The flasher unit is not adjustable If the other parts of the direction indicating system switch wires and lamps are in good order erratic flashing must be due to a faulty flasher unit In these circ...

Page 262: ......

Page 263: ...lly under its edge with a knife or similar implement REMOVAL OF HORN BUTTON MODEL 1967 A 3 Disconnect the horn lead from the contact plate 4 Back off and remove the nut and take away the sprung washer...

Page 264: ...casing r Remove the guard Wlth the horn contact from the stee The sliding Contact can t ing wheel by undoing the four scram which are accessi b undoing the retaining screw ble from under the steering...

Page 265: ...unit straight from the steering wheel The unit is fitted to the steering wheel by means of three spring fasteners DISCONNECTING THE ELECTRIC CONNECTION Installation is made in the reverse order See a...

Page 266: ......

Page 267: ...e working cycle thus giving the motor two alterna tive earth connections if the switch is on Every time the wiper blades are in their horizontal position where they are normally parked the contact in...

Page 268: ...mit switch moving contact 15 Bearing retaining ring 16 Grommet 17 Brush lever retainer 18 Field coil 19 Rotating output crank 20 Drive and bracket 21 Final gear 22 Limit switch fixed contact plate 23...

Page 269: ...arm goes in the wrong direction and damages the paintwork Right side L H D cars Left side R H D cars 1 Remove the wiper arm outer nut and sealings 2 Remove the fresh air channel between the fresh air...

Page 270: ...or has broken the connection betwe9n 4 and 2 in the windshield wiper motor and between 53a and 53 in the headlight wiper motor The motors start very quickly when connections and 31b respectively have...

Page 271: ...that connection 85 on relay 2 is connected to earth via relay 1 the contact in this relay in the upper position and connection 54c Electrical connection and operation as from model 1972 As from model...

Page 272: ...of 7 2 ft lb 10 Nm 1 0 kpm and lock with Loctite Before springs and bushings are fitted the recesses in the 2 Unhook the springs which hold the wiper shaft bush front sheet must be greased on both sid...

Page 273: ...t glasses and make sure that the bushing does not stick in the recesses in the front sheet The pressure Adjustment of the wiper blades measured in the parked position must not exceed 11 oz 3 N 300 p C...

Page 274: ...Changing wiper blades 1 Remove the circlip from the wiper shaft and Du Off the wiper blade 2 Fit a new wiper blade and refit the circle 363 8...

Page 275: ...t is placed on the master cylinder As from chassis No 46 816 resp 439 334 a mechanI cally operated stop light switch has been introduced ThIs switch is actuated directly by the brake pedal As from mod...

Page 276: ...pper position and the big tact at coil WM h beam is connected through the can h is grounded through the light switch TOWN LIGHT RELAY thetifuti in the town light relay The contact IS pushed down and t...

Page 277: ...E SWITCH TEMPERATURE TRANSMITTER Installation Installation NOTE Smear sealing compound on threads before instal NOTE Smear sealing compound on threads before instal ling ling 1 Screw in oil pressure s...

Page 278: ...gets the seat belt a buzzer and a warning light start working The following components are included in the warning device Buzzer below instrument panel Warning light on instrument panel Seat contact i...

Page 279: ...by testing Bear in mind however that fuses will not burn out if a short occurs before the fuse When installing new wiring always check positively that the rating of the selected wires and cables is a...

Page 280: ...ghts Headlights Horns Ignition coil Spark plugs Distributor Voltage regulator N99199 NT 371 2 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Alternator Starter...

Page 281: ...WIRING DIAGRAM SAAB 95 R H D MODEL 1967 371 3 March 1979...

Page 282: ...69 70 74 20 Oil pressure warning light 21 Clock 22 Temperature gauge 23 Speedometer with odometer 24 Fuel gauge 75 85 93 142 25 Dimmer switch White 20 23b 24b 40 40c 42b 66 82 83 118 25 F aShe 122 122...

Page 283: ...WIRING DIAGRAM SAAB 95 L H D MODEL 1967 371 5 March 1979...

Page 284: ...8 101 104 110 133 I 22 Temperature gauge Grey 8529 29 35 443 62a 62b 64 69 70 74 75 23 Speedometer with odometer 24 Fuel gauge 21 Clock White 20 8232 243 34bg 34bf 40 42b 66 82 83 25 Foot dimmer switc...

Page 285: ...1 2 s 1 E s cilia 23 21 is x n __ web 13 _ 69 w 1967 WIRING DIAGRAM SAAB 95 USA MODEL 371 7 March 1979...

Page 286: ...ts 3 Horns 4 Ignition coil 5 Spark plugs 6 Distributor 371 8 10 I 12 3 14 5 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 38 Voltage regulator Generator Starter motor Battery Fuse box...

Page 287: ...38 L 1 E l s 67 WIRING DIAGRAM SAAB 96 R H D MODEL 19 371 9 March 1979...

Page 288: ...56 58 m 23 WWW Grey 4 2511 29 35 44a 62a 62b 64 69 7o 74 75 Z 5 142 5 WW White 20 2311 246 40 40 42b 66 113 122 122e 25 123 L 27 Control relayfor headiightflaher Yellow 17 233 24a 33_ 43 441 73 34 12...

Page 289: ...35 wit 5 I 35 I IIIII no eel E still we is WIRING DIAGRAM SAAB 96 L H D MODEL 1967 March 1 979 371 1 1...

Page 290: ...rev 4 25b 29 _ 85 35 44a 628 62b 64 69 70 74 75 24 Speedometer With odometer 25 Fuel gauge 26 Foot dimmer switch 27 Flasher 28 Cigarette lighter 29 Ignition and starter switch 30 Headlight and parkin...

Page 291: ...March 1979 S WIRING DIAGRAM SAAB 96 USA MODEL 1967 371 13...

Page 292: ...Temperature gauge 28 Fuel gauge 143 Grey 4 25b 25be 29 299 35 44a 623 64 69 70 29 Speedometer odometer and trip meter 30 Clock 74 75 85 89 113 117 142 144 White 20 23b 24b 40 42b 66 95 97 98 118 122 3...

Page 293: ...DEL 1967 RING DIAGRAM MONTE CARLO R H D MO WI 371 15 March 1979...

Page 294: ...52 53 54 55 56 57 58 BO 82 101 102 103 104 110 119 121 133 143 Grey 4 25b 29 35 44a 62a 62b 64 69 70 74 75 85 89 113 117 142 144 28 Temperature gauge 29 Fuel gauge 30 Tachometer White g 223 a b 40 42b...

Page 295: ...ODEL 1967 CARLO L H D M RAM MONTE WIRING DIAG 371 1 7 March 1979...

Page 296: ...04 110 119 121 27 133 146 147 28 Temperature gauge Grey 4 25b 29 35 44a 623 62b 64 69 70 74 29 Fuel gauge 75 85 89 113 117 142 144 30 Tachometer White 20 23b 24b 24be 24bf 40 42b 66 95 97 31 Flasher 9...

Page 297: ...March 1979 Ili EEE late 67 ING DIAGRAM MONTE CARLO USA MODEL 19 WlR S 1392 371 19...

Page 298: ...park plugs G Distributor 7 Voltage regulator 8 Alternator 371 20 10 I 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Starter Battery Fuse box Temperature...

Page 299: ...March 1979 m BE EFTIII l i 18C 68 WIRING DIAGRAM SAAB 95 R H D MODEL 19 371 21...

Page 300: ...tributor Voltage regulator Alternator 33 pr 371 22 IO 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 41 42 Starter Battery Fuse box Temperature gauge sending unit...

Page 301: ...March 1979 i l C 42 4 _s _ 41 P 0 40 sI IO I v l u I v III lg 232 ii tas o I V 3 m 1 i L M 51111 E i Illl _ team a g WIRING DIAGRAM SAAB 95 L H D MODEL 1968 371 23...

Page 302: ...oil Spark plugs Diswibumr Voltage regulator Alternator PNF P PP N 10 1 I 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 37 8 8 33 42 Starter Battery Fuse box Temperature gall Oil pressure sw...

Page 303: ...S 1553 Ea Elli 0 EEEEIE 8 e xiii 9151 Wll g WE II n S I E b m 2 gari 55 E ii Ei__ WIRING DIAGRAM SAAB 95 USA MODEL 1968 March 1979 371 25...

Page 304: ...5 56 57 58 59 60 26 Temperature gauge 101 104 110 121 133 143 ment Grey 4 16 lee 25b 25be 29 29e 35 44a 62b 64 27 oc ellextra equ1p 69 70 74 75 85 142 144 28 as rela light White 20 23b 24b 40 40c 42b...

Page 305: ...o 7 371 27 March 1979...

Page 306: ...gulator Alternator esomewwr 371 28 IO 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 34 35 36 37 38 39 40 41 42 Q _ Starter Battenl Fuse box Temperature gauge 5 Oil pressure switch Sto...

Page 307: ...March 1979 uni I176 EWEEEEE 68 WIRING DIAGRAM SAAB 96 L H D MODEL 19 371 29...

Page 308: ...Voltage regulator Alternator Starter 371 30 10 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 46 41 42 43 Battery Fuse box Temperature gauge sending unit Oil p...

Page 309: ...March 1979 V R n i m 9 O n m H II l u I Y _ Ill Ill 5 EEE ere E WIRING DIAGRAM SAAB 96 USA MODEL 1968 S 1552 371 31...

Page 310: ...Alternator 10 Starter 1 1 Battery 12 Fuse box 371 32 1 3 1 4 1 5 16 1 7 18 1 9 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 47 48 49 Temperature gauge sending unit Oil p...

Page 311: ...March 1979 sessil WIRING DIAGRAM MONTE CARLO L H D MODEL 1968 371 3...

Page 312: ...56 57 58 dometer and trlp meter 59 101 28 Speedometer o 102 103 104 110 121 133 29 Temperature gauge Grey 4 16 16c 25b 29 35 44a 62a 62b 64 69 70 74 75 85 White 20 23b 24b 24be 24bf 40 42b 66 95 97 9...

Page 313: ...l iiiiiii WIRING DIAGRAM DE LUXE USA MODEL 1963 371 35 March 1979...

Page 314: ...0 75 124 black 0 75 125 black 0 75 126 white 0 75 129 white 0 75 130 brown 1 0 131 white 1 5 133 green 0 75 135 black 0 75 136 black 0 75 137 brown 0 75 137c brown 0 75 138 black 1 0 139 black 1 0 13...

Page 315: ...412 Cf m_1 g mgz g 4 all p 3 In I 3 ll 5 a _l 7 f lIIliIIIl 0 QEEEEEl z PW WIRING DIAGRAM SAAB 95 R H D MODEL 1969 March 1979 371 37...

Page 316: ...09 black 0 75 1 10 green 0 75 red 0 75 12 blue 1 0 13 white 0 75 15 yellow 0 75 16 red 0 75 18 white 1 0 122 white 0 75 124 black 0 75 125 black 0 75 126 white 0 75 129 white 0 75 130 brown 1 0 131 wh...

Page 317: ...iriii iill 0 MODEL 1969 WIRING DIAGRAM SAAB 95 L H 371 39 March 1979 an...

Page 318: ...5 white 1 5 white 1 5 white 1 0 green 0 75 green 0 75 black 0 75 black 0 75 green 0 75 red 0 75 blue 1 0 white 0 75 yellow0 75 red 0 75 white 1 0 white 0 75 black 0 75 black 0 75 white 0 75 white 0 75...

Page 319: ...March 1979 EEEEEEIEE u aggrim giamaaama a 7 lg Emu Ill E i W 2 up 45 E 5 a k WIRING DIAGRAM SAAB 95 USA MODEL 1969 371 41...

Page 320: ...30 brown1 0 25be grey 1 0 63 red 0 75 133 green 0 75 28 red 1 0 64 grey 0 75 135 black 0 75 28a red 1 0 65 red 0 75 136 black 0 75 28f red 0 75 66 white 0 75 137 brown 0 75 29 grey 0 75 67 red 1 5 137...

Page 321: ...5 b canm___J 42 m r ll 0 s IMO when QEEBEEBE Em WIRING DIAGRAM SAAB 96 R H D MODEL 1969 March 1979 37143...

Page 322: ...0 75 28 red 1 0 64 130 brownl o 29 28c red 1 0 65 133 green 0 75 30_ 28 red 0 75 66 135 black 0 75 29 grey 0 75 67 136 black 0 75 31 30 brown 0 75 68 137 brown 0 75 32 32 red 0 75 69 137C brown0 75 3...

Page 323: ...March 1979 E 42 E iflg gi ii it may iijiiiiiEJ gfea EM ill r m E W 69 WIRING DIAGRAM SAAB 96 L H D MODEL 9 371 45...

Page 324: ...0 121 green 0 75 122 white 0 75 124 black 0 75 125 black 0 75 126 white 0 75 129 white 0 75 130 brown 1 0 131 white 1 5 133 green 0 75 135 black 0 75 136 black 0 75 137 brown 0 75 137C brown 0 75 138...

Page 325: ...March 1979 3 5 Qt es 3 a 5 E rt 5 z _ a E 0 K i ll 15 tilts ts ii a me e m a 371 47...

Page 326: ...121 green 0 75 122 white 0 75 124 black 0 75 126 white 0 75 128a white 0 75 128b yellow0 75 129 white 0 75 130 brown 1 0 131 white 1 5 133 green 0 75 135 black 0 75 137 brown 0 75 137C brown 0 75 138...

Page 327: ...30 Willi 5 1969 WIRING DIAGRAM DE LUXE USA MODEL 371 49 March 1979...

Page 328: ...butor Voltage regulator Alternator Starter Battery Fuse box Temperature transmitter Oil pressure switch Back up light switch Stop light switch Brake warning contact Heater fan motor Windshield washer...

Page 329: ...am _ _u_ mm ii Fag ii WE RE iii III as am as 8 Ijz s Asaaeai W to 2 0 v I WIRING DIAGRAM SAAB 95 R H D MODEL 1970 March 1979 371 51...

Page 330: ...75 brown 0 75 red 0 75 white 1 5 white 1 5 white 10 green 0 75 black 0 75 green 0 75 red 0 75 blue 1 0 yellow0 75 white 1 0 white 0 75 white black black black black black black 1 5 brown 0 75 brown 0...

Page 331: ...mm 3 Emmmw In 5111111111111 55 E up 5 5 iii _ 70 WlRlNG DIAGRAM SAAB 95 L H D MODEL 19 371 53 March 1979 n...

Page 332: ...ed 0 75 blue 1 0 yellow0 75 white 1 0 white 0 75 black black black black black brown 0 75 grey 2 5 black 0 75 yellow0 75 HWY 0 75 black 0 75 Components Opwwewewwd PP 14 15 16 17 18 19 20 21 22 23 24 2...

Page 333: ...March 1979 mamas til sesame III A nun o I 3 v or W in 2 g _ age a a 115 iv JEE a A 9 v u n v_ WIRING DIAGRAM SAAB 95 USA MODEL 1970 371 55...

Page 334: ...y 4 0 red 1 0 grey 1 0 yellow1 5 grey 4 0 black 0 75 black 0 75 brown 0 75 green 0 75 black 0 75 green 0 75 red 0 75 blue 1 0 yellow0 75 white 1 0 green 0 75 white 0 75 brown1 0 black 1 0 black 1 blac...

Page 335: ...March 1979 S n S 3 O 1 __ U 57 1 4 3 f R n I N o nn Hil miiI In iI E111111111111 1 WIRING DIAGRAM SAAB 96 R H D MODEL 1970 5 371 57...

Page 336: ...White 50 9196 W 9 99 0 75 23 Temperature and fuel gauges 21 red 53 bl e 0 75 black 0 75 22 green 53a bl 0 75 9 39 0 75 24 Indicatorlight fuel amount 22e green 54 green 0 75 red 0 75 25 Oil pressure w...

Page 337: ...March 1979 MODEL 1970 DIAGRAM SAAB 96 L H D WIRING m iijiiii W _ 371 59...

Page 338: ...75 black 0 75 black 0 75 green 0 75 red 0 75 blue 1 0 yellow0 75 White 1 0 green 0 75 white 0 75 brown1 0 white black black black black black black brown 0 75 brown 0 75 grey 2 5 black 0 75 yellow0 75...

Page 339: ...I rmi l llil e e March 1979 371 61...

Page 340: ...32 Red We Red 35 33 Yellow 77r Red 36 35 Grey 78 Brown 39 Yellow 79 Green 37 38 39 40 41 42 43 44 45 46 47 48 49 371 62 Parking light and direc Headlights Horn Headlight wiper motor Ignition CO Spark...

Page 341: ...gmagaa aaei Jiii D MODEL 1971 WIRING DIAGRAM SAAB 95 R H 371 6 March 1979 m...

Page 342: ...1 5 while 1 5 white 1 0 green 0 75 black 0 75 green 0 75 red 0 75 blue 1 0 vellow0 75 white 1 0 white 0 75 brown1 0 white 1 5 black black black black black black 1 5 brown 0 75 brown 0 75 WW 2 5 blac...

Page 343: ...March 1979 liIilli mm ii iiiiiiiiiiigija EEIEEEEE 3 __l I o jiiiii Iii em S 371 65...

Page 344: ...red 0 75 White 1 5 white 1 5 white 1 0 green 0 75 green 0 75 black 0 75 black 0 75 green 0 75 red 0 75 blue 1 0 yellow0 75 white 1 0 white 0 75 black brown0 75 brown0 75 grey 2 5 black 0 75 yellow0 7...

Page 345: ...Map d nan mmmi E5 g I I III T31 4 j a n 4 me 5 j 55 35 9 v 3 371 67...

Page 346: ...68 Red 1 0 12 Blue 0 75 2ae Red 1 0 369 Black 1 0 130 Bvom 1 0 KZU Rea 0 75 i 70 81x11 1 5 131 Mme 1 0 in Grey 0 75 in Black 1 5 135 Black 1 0 18 Grey 0 75 e 72 Red 1 0 138 Brace 1 0 291 Grey 0 75 72...

Page 347: ...March 1979 551 _ Ill MEEF ESP E EH iiii i l L WIRING DIAGRAM SAAB 96 R H D MODEL 1971 reiterate 9 371 39...

Page 348: ...5 123 blue 0 75 28 red 1 0 68 red 1 0 130 brown1 0 280 rod 1 0 69 black 1 0 136 black 1 0 281 red 0 75 70 black 1 5 138 black 1 0 29 grey 0 75 71 black 1 5 139 black 1 5 29c green 0 75 red 10 1393 bl...

Page 349: ...33 m 71 WIRING DIAGRAM SAAB SEDAN L H D MODEL 19 371 71 March 1979...

Page 350: ...2 blue 1 0 23aeyellow1 0 23b white 1 0 23bewhne 1 0 24a yellow1 0 24ae yellow 0 241 white 1 0 24bewhite 1 0 25a blue 1 0 25b grey 1 0 24 Speedometer with odometer 25 High beam indicator light 26 Direc...

Page 351: ...March 1979 4 In Etna mil reiterate lam l WIRING DIAGRAM SAAB 96 USA MODEL 1971...

Page 352: ...ning signal switch Cable ref No 21 Hazard warning signal rem 22 Direction inditztor lights L 23 Direction indicator lights R 24 Stop 1 Contact 25 Stop lights 26 Ventilator fan switch 13 27 Ventilator...

Page 353: ...ea in 3 or IE __ 1 an WIRING DIAGRAM SAAB 96 R H D MODEL 1972 1974 March 1979 371 75...

Page 354: ...R Stop light contact Stop lights Ventilator fan switch Ventilator fan motor Horn Horn contact Brake warning contact Oil warning contact Temperature transmitter Fuel level transmitter Combination instr...

Page 355: ...15 6 2 0 a 5 mm mm 72 1973 RING DIAGRAM SAAB 96 L H D MODEL 19 WI March 1979 371 77...

Page 356: ...ator fan switch 27 Ventilator fan motor 28 Horn 29 Horn contact 30 Brake warning contact 31 Oil warning contact 32 Temperature transmitter 33 Fuel level transmitter 34 Combination instrument fuel gaug...

Page 357: ...Ell um am iL 1 EL I L RING DIAGRAM SAAB 96 USA MODEL 1972 1973 WI March 1979 371 79...

Page 358: ...28 Horn 29 Horn contact 30 Brake warning contact 31 Oil warning contact to N Temperature transmitter Fuel level transmitter Combination instrument fuel gauge fuel warning 538 light temperature gauge...

Page 359: ...lawman Iii y m a 371 81 MarCh 1979...

Page 360: ...5 Stop lights 26 Ventilator fan switch 27 Ventilator fan motor 28 Horn 29 Horn contact 30 Brake warning contact 31 Oil warning contact 32 Temperature transmitter 33 Fuel level transmitter 34 Combinati...

Page 361: ...in 2 U 7 WIRING DIAGRAM SAAB 96 R H D MODEL 19 5 371 83 March 1979...

Page 362: ...n switch 17 Fuse box 18 Direction indicator flasher unit 19 Direction indicator switch 20 Hazard warning signal switch 21 Hazard warning signal repeater 22 Direction indicator lights L 4 GR 1 5 23 Dir...

Page 363: ...114 114 H II I ll I I J f H I M i 132323233211 WIRING DIAGRAM SAAB 96 L H D MODEL 1975 371 85 March 1979...

Page 364: ...ure gauge oil warning light charging light instrument panel illumination 35 Speedometer 36 Brake warning light 37 High beam indicator light 38 Direction indicator warning light 39 Instrument panel ill...

Page 365: ...mu m as gg m I WIRING DIAGRAM SAAB 96 R H D MODEL 1976 371 87 March 1979...

Page 366: ...smitter 34 Combination instrument fuel gauge fuel warning light temperature gauge oil warning light ignition light instrument panel illumination 35 Speedometer 36 Brake warning light 37 High beam indi...

Page 367: ...WIRING DIAGRAM SAAB 96 L H D MODEL 1976 371 89 March 1979...

Page 368: ...ator switch 20 Hazard warning flasher switch 21 Hazard warning flasher repeater 22 Direction indicator lights L 4 GR 1 5 ii 25 Brake light Color of cable 26 Ventilator fan switch 27 Ventilator fan mot...

Page 369: ...WIRING DIAGRAM SAAB 96 L H D MODEL 1977 371 91 March 1979...

Page 370: ...ator flasher unit 19 Direction indicator switch 20 Hazard warning flasher switch 21 Hazard warning flasher repeater 22 Direction indicator lights L 4 GR 1 5 23 Direction indicator lights R C 2 24 Brak...

Page 371: ...S 5769 1 911 V E m JH WIRING DIAGRAM SAAB 96 L H D MODEL 1977 8 March 1979 371 93...

Page 372: ...nt panel illumination 16 Ignition switch 17 Fuse box 18 Direction indicator flasher unit 19 Direction indicator switch 20 Hazard warning flasher switch 21 Hazard warning flasher repeater 22 Direction...

Page 373: ...WIRING DIAGRAM SAAB 96 L H D MODELS 1978 AND 1979 371 95 March 1979...

Page 374: ...CONTENTS 400 GENERAL 411 CLUTCH 412 CLUTCH OPERATION GEAR BOX 470 REMOVAL INSTALLATION 471 DISASSEMBLY REASSEMBLY 473 DIFFERENTIAL AND PlNION IRING GEAR 475 UNIVERSAL JOINTS AND SHAFTS Febr 1977 SAAB...

Page 375: ...is carried in a self lubri eating bearing in the crankshaft and the other in a needle bearing in the gear box primary shaft In the middle of the FRONT WHEEL ENGINE CLUTCH FRONT WHEEL clutch shaft is a...

Page 376: ...TRANSMISSION 400 2 SAAB Enh 1 11...

Page 377: ...In 3rd and 4th gears power is transmitted from the pri mary shaft to the 3rd or 4th speed gear as applicable which is then locked to the primary shaft by means of a sliding sleeve In reverse power is...

Page 378: ...sleeve the primary shaft is forced to rotate at the same speed as the clutch shaft with which it is thus vir tually united if on the other hand the primary shaft tends to rotate faster than the clutch...

Page 379: ...ck off the six bolts holding ance the pressure plate assembly to the flywheel 1 Lift the three retaining springs and remove the release 3 Remove the pressure plate assy and the clutch disc Plate 2 Com...

Page 380: ...end 3 Tighten gradually the six retaining bolts of the clutch 4 Install the engine see section 201 CLUTCH DISC Checking the clutch and changing disc facings 1 Examine the clutch face in the flywheel...

Page 381: ...nut 5 Bleeder nipple Installation takes place in the reverse sequence ADJUSTMENT OF CLUTCH PEDAL FREE MOVE MENT The clearance between release bearing and release plate is gradually decreased by wear o...

Page 382: ...Separate the pus DisassembllI Ease the rubber dust cap back and remove the lock ring using long nosed pliers It Is now possIble to remove the push rod and the cupped washer Removal of the push rod rev...

Page 383: ...same time easing the piston seal lips slowly into the bore Remount the push rod in the cylinder followed by the lock ring placing this in the milled groove in the cylinder body Replace the rubber dus...

Page 384: ...dust cap 2 Refit and tighten the retaining screw 3 Remove the release bearing 3 Reconnect the hose After changing the bearing reinstall in the reverse se 4 Bleed the system quence If the release beari...

Page 385: ...e screw on the clutch housing located in the opposite side in rela tion to the slave cylinder The free movement is in creased by turning the screw counter clockwise The clearance is checked by pressin...

Page 386: ...clean with pure brake fluid Reassembly Fit the return spring and spring retainer Lubricate the piston and seals thoroughly with Wakefield Girling Rub her Grease 3 and refit gasket washer and piston wi...

Page 387: ...lubricate the cylin der bore with brake fluid when reassembling this unit Installation 1 Locate the slave cylinder on the clutch housing and pass the push rod through the hole in the rubber dust cap 2...

Page 388: ......

Page 389: ...e front panel and de tach the two radiator supports from the car body Detach the clamping straps from the radiator and remove the hood lock and control wire Model 1969 1970 4 Remove the headlight deco...

Page 390: ...l of the taper pin Disconnect the speedometer cable from the gear box Lift up the front part of the floor mat and remove the rubber plug so that the center screw of the rear engine bracket becomes acc...

Page 391: ...exhaust pipes to the cylinder heads Fit new gaskets 15 Refit the clamps for the exhaust pipes and the sus pension under the car 16 Reconnect the throttle control 17 Reconnect all hose and cable conne...

Page 392: ......

Page 393: ...Remove the transmission case cover together with the gear shift fork shaft 5 Fit the transmission case in the fixture tool 6 TRANSMISSION CASE HELD IN FIXTURE Tool 78 41 000 Differential and freewheel...

Page 394: ...the and cover bolts and drive out the 1st 2nd and 3rd 4th gear shift fork theft from the from using an arbor or similar tool 10 When the cover is free take it off reerwerds keep ing the gear shift fo...

Page 395: ...tems are also to be removed As from transmission No 108911 an oil cup is fitted for lubrication of the counter shaft This must be removed before the end nut When removing the end nut tool 78 61 321 wi...

Page 396: ...ing can be removed sepa rately for bearing renewal or pinion adjustment as soon as the end cover has been removed i e with out removing the primary shaft and counter shaft 24 Remove the speedometer dr...

Page 397: ...eel SIS RING AND PRESSING OFF THE FRONT PlNlON SHAFT BEA 4TH GEAR W A PRESS Tool 78 41 232 The bearing should on no account be taken apart if it is to be refitted See to it that the rollers do not fal...

Page 398: ...align the Woodruff key in rela tion to the groove in the 3rd gear 4 Insert the guiding arbor 78 41 224 in the rear bear ing seat so that the pinion shaft passes into it 5 Secure the arbor with the re...

Page 399: ...rear bearing seat and secure the arbor with the press screw Pass the shaft in carefully from the front until its splines enter the synchronizer hub Fit the arbor 78 41 042 into the freewheel sleeve NO...

Page 400: ...d the seat with the bearing are mounted separately 25 Engage two gears simultaneously e g 2nd and 4th and turn the 3rd speed gear in order to align the key grooves in the counter shaft and the counter...

Page 401: ...o the neutral position and insert th gear e gear shift forks 31 Note that springs and poppet balls m Ust be f with tool 78 40 697 before the for med in the transmission case ks are inserted 32 WA R N...

Page 402: ...hub and an undamaged erted in the primary shaft hub should engage firmly tool 87 90 305 Check the fu Check that th needle bearing are Ins freewheel sleeve The when twisted to the right Use for assemb...

Page 403: ...5 5 2 58 33 5 o 5 3 8 5 mm 3 0883 m a i n 8 8 8 3 8 5 2 5 58 8 5 5 2 5 8 2 5 0 5 2 3 8 4 0 85 8 5 5 5 9 6 8 1 8 mam 8 5 5 55 836828 0 23m 5 35 8 c m 5505 2 5 5 8 8 8 0 m ca 85 8 55 581 m 5 SN 5 8 025...

Page 404: ...0 m one 0 0 0 0 8 No we 05m 334 8 m 82 No m cam 20 mo wmm 20 m 0mm we m owe O 03 0 u 3 0 8 8 35 3 5 2 3 8 35 5 3 5 3 3 5 0 1 8 8 5 2 0 0 5 3 3 m 3m 3 3 8 8 5 2 5 35 0 8 0 5 0 5 35 3 5 8 5 3 8 0 m mom...

Page 405: ...3 6 m S E E 25 58 622mm 3m 2 3 3 mm 3 an 2 3 or o 3338 5 3o 6323 9 3 m m a 4 3 5 mac 8 3 8 8 8 w 9 5 0 50 ms 3 22am man 8 8 6 0052 8 5 25 2 3 5 3 8 2 8 3 3 6 3 1 A 5 5 0 9 8 0 5 S 3 8 9 A 12 05 6 331...

Page 406: ...3 0 80 m 3 30 2 53 230 3 8 2 3 8 0 8 8 w 382 00 3 mo mm 3 30 20 38 0 38 8238 3 0 P 0 00 303 m_8 0 3 m o w m 08 33 530 8238 0 88 0 8 8 30 3 3 2 2 5 3 0 3 2 3 0 5 0 530 8 3 0 5 3 0 m m 0 2 0 4 1 m m m m...

Page 407: ...8 36 58838 633 9 H36 80 2626 638 36 3 63 9663 3n 3 6 6333 8 H 32 32 5 3 22 38 6 3 6 P 3me 6 6133 E53363 633 3 63 36 3 3 238 9 26 6666 43mm 0826 3 6 3 3 8 6 2 0 S 8 6 63 553 5 8303 mu mo mg 6 36 8 3 6...

Page 408: ...6 2 6 6 8 6 3 3 4 3 8 8 6 1 3 3 6 0 3 6 6 3 6 3 3 3 5 8 8 3 0 6 3 0 0 6 3 6 0 6 6 0 3 0 1 8 6 6 3 3 0 3 5 3 6 6 5 3 6 3 3 6 m 0 3 6 8 3 3 666 3 63 36 0 0 3 8 6362 3 6 6 3 0 _ 3 m 36 36 3 3 0 3 5 3 6 6...

Page 409: ...5 amwozcma S 2 5 U85 5 5 3 z a 3 5 93 5 8 3 5 4 5 2 3 3 c m 5 3 9 5 g a s 5 2 3 5 2 253 a m u m E m m m m m a g a 2 5 1 3 5 _ 3 2 5 5 8 2 5 S 9 20 cm 5813 m 5 Sam 3 3 8 9 9 5 m m 3 2 5 S 2 5 058 5 3 5...

Page 410: ...5 5 0 5 0 0 5 0 5 2 0 5 0 8 0 5 5 5 0 5 5 5 5 0 5 0 5 0 5 0 5 5 5 0 5 2 0 5 5 5 3 5 0 0 3 5 0 5 0 5 0 0 2 0 5 0 2 0 5 0 0 5 0 5 0 0 5 0 0 0 5 5 0 5 0 0 0 0 5 2 0 5 0 8 0 5 2 5 0 1 0 0 5 0 5 5 5 0 0 0...

Page 411: ...3 0 5 8 a Gaza a 28 xaoox 8 353m 82 22 81A 53 05 263 3a 6 2 00 52 Em 882 cm 03 3a 815 8 3 3 z 8 mm 3 anon 853 38 5 3 3 3 2 0 8 8 2 0 3m 2 3m m2 m3 818 22 0 3 3 0 83m 238 3 3 o 83 8 5 3 4 2 28 o 88 I m...

Page 412: ...um AD 8 m O O F P m O d M U w Qm x uOIK m 1 n w 0 m m Z 2 A 0000 0 0 8 000 8 0 0 010 0 0 0 0 0 0 9 0 0 0 8 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 0 8 0 0 1 0 8 3 0 8 0 0 0 0 0 0 9 0 0 0 0 8 0 0 0 0 0 0 0 0 0...

Page 413: ...m 9 3 3 5 c 2 3 3 2 5 8 m e a n S u n 2 05 m 9 0 0 8 2 9 8 5 85 8 3 o _ ma 6 32 D r m v m m U O E M A m m U m z m Q m m 0 3 8 3 3 2 2 3 8 2 3 9 0 8332 Em 38 03qu 9 2m 82m 203 6 2 2 3 5 0 8 8 m wmox 0...

Page 414: ......

Page 415: ...8 0 050 0 0 0 0 30 83 2 300 000 30 0 0 3 0 o 0 0 0 3 0 0 0 2 0 0 0 1 3 0 3 0 0 2 1 0 0 0 0 0 0 0 30 0 02 00 313 0 3 0 0 0 0 0 3 0 7 3 0 0 0 0 0 3 0 0 0 3 0 0 5 0 3 0 0 0 0 0 0 0 0 0 0 0m 0 00 0 000 00...

Page 416: ...000 000 00 0 3 0 00 0 3300 2 8 0 3 0 0 0 0 0 000 m 0 0 3 0 0 0 0 0 0 3 0 0 0 2 3 m 3 0 N m 0 0 0 0 3 3 0 0 0 000 030 000 000000 5 w 0 20 0000 3 0 00 039 00 0 0 0 000 8000 0 00 300210 um 0 03 5 0 0 003...

Page 417: ...cog 8 3 8 2 8 2 3 8 3 3 U m 3 9 r m a 8 3 2 8 3 8 6 6 0 58 man I g o o 2 8 wk lh w cum m x _ u _ u m O m 3 9 9 0 2 0 I m 2 _ _ m z _ m O O m m m O H 3m EEO a B alsa IN 5 35 83 5 32 9 99 2 3 9 3 8 1 0...

Page 418: ...mg Um 3 3 8 3 8 3 2 3 5 8 3 323 3 8 1 3 3 3 3 3 2 0 4 m 2 3 6 m 2 c o x m 3 3 3 8 3 5 3 3 25 3 9 8 2 Em 33 m2 228 38 3 3 03 381 53 332 6 u n m o m q 5332 5 6 3 30 6 m _ m m 368 8 2 3 3 3 8 3 S S m 3...

Page 419: ...8 0 8818 83 u 3 8 335 3 2282 8 8 arm m u 8 38 3 8 18 383 8383 8 8 3 03 81 35 2 5 1 m 8 3 8 0 mo 23 mm 2 6 N 63 as 3 5 2 3 8 2 3 Km m 5 3 m a c 8 35 m8 82 03 m 8 m 8 3 3 0 8 3 2 3 3 8 3 N m om 18 831 0...

Page 420: ...3 2 1 0 8 c m 3 2 6 3 5 m a m a S S 3 0 3 2 8 3 8 EOE 3 2 8 3 9 3 3 3 5 1 0 30 80 a 3 3 0 3 3 3 3 3 3 0 3 8 5 3 8 2 8 9 m o 3 3 8 3 5 8 3 3 a s 3 8 5 3 5 5 5 5 F d o S W a m m o 0 3 2 5 3 8 2 3 4 5 9...

Page 421: ...0 man a rear 5 05 0 25 c 05m 0 2 5 5 5 0 5 0 5 3 3 33 5 2 5 0 5 8 0 3 3 2 0 1 5 5 1 0 9 5 a 0 3 5 5 5 2 5 0 5 3 5 5 2 2 8 2 5 9 0 25 0 8 52 3 3 55 a m an 5 3 8 6 m e 3 0 2 3 3 3 0 0 2 5 c 308 5 H 0 00...

Page 422: ...5 0 0 8 3 0 0 2 0 30 3 0 a x 0 0 0 30 05 0 00 00013 00 0 000300 2 0 00 005 3 0 00 0 0 0 0 0 0 0 0 50 0 0 0 0 0 0 0 3 3 3 3 30 030 0 3 0 5 2 0 0 0 8 5 0 3 3 0 3 3 0 5 00 0 0 0 0 0 8 0 m00 00010 3 303...

Page 423: ...3 3 8 5 6 0 8 5 3 u 8 3 0 3 m m 23 m 2 3 Pm 5 3 208 3m 3m 23 03 8 8 5 8 3 2 8 3 0x 3 2 2 2 3 3 3 r m a i m Z m mmoca 3o 3 mama Gaza 59 8833 39 man 30 83 3 5 8 1 3 m m 0 2 3m 3 m m gm 8 3 3 8 m 333 3m...

Page 424: ......

Page 425: ...00 30 000 0 0007 300 3 0 0 0 2 03 O 30 3 2 0 22 0 0 3 3 0 0 2 0 0 0 2 um wm 0 m m 0 5 30 02 30 3 00 0 0002 8 032 3 30 2 02 0 0 3 3 0 30 2 0 0 0 0 0 20 O m 2 2 m m U m m w 203 0000 02 300 0 0 0 22 30 2...

Page 426: ...3m 3 m m 8 8 3 3 3 3 c m 815 m m O r O m m r _ 2 0 3 20 I O C Z O O C H v C m 1 m _ A 01 m E S 82 5 1 6 3 5 5 2 0 um 3 www man um 8 w ow 25 18 3 3 8 920 3 o S ANm 33 2 3 9 2 S 2 3 29 6 3 c a n 3 2 5 3...

Page 427: ...mm 8 S 05 5 mg m 6 3 6 5 5 m m _ n 5 4 5 3 5 38 3 13 m 8 3 9 8 m e u 8 8 80 ma 5 m y a 3 m 3me 5 8 5 3 5 9 5 or 80 a 8 me S 3 2m 6 32 0 0 3m 3 E m m m m m B E F c 28 3 826 318 m m m E m m3 8 9 8 3 5...

Page 428: ...6 5381 man 8 5 8 38 2 03 828 3836 saw 2 m m 8 3 5 2 S e n e c a 2 3 8 3 0 8 8 5 m a n 3 2 8 2 0 3 38 3 8 8 1 3 3 5 5 8 C8 8 9 8 m e 8 um AC M o o 3 q u U 1 8 Eu 8 5 8852 33 m 830 0 032 2 828 3 0 8 3 0...

Page 429: ...iate drive shaft and compress by means of tool 78 41 612 NOTE The circlip ends should overlap under a jaw of the pliers They will therefore not be clear of each other when the pliers are closed it PLA...

Page 430: ...e screws with tabbed washers 15 Refit the wheel and lower the car to the floor Tighten the axle nut to a torque of 180 Nm 130 PRESSlNG IN THE BALL BEARING IN THE STEERING ft lb 18 kpm and secure KNUCK...

Page 431: ......

Page 432: ...511 BRAKE SHOES 512 BRAKE LININGS 515 BRAKE DRUMS 516 BRAKE DISCS 517 FRICTION PADS 520 HYDRAULIC FOOTBRAKE SYSTEM 521 MASTER CYLINDER 522 BRAKE LINES 523 WHEEL CYLINDERS 524 BRAKE OPERATION 551 HAND...

Page 433: ...nt screw rear wheel brake BRAKE SYSTEM AS FROM MODEL 1969 1 Master cylinder with 7 Stoplight contact brake fluid container 2 Vacuum servo 3 Filter vacuum servo 4 Handbrake lever 5 Brake pedal 6 Wheel...

Page 434: ...ggg E I1I IIIII M _ l l s f 3 m k XII I I I 5 between the pistons is determined by a Spiriil spring and a wire clamp The semndary piston has a primary u p and a secondary cup at front and rear respec...

Page 435: ...CYLINDER SECTIONED LHD MODEL 1969 1970 RHD MODEL 1969 CH No 96722017570 95722006474 3 5 vvvvvv Iii 1 121114 __ WI a 6 J kE_I 3 le _ 5 37 ng Al 5 591 3 MASTER CYLINDER LHD AS FROM MODEL 1971 SAAB Marc...

Page 436: ...of the movement taking place around the hinge pin The outer friction pad is mounted in the brake body assembly whereas the inner pad rests against the brake piston and is held in position by the suppo...

Page 437: ...cylin der and the movable brake unit is that both friction pads are pressed together with a torsional movement which tends to give irregular wear on the friction pads This wear is made up for by the...

Page 438: ...tmo e right hand side of the When pressing the brake to the left the vacuum channe spheric pressure flowes in on th brane xlwum prevails on the L H side of the diaphragm and atmospheric pressure on th...

Page 439: ...ings It may then be sufficient to change the two rear linings only stem is operative for complete brake nt device Re 6 Examine the linings on 7 An exchange sy shoes with fitted automatic adjustme plac...

Page 440: ...to keep the brake pis tons in position REAR WHEEL BRAKES s 712 5 Adjust the shoes to a position concentric with the L Adjustment backplate Refit the springs holding the shoes against 2 Spring the bac...

Page 441: ...djusting screw for the rear brakes consists of a sQuare peg located on the rear of the backplate Turn with a special spanner until the wheel is locked Then back off one or more steps until the rear wh...

Page 442: ......

Page 443: ...ivets in the center 4 Fix the other rivets in turn proceeding from the cen ter and out towards the ends Stretch the lining well to secure good contact with the shoe Any clearance left between the shoe...

Page 444: ...f the brake drums are moderately scored and more or less equally on both left and right sides this will not in fluence the braking effect or the life of the brakes If on the other hand only one drum i...

Page 445: ...Do not disconnect the brake hose instead place the brake housing in such a way that the hose is not ex posed to tension 4 Pull off the wheel hub with the brake disc attached using wheel puller 7840028...

Page 446: ...FRONT AXLE UNIT WITH DISC BRAKE 1 Brake disc 10 Ball bearing 2 Brake pad 11 Shaft seal 3 Brake piston 12 Ball 4 Brake housing 13 Backing plate 5 Nut 14 Clamp 6 Wheel hub 15 Inner drive shaft 7 Outer d...

Page 447: ...heel and fit the outer friction pad Make sure that it movesd freely in its position in the yoke Possrbly protru ing parts will have to be trimmed with a file IMPORTANT If used friction pads are refitt...

Page 448: ...isc 12 Top up with brake fluid in the reservoir WARNING Do not forget to pump repeatedly with the brake pedal otherwise the pedal will go all the way down when the brakes are applied sen 517 2 Ree I17...

Page 449: ...may lack lubricating properties and initiate corrosion Further more they may be escessively viscous at low temperatures or have a low boiling point which would cause vaporiza tion in the system upon...

Page 450: ...the reservoir is completely full of brake fluid and that the air vents in the reservoir cover are not choked 2 Bleed either one wheel at a time or two wheels at the same time One circuit should be ble...

Page 451: ...emove the rubber bellows 11 together with retain 2 Remove the rubber boot from the push rod or back ing plate 8 and the push rod 31 l I 15 2 5 6 7 B 9 10 11 Ffij ii l We Aa mll W W uh I ll f 12 13 141...

Page 452: ...ylated spirit can be used for cleaning washer so that the surface of the pistons not be dam but the parts must then be wiped thoroughly dry aged 5 Compress the intermediate spring 18 together with spr...

Page 453: ...Attach the brake cylinder 3 Refit the rubber boot to the push rod Reassemble the push rod if it has been disassembled 4 Reconnect the outlet brake lines and refill the system Cabs I l l with brake flu...

Page 454: ...gasket red so V l I V II Wemmmemea w ml _ 26 25 S 10 II 12 13 141516 18 I9 20 23 2149 MASTER CYLINDER SECTIONED MODEL 1969 1970 1 Outlet to the secondary circuit 11 Piston washer 21 Piston stop ring 2...

Page 455: ...older 18 and drive out the retaining rubber parts should be replaced by new ones pin using a suitable pin punch This will sepa rate the two pistons Q and 12 and allows the withdrawl of the spring 16 a...

Page 456: ...93 and check that it is correctly located Take grim can not to damage the surface finish of the puma ry piston since this could cause leakage past the so condom cup Fit the plain W 23 into the cylinde...

Page 457: ...d to gain access to the seal ring 3 F e pmon 12 wuth Spnng and seals 6 Clean the parts in brake fluid or methylated spirit 4 B l o i sltler gc y1lf2d t th st t I er 0 e power as uni 5 Cover all openin...

Page 458: ...ver be annealed and reused Pipes which are to be installed must fit well at both ends and at the clips Never stretch a badly fitting pipe by means of the compression nuts or bend an already fitted pip...

Page 459: ...r boot 6 Bleeding nipple Removal 1 Remove the wheel brake drum and brake shoes 2 Disconnect the hand brake wire from the levers 3 Disconnect the brake line from the rear of the back plate 4 Remove the...

Page 460: ...taining ring and bleed nipple The cylinder has a steady pin a hole to receive this being provided in the back plate ATTACHMENT OF REAR WHEEL CYLINDER 2 Reconnect the brake line 3 Refit the brake shoes...

Page 461: ...brake hose fit a new cop per washer and tighten the hose securely in the cyl inder 7 Put the brake in place and tighten the retaining bolts Remember to secure the bolts with the retaining plate IMPO...

Page 462: ...NG Make quite sure that the brake hose is not twisted If it is not mounted in a neutral position slacken its attachment at the wheel housing and then retighten it in the correct position 4 Refit the f...

Page 463: ...h necessary od at the adjusting the brake ped ings if Reinstall in the reverse order and then adjust the brake pedal free movement Adjustment In order to ensure that the piston in the master cylinder...

Page 464: ...the bracket of the brake light and the brake warning contacts REMOVAL OF COTTER PIN 4 Loosen the clutch pedal spring 5 Remove the cotter pin from the R H end of the pedal shaft 6 Pull the shaft Out to...

Page 465: ...f the front seats and the rear seat cush ions Jack up the car 2 Remove the rear wheel 3 Back off and remove the adjusting Wt under th brake lever 4 Pull the cable sheathing out of the sleeve under the...

Page 466: ...lever e e and its component parts Removal 1 Push back th them to provide bet 2 Remove the rubber 3 Back off and remove the adlustlng nuts 4 Remove the locking washer and the lever bearing pin from the...

Page 467: ...f the footbrake if the handbrake still requires adjustment this can be done in the manner described below with the ad justing nuts which are accessible from the driver s seat NOTE Always adjust the br...

Page 468: ...CONTENTS 600 GENERAL 601 WHEEL ALIGNMENT 631 STEERING KNUCKEL HOUSING AND BALL JOINTS 632 CONTROL ARMS 641 STEERING WHEEL AND COLUMN SHIFT GEAR 642 STEERING GEAR 643 TIE ROD ENDS ebv 1917...

Page 469: ...nnor ends of those are curried 5 All mm wlmaln have coll springs Each front wheel II at fubbgr Cldd boarln I on the bod The vertical SWING mulmd to the nearing knucho which Ia nulpended thor travel of...

Page 470: ...ta unit 12 m r wane osn Iv 3 1 irate wow Swat fearwrtgtaa 2 31pmzemeczt esaarrgmm nemM ahz mbh kd nmamTrzmsi qm rmhm bmsmmmwmh dde 2 J FRONT AXLE UNIT 600 2 E Te rig Dr as gr 31 ol rsa t mm angry 19 7...

Page 471: ...n either Slde each Of them being carried in rubber bush Incl ChaSSiS No 95722004645 interconnecte by means 10f a stabilizer bar ings on Me mounting brackets bolted to the body 14 I2 11 IO Inn v mum S...

Page 472: ...ement to the steering arms 4 which are attached to the steering to the tie rous unuugn me omel connected knuckles and ball joints Bil mp with a column shift gear The gear The car IS eq ivoted to the o...

Page 473: ...just any faults see section 642 4 Check the function of the shock absorbers and renew any defective shock absorbers and rubber bushings 5 If the car has been involved in an accident driven into the di...

Page 474: ...scribed mark comes in axle height again Check measure B If adjustment is called for alter the length of the tie rods 3 Back off the lock nut on the outer end of the tie rod ADJUSTMENT OF TOE l N 1 Loc...

Page 475: ...ted is iNClined fa en said to be positive If the king pin Daily the ki Wards caster IS said to be negative Fi case ca may be perfectly vertical in which Stet Is 0 The caster should be 2 i 1 2 positive...

Page 476: ...se is made of two standard type turn tables with arc graduations or optical measuring equipment Position the turn tables as close to the wheel turning center as pos sible Turn the steering wheel to th...

Page 477: ...2 45 F 5 F 5 F 5 5 FMS F 6 F 6 F 6 5 F 7 F 7 F 7 5 F 8 7 5 3 7 3 7 3 e 5 3 6 B 6 B 6 3 5 5 3 5 3 5 3 4 5 3 4 F 3 5 F 3 5 F 4 F 4 5 F 4 5 F 4 5 F 5 F 5 5 F 5 5 F 6 F 6 5 B 6 3 5 5 e 5 5 3 5 3 4 5 3 4 5...

Page 478: ...M4 5 WM 55F _L5I COME 5 1m BIZ rm 5IsI 5 5I lI1I OIZI 5I5I M5I 75 5I3I 42 F3 5I RADIAL T m...

Page 479: ...ut 1 SM out 0 28 2 Toe out inmm and in 1 1 4 out SM out a 1 SM out 1 1 4 out 3 4 out Correct settin Correct setting S 3574 CHECKING THE LENGTH OF A TIE ROD WITHOUT KEY GRIP I 7 1 1 4 in 1 3 4 in 0 28...

Page 480: ...he following limits Camber 0 i 1 Toe in toe out must not exceed per wheel 0 1 3 4 both wheels together 0 i 10 both wheels together measured rim to rim O i 0 28 in 7 mm Max difference in wheelbase left...

Page 481: ...EERING KNUCKEL HOUSING AND BALL JOINTS memmm Serf Em smahmlfnmm Mxmmmmnam dehu WWW km 2 3 3 um Stilt mam 4 mmt armmt x DOW mammacrs l e 36 7155 mt emnmmr EMF II 7 3 12 8th t Ilmhihh gun chi III R F la...

Page 482: ...s unit thoroughly PRESSING OUT THE OUTER DRIVE SHAFT 8 Press the bearing out of the steering knuckle from the inside 9 Remove the two sealing rings their seats in the steering knuckle and nut if they...

Page 483: ...l 78 41 612 NOTE The circlip ends should overlap under a jaw of the pliers They will therefore not be clear of each other when the pliers are closed PLACING OF LOCK RING IN THE TOOL Tool 78 41 612 4 I...

Page 484: ...packed with Saab special grease Then reassemble the inner universal joint and tighten the clamp round the rubber bellows Refit the steering knuckle to the steering arm and lower ball joint Remember t...

Page 485: ...for as such play adversely influences characteristics of the car and gives rise to unwante 1 Jack up the car and remove the wheel Wash the ball joint and adjacent parts carefully 2 Detach the ball jo...

Page 486: ......

Page 487: ...pper ball I Dint from the steering knuckle Back off the clamping screw whic ball joint to the steering knuckle Open up the inner universal joint and remove the entire front axle assembly Clean thoroug...

Page 488: ...efit the front axle assemblies If removed lubricate ngs Wm r _ I the T shaped end of the axle Fit the 73 23 736 to protect the needle bear t that the inner driver is clean and has fresh Saab special c...

Page 489: ...cate the bushing with soft soap and water before pressing in DRIVING IN A WHOLE RUBBER BUSHING Tool 78 41 331 for upper bushing Tool 78 41 349 for lower bushing F0 1977 NOTE In no circumstances may oi...

Page 490: ...d the angle between the control arm and the con tact surface of the brackets should be 0 3 2 ANGLE BETWEEN LOWER CONTROL ARM AND BEARING BRACKET 2 Refit the control arm by bolting the bearing brackets...

Page 491: ...ft until the clamping screw comes opposite the groove in the shaft The inter mediate shaft should normally slide freely on the shaft If the splines stick do not on any account knock on the top end of...

Page 492: ...s with the center axis of the switch housing when the wheels are straight ahead 3 Fit the steering wheel on the column Make sure that the front wheels are aligned straight ahead and push the steering...

Page 493: ...neutral Adjust by inserting shims between the switch and the column stand NOTE Fit the return yoke so that its center line coincides with the center axis of the switch housing when the 6 wheels are s...

Page 494: ...e joint or impair its shockab sorbing effect The wheel must not be knocked off Ol 00 1 If removed refit the return yoke 2 Check the clearance between the return yoke and the projection on the directio...

Page 495: ...n con tact 1 Mount the actuator if it was removed 2 Check the clearance between the actuator and the tooth of the switch which should be 0 008 0 024 in 0 2 0 6 mm when the switch is in the neutral pos...

Page 496: ...el shaft introduced as from model 1969 must be handled with care It must not be subjected to impacts jolts or other rough treatment liable to alter the adjusted length of the telescope joint or impair...

Page 497: ...gear Dog tions GEAR SHIFT MECHANISM LEFT HAND DRIVE DisassembIY 1 If the c mplete gear shift mechanism is to be re moved from the car disassemble the steering co lumn stand with column and gear shift...

Page 498: ...5 Gear shift lever 16 Ball 17 Spring 18 Turn stop 19 Pin 20 Plastic bearing 21 Lever housing 22 23 Washers 24 Nut 25 Fiber washer 26 Snap ring 27 Washer 28 Spring 29 Bushing 30 Washer 31 Felt ring 32...

Page 499: ...against one shank of the turn guard at the same time turning the gear shift lever through 4 turn thus locking the lever 12 Reassemble the complete steering co with column and gear shift mechanism I re...

Page 500: ...turn movement 9 Refit the steering wheel and horn button assembly 10 Adjust the steering column stand in the vertical di rection to ensure correct gear shift positions and then adjust the twist stop f...

Page 501: ...ollowing positions GEAR LEVER AND lGNlTlON LOCK L Locked The lighting is out when the key is turned to locked position The key can be taken out only When reverse gear is engaged 6 Garage ignition etc...

Page 502: ...the twist stop is called for The procedure is the following 1 The twist stop is marked on the side that is to face up wards towards the steering wheel The marking shows for which version the twist sto...

Page 503: ...pressed in by inserting a wire Dicklock in a hole on the underside of the steering column stand See figures 0 32 in 8 mm 0 1 in 2 5 mm I R 0 4 in 10 mm WIRE PICKLOCK REMOVING LOCK CYLINDER 1 Lock cyli...

Page 504: ...r into the gear lever lock and then fit the look into the steering column stand 2 Insert the screw and drive it in slightly Insert the lock plug 3 Using flat nose pliers turn the pin in the lock until...

Page 505: ...positiOned lock sleeve Adjust as necessary u In the sing flat nose pliers S 6168 I 2 POSITION OF DRIVER FOR INSTALLATION OF CYLINDER 1 Hole for locking pin 2 Driver 2 Insert the cylinder in the lock...

Page 506: ......

Page 507: ...at on shows a steering gear for a car with left hand drive U as the steering gear for cars with right tions are e Is Slmllal In prInprle the following instruc qually appllcable to both versions 23 Q...

Page 508: ...the dash panel Lift the left hand resp right hand on R H D cars side of the steering gear forwards over the gear shift fork shaft until the stub axle on the steering gear is clear of the dash panel 15...

Page 509: ...t of the steerl must be backed off so that the Sta to its upper position ping screw in the the steering wheel yoke In certain cases ng column stand d can be moved WAR N NG The collapsible steering whe...

Page 510: ...g washers 4 If the gear pinion has been removed put it back in place 5 Release the two tie rod ball joints with tool 78 40 713 If the nut is left on the rack it can be removed using the shaft of wrenc...

Page 511: ...bolts of the pinion bearing and lift out bearing and pinion 7 Pull the rack out 8 Remove the spacer ring from the pinion Press the pinion bushing out REASSEMBLY LATER DESIGN Exercise the greatest clea...

Page 512: ...other adjustments can be done quite simply in the car unless removal of the steering gear is neces sary for some other reason The inner ball joint very sel darn requires adjustment since there is ver...

Page 513: ...arried out without removing the steering gear from the car 1 Back off the lock nut 2 Tighten the adjusting screw to the smallest 9055 play without the rack moving stifle 3 Tighten the lock nut Turn th...

Page 514: ...er bearing cup 6 Spring 3 Tie rod 7 Rack 4 Lock pin AAA 0 ne side Remove by drilling ball joint ing cup and the lock nut 40 713 and 78 39 624 Pull the rack out to o the lock pin from the Remove the ou...

Page 515: ...oe in as de scribed in section 501 Tighten the lock nut 2148 SECURING LOCK PIN WITH CENTER PUNCHES Q The final adjustment is then made in the same way as that used for the other tie rod 10 Fit the rub...

Page 516: ...arm The The tie rod ends cannot be disassembled Consequently if excessive play develops the tie rod ends must be re pivot is secured by a castle nut and cotter pin The tie rod newed ends cannot be di...

Page 517: ...with ml is lined in with ball joint ll this is dam aged m that it no Iowan attends an effective seal it must he rejected and a new one titted lhe piowduie is as lul lows 1 Jack up the car and ioniove...

Page 518: ...Fab 1917 CONTENTS 700 731 732 761 762 771 772 774 GENERAL COIL SPRING SUSPENSION FRONT COIL SPRING SUSPENSION REAR SHOCK ABSORBERS STABILIZER WHEELS TIRES HUBS...

Page 519: ...r bell joint 8 Brake disc 7 Lower ball joint 8 Shock absorber S Stabilizer bar 10 Lower control arm 16 Hub 11 Inner drive shaft 12 Rubber bumper No 96722013535 and Saab 95 up to and incl chassis No 95...

Page 520: ...l side links attached to both the bOdy and the rear axle by means of rubber hushed bearings The lower coil spring seats are bolted to the stub axle ex tension on the inside of the rear axle end plates...

Page 521: ...ic y are connected by means of rubber bushed hear he body at the top and to the rear axle at the bot REAR SUSPENSION SAAB 96 1 Center bearing 2 Rear axle tube 3 Shock absorber 4 Upper spring mt 5 Rubb...

Page 522: ...rear wheels also serve as brake drums The hubs are shaped to form an annular seal against the back plate thus preventing water sand and other foreign matter from entering the hubs and brakes The hubs...

Page 523: ...are described below Alternative is removal and installation of the front coil springs using spring clamp 78 40 820 and spring compres sion tool 78 40 812 Alternative 2 is removal and installation of t...

Page 524: ...eat at the same time inserting the previously removed upper bumper in the spring 5 Locate the lower spring seat between the spring and the control arm and refit the ball joint 6 Back off the spring cl...

Page 525: ...er spring seat to facilitate removal and fitting of the spring 5 Remove the spring 6 Check and if necessary replace the rubber spacer on the upper spring support 7 Check the two rubber buffers under t...

Page 526: ...dition of the stop strap to see if a new One is required Reassembly 1 If the rubber buffer has been removed screw 3 new one in place 2 Refit the spring Fit the spring with the unground end facing down...

Page 527: ...ll worn or damaged parts installation is carried out in the reverse order to removal Bear in mind however that the rubber bushed bearings must be fitted in such a way that no stresses are incurred whe...

Page 528: ...l between the body and the axle on either side of the center bearing 5 Remove the rubber bushing with tool 78 40 739 EXTRACTION AND INSERTION OF CENTER BEARING RUBBER BUSHING WITHOUT REMOVING THE REAR...

Page 529: ...SSING IN RUBBER BUSHINGS Tool 78 40 762 4 Refit the body brackets to the links noting that the angle between the link and the bracket should be 4 when the bushing has been tightened 5 Refit the links...

Page 530: ...bsorber in the same position as it has on the car and pump it up and down several full strokes Now FRONT SHOCK ABSORBERS fit the shock absorber to the car immediately if t is Put down air may re enter...

Page 531: ...e shock ab sorber and its connecting parts smear the pin threads with grease and tighten the nuts hard The connecting parts belonging to the shock absorber are shown in the figure below Topping up sho...

Page 532: ...that th 5 and waSherf Fit the shock absorb On are Correcu rubber bushings in the upper Con e into the holeY located then ease the upper bushing properly center the body 50 that the shock absorb Spect...

Page 533: ...dy 5 Stabilizer bar 762 1 SAAB Jack up the front part of the car and remove both front wheels Back off and remove the two bolts on either side that hold the ball joints and stabilizer bar brackets to...

Page 534: ...s due to rim deformation the tire should be taken off so that the wheel can be inspected and adjusted if necessary If the rim is rusty at the bead seating the rust must be removed this can suitably be...

Page 535: ...d which in turn demand powerful brakes This contributes to faster wear on the tires 6 Road surface Dry roads offering a good grip fOr the tires cause a great deal of wear 7 Manner of driving The tempe...

Page 536: ...EEL HUB 1 00th 2 0 stlonm am LHuo intruder h 1977 FRONT WHEEL HUB L S Sheel hub is splined to the outer drive shaft slid r by meansvofa castle nut and cotter pin The mg surface on the insude of the hu...

Page 537: ...REAR WHEEL HUB Ball bearings are fitted in the rear wheel hubs These to gether with the shaft seal accompany the hub when it is removed ill ll REAR WHEEL HUB S 2495 Feb 1977...

Page 538: ...roughly and make sure that there is no dirt in the shaft seal 1 Bafore installing grease the tongue and sliding surface of the shaft seal Fit the hub on the shaft Put on the washer and tight en the ca...

Page 539: ...e is applied it may ooze out and ruin the brake linings 4 Insert the spacer sleeve and press in the big bearing using tool 78 40 325 I tunnel HI Iii PRESSING IN THE BIG BEARING Tool 78 40 325 5 Refit...

Page 540: ...F bvtsrv CONTENTS 800 810 820 830 850 860 890 GENERAL BODY ASSEMBLY HOOD FRONT PANEL AND FENDERS DOORS AND LIDS GLASS UPHOLSTERY AND INTERIOR FITMENT BUMPERS BODY FINISHING...

Page 541: ...adiator Some of the air outlets are fitted with gills The brackets for the front control arms are welded to the inside of the wheel house walls and to the engine compartment floor One of the rear whee...

Page 542: ......

Page 543: ...rts are replaced Any parts of the body assembly that have been so seri rather than repaired ousjy damaged as the result of a collision or other acci BODY ASSEMBLY COMPONENTS AVAILABLE AS SPARE PARTS 1...

Page 544: ...rrnzd portions of the car body It con5ists of a lever w IC is secured at the bottom by a chain to two of the legs of the alignment jig A hydraulic pressure cylinders at tached to the middle of the lev...

Page 545: ...is to use a fork lift trolley or overhead traveling crane If these are not available the job can be done with a high lift garage jack and a mobile collapsible trestle set con sisting of four legs on...

Page 546: ...ore favor able working height and simplifying mounting The draw tion of the draw aligner aligner is secured directly to the jig which makes it easier to work with The jig is mounted on four castors an...

Page 547: ...TED TO DRAW ALIGNER ARM R THE APPLICATION OF LOADS AT ROOF HEIGHT __ seam ALIGNMENT JIG WITH EQUIPMENT 1 Alignment jig later design 2 Wheels 3 Side support 4 Draw aligner 5 Extension 6 Support set Saa...

Page 548: ...igner IS available and can 9 mp With one or two pillars Scania in Nykoping under the ordering number 101733 MOUNTING THE CAR IN THE JIG The car can also be mounted in the jig by hoising it onto high t...

Page 549: ...EWed or straight Sm and power u e IlttaChmem points 0f the suspen nit Diagonal measurements should also ened it is important to ch eck the measurements of the be made to ch metrY after re st hat there...

Page 550: ...3310 5 52 95 10 16 134514 6 34 10 16 16114 VIEW C C 27 80 10 12 70613 41 34 10 12 1050 1 3 To leading edge of pil lar reinforcement tube 5 1485 47 52 10 16 1207 14 402810 16 102314 90 90 54 21 10 20...

Page 551: ...nil 13...

Page 552: ...1 0 04 Body measurements Saab 96 213812 347 11 3810 5 84 51 1 5 210 11 99 10 5 249 5 11 5 100 10 5 48511 5 229413 78413 730 12 327 13 36513 13913 23711 5313 3010 5 116114 20314 70613 105013 1207 14 1...

Page 553: ...ocking needles of the pivot pins the press one of the hinge stays slightly inwards to gar the pin The assistant holding the hood n the 0 side helps to lift it off Open the hood with the control mechan...

Page 554: ...nd wheel housing brackets REMOVAL OF SCREWS FRONT PANEL 820 2 Disconnect the hood control and the cable connections for the headlights and direction indicators and parking lights REMOVAL OF FRONT PANE...

Page 555: ...cor frame there is a screw and a clamp which retain the front plate to the wheel housing At its upper edge the front plate is attached to each fend er and wheel housing stay with a screw At removal fi...

Page 556: ...t the wiper motor goes free Remove the cables from the wiper motor Note the cable connections 3 Move the front plate forwards and lift it out of the brackets Installation is made in the reverse order...

Page 557: ...he fender with underbodv coating and refitted the moldings lights and possible rubber grommet left rear fender reinstall as follows 1 Locate the fender and tadpole sealing head in 905i tion and insert...

Page 558: ...the old fender Clean the wheel housing to prevent dirt from entering the fuel tank 2 Remove the filler tube and connecting hose Leave the vent tube connecting hose in place on the vent tube of the ta...

Page 559: ...e door stop Pin and the interior trim and remove the door NOTE Be careful not to damage the outside of the door Window regulator with the tools used to release the nuts Removal and installation _ 1 Re...

Page 560: ...ed If the play is less than this adjust as follows a Cars up to and incl model 1971 File down the part of the push button arm that actuates the door look b Cars as from model 1972 Bend the outer part...

Page 561: ...washer 1 securing push button 6 to the handle 2 Now remove the push buttOn with the lock cylinder The push button and lock cylinder form an integral unit and must not be taken apart SCI OUTSIDE DOOR H...

Page 562: ...hinge which are accessible when the door is open 4 Remove the lever of the door lift from the gate by removing the nuts Be careful when removing the lever as it is spring loaded 5 Close the door 6 Rem...

Page 563: ...whereupon the latch can be removed Put the new latch in place with the serrated nut threaded on as far as possible The latch should be turned so that the joint for the right hand side door lock rod i...

Page 564: ...andle Fitting is carried out in the reverse order Position the locking pin so that the recess in the pin mates with the driver on the lock cylinder 830 6 TRUNK LID SAAB 96 Removal and replacement I Ra...

Page 565: ...t the torsion spring 4 and the housing mak ing sure that the spring is inserted in the smallest of the notches in the sleeve and in the hole in the hous ing 3 Refit and press together the lock ring 4...

Page 566: ...e the weather strip joint possibly marked T00 32 9 023 with a yellow dot in the middle of the lower edge of the windshield 5 Ca P sthetrim rs Nth chromium plated molding res 10 Inject sealing compound...

Page 567: ...etainer channel and secured to the door frame by means of two screws A run channel guides the rear edge of the window glass Removal 1 Wind down the window until its rear edge is just be low the weathe...

Page 568: ...egulator pin into the slot g I e 3 Now twist the glass to bring the hinge up into posi tion moving the glass rearwards at the same time so that it enters the run channel 4 Insert the two hinge screws...

Page 569: ...nd spring clips Insula mm allainst sound and heat is afforded W a thiFk qwlt 0f glass fiber between the dash Panel and the mm HEADLINING SAAB 95 HEADLINING SAAB 95 1 Headlining 2 Retainer 3 Wire spira...

Page 570: ...bow and pull backwards and at the same time with the other hand stretch bow by bow backwards Make sure that the headlining stretches evenly This is done by comparing the distance between the seam at t...

Page 571: ...n each other S 1297 BAR INSTALLATION OF MOULDING AT THE REAR CROSS curve Fit the rear shelf windows sun Visors dome lanvlliitlh back loop brackets side trims and rear seat cushion rest The removal is...

Page 572: ...he backrest is mounted The upholstery consists of moulded rubber cushions laid on rubber sheets and covered with textile and plastic coated fabric Both front seats are mounted on rails to allow legroo...

Page 573: ...ing I h n th b k lines l t r e iate t e e e ac rest can be hooked off from the seat 2 Turn the twist ring and intermediate tube counter clockwise until all play is eliminated and the release button is...

Page 574: ...he back rest and pull the band and clip to the front of the seat A UNHOOKING THE THREAD 5 Bend the plastic ring which secures the upholstery at the hole and thread it through the hole from the back to...

Page 575: ...The thermosmt mounted in the seat cushion cuts cu is higher than 81 F 2700 en the temperature Checking of heating pads I 22 0le igire connection 67 93 red and yellow wires Connect a test lamp between...

Page 576: ...e backrest cover can be removed when the zip at the bottom has been opened The seat cover is removed by undoing all the staples at the front bottom of the seat and unhooking the two retainers holding...

Page 577: ...odel 1976 the auxiliary jump seat is removed The rear seat is moved rearward SWINE the rear seat pas senSlers improved legroom R ear seat Saab 96 up to and incl model 1969 1st the rear seat cushion an...

Page 578: ...possibly with the addition of a little soap solution After drying any resi dual stains may be removed with carbon tetrachloride Battery acid should be treated instantly with large quan tities of cold...

Page 579: ...the upper edge which possibly also retain the defroster duct and remove the over lav from the panel 4 When refitting apply glue only to the projecting part of the instrument panel and the correspondin...

Page 580: ...1968 there are splash guards in the rear override the body rs to prevent flying stones from attacking Each bumper comprises a middle bar and two Outer bars S 3609 BUMPER FRONT 1 Overridar up to and in...

Page 581: ...d with a bracing strip on the outside Up to and incl model 1976 the bracing strip is of stainless steel and as from model 1977 of rubber with a plastic strip with a chromrum In sert Provision has been...

Page 582: ...ng strip Note the spacing sleeves un der the filling plates at each end of the bracing strip 3 Remove the anchorage bars on the side of the bumper where the cellular block is to be changed If the cen...

Page 583: ...man 22 new 2 3 52 I80 23322 4 xoa F uEbnaTxona 0 8 2 e 5 5 2 5 2 xogo Races 53 2 9 5 2 a 8 2a 3 9 333 5 ozs wwozF oo page9 isoz_t _uoz_z m o53502 02 50 2268 En do do Eoon Q 8 0 055 new 289E mending c...

Page 584: ...rt Herberts appr 25pm 35 45 sec Saab standard 860 at 68 F 20 C Hot spraying Paint temperature approx 122 F 50 C 20 min at 320 3380F ISO 170 C AB Wilhelms Beckers appr 25 um 35 40 sec Saab standard 860...

Page 585: ...f neces sary before flattening with wet abrasive paper P 490 Finally reclean the parts with spirit or cellulose thinner Th U9hness in this respect is vital to 900d adhesnon Priming Coat all bared meta...

Page 586: ...ying touch up enamel l68 176 F 20 80 C When air drying enamel is used no special arrangements are necessary other than a well heated dustless booth The drying time can however be speeded up consider a...

Page 587: ...CONTENTS 900 GENERAL 911 INSTRUMENTS 920 ACCESSORIES MECHANICAL 930 ACCESSORIES ELECTRICAL 941 HEATING AND VENTILATION SYSTEM 2 TOWHOOK ASSEMBLY...

Page 588: ...plate for the installation of a radio if desired Direction indicator 5 headlight flasher Free wheel control To lock out the free wheel action pull the handle right out See page 19 Handbrake Dimmer sw...

Page 589: ...AND WINDSHIELD WIPE RSI WASHE R Pas 0 3 0 Windshield wipers neutral position 1 Windshield wipers low speed 2 Windshield wipers high Speed 3 Windshield wipers high speed and washer 9 Gear lever 10 Loc...

Page 590: ...too large due to any of the fol lowing faults a Leakage in one of the two brake system circuits b Rear brakes need adjustment If the warning light glows an authorized Saab Service garage should be con...

Page 591: ...ased and can be moved forward or backward as desired 18 Control for adjusting angle of seat backrest 19 Fresh air ventilation lid The lid may be opened by pushing the handle of the lid forward The int...

Page 592: ...here it is 10_ liable to endanger or obstruct traffic Instruments and indicator lights 11 Instrument lighting rheostat Turn the switch to 12_ control the intensity of illumination This switch 13 Opera...

Page 593: ...rn ing light comes on when there are less than 3 4 US gallons 7 liters left in the tank Charge indicator light Glows orange when the alter nator is not charging Oil pressure warning light Glows when e...

Page 594: ...instrument with warning lights Direction indicator warning light Speedometer with warning lights Instrument illumination rheostat Hazard warning signal switch 10 11 12 13 14 15 16 17 Warning light fo...

Page 595: ...investigate the cause MPH Speedometer and odometer This speed ometer is graduated in MPH and the odometer shows the total mileage of the vehicle in miles and tenth of a mile w Brake warning light The...

Page 596: ...in rings with a diameter of less than about 12 inches 300 mm Otherwise there is a risk of damaging the flexible inner wire which might lead to unwanted noise after installing When fitting the speedome...

Page 597: ...ution counter in the other models follow the wiring diagram below ment may get ruined WIRING DIAGRAM FOR FITTING AN ELECTRIC REVOLU TION COUNTER Revolution counter Ignition coil Distributor Ignition s...

Page 598: ...etractors are placed below the rear seat cushion The rear seat retractors are placed below the rear backrest Sweden Norway and Finland as from model 1974 The belt consists of a strap with one end secu...

Page 599: ...and has a sliding buckle which is secured in a locking device between the passengers To fasten the belt pull out the strap carefully and feed it under the yoke located between the front seats see illu...

Page 600: ...p As a general rule the following applies Current consumption less than 8 A 96 W use a wire with a sectional area of 0 002 sq in 1 5 sq mm 0 th consumption more than 8 A 96 W use a wire with a section...

Page 601: ...take 17 in front coo led to the floor or thro ways at the same time As from model 1971 the car nels to the floor space in th When the road speed excee speed wind is generally 5 function of the heat ax...

Page 602: ...ionfree running An exchange system is operative in respect of the complete fan unit Reinstall in the reverse order HEAT EXCHANGER Removal and installation 1 Drain off the cooling water and disconnect...

Page 603: ...of the fan housing Lift out the fan motor SEPARATING THE HEATER CASING 5 Back off and remove the screws holding together the fan housing msings Sign screws are accessible from the engine compartment...

Page 604: ...g bar with the bumper retaining screws Chip away the underbody coating with a chisel or similar so that the other attachment points of the IOWhook make direct contact with the deck plating Drill four...

Page 605: ...DIAGRAM NOTE The cable 121 H GR 0 75 is according to the wiring instructions intended to be connected to 121 GR 0 75 This method of connection is sufficient to pro vide normal interior lighting in a...

Page 606: ...re for both left and right side 8 Tape L Tape to permanent wiring Mount cable shoe 85 03 286 on cable No 121H gray and then connect to cable No 92 red at dome light 140 mm 51 2 l Towhook Ground connec...

Page 607: ...ng to the wiring diagram and that strut makes direct contact with the deck plating instruction and drill two holes 25 mm and 3 8 mm 2 Drill six 8 5 mm 1 3 holes through the deck plat o_152 in the body...

Page 608: ...5 is according to the wiring Instructions intended to be connected to 92 RD 0 75 This method of connection is sufficient to provide normal interior lighting in a house trailer COLOR CODE VT WHITE RD...

Page 609: ...nning the wire to the trunk light Tape to permanent wiring Ground connection Scrape surface clean to obtain good ground contact Secure cable shoe with self tapping screw 79 22 800 hole dia meter 3 8 m...

Page 610: ......

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