Saab 95 Estate Workshop Manual Download Page 91

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Summary of Contents for 95 Estate

Page 1: ...WORKSHOP MANUAL for SAAB 95 96V 4 ...

Page 2: ...Saab 95 Estate Saab 96 Saloon Saab Monte Carlo ...

Page 3: ...Monte Carlo 1966 1967 1968 1970 1966 1967 1968 1970 1966 1967 42 001 50 197 52 001 62 059 65 001 74 986 80 001 420 001 458 526 470 001 507 018 520 001 552 859 560 001 420 001 458 526 470 001 507 018 Chassis number and paint code plates Chassis number plate Colour code plate Chassis number and colour code plates USA versions models 1969 onwards r Chassis number imprinted on body ...

Page 4: ...Front end jacking point Front end support points Rear end jacking point Rear end support points Sidejacking point Side support points ...

Page 5: ...e taken for the sake of accuracy Brevity and simplicity have been the aim in compiling the manual relying on the numerous ilh is trations and clear text to instruct and inform At the request of the users of our manuals the book has been slanted towards repair and overhaul rather than maintenance NO LIABILITY CAN BE ACCEPTED FOR ANY INACCURACIES OR OMISSIONS IN THIS MANUAL although every possible c...

Page 6: ... Intake air pre heater plate 9 Engine side stay bracket IO Rocker cover II Air cleaner I2 Carburettor II Fig A 2 Right hand View of the engine assembly I Carburettor automatic choke 2 Ignition distributor 3 Water distribution manifold 4 Clutch 5 Cooling ry tem by pe tS pipe 6 FlywheeL 7 Oil filter 8 Sump drain plug 9 Radiator bottom hose connection IO Water pump II Alte1711ltor I2 Oil filler cap 2...

Page 7: ... iet and smooth running of the engine the valve clearance should be adjusted carefully and accurately with the engine warm With the engine at normal operating temperature remove the air clemer Detach the spark plug leads from the rocker covers unscrew the retaining bolts and lift offboth the rocker covers The cylinders are arranged with No 1 and 2 in the right hand bank and Nos 3 and 4 in the left...

Page 8: ...l filter 3 Balance shaft 4 Crankshaft 5 Camshaft Fig A 4 Semi closed crankcase ventilation system 6 Cylinder head 7 Rocker assembly 8 Main oll gallery 9 Oil pressure switch Fig A 6 Removing the oil filter Fig A S Closed crankcase ventilation system 4 ...

Page 9: ... Kerosene as cutting oil while reaming After reaming the valve guide bore the valve seat must be recut to ensure that the seat is concentric with the valve guide Valve seats Inspect the valve seats for pitting or burning Check the valve seat run out using an accurate gauge If run out is excessive or ifany other of the above faults are present the valve seats must be recut The valve seats should al...

Page 10: ...ion of the cylinder head gaskets I Rocker shaft with rockerarms 2 Oil return plate Fig A 13 Cylinder head assembly Fig A 12 Removing the valves and valve springs I Split tapered collet 2 Spring retainer Fig A 11 Cylinder head bolt tightening sequence 3 Valve spring 4 Valve stem oil seal 5 Cylinderhead 6 Inlet valve 7 Exhaust valve 6 ...

Page 11: ...screws 4 Rocker shaft pillars S Spring 6 Rollpins 7 Cover plate 8 Spring washers 9 Plugs Fig A 16 Valve seat angles Fig A 18 Removing the front cover oil seal Fig A 1S Reaming the valve guides Fig A 17 Grinding the valves Fig A 19 Installing the front cover oil seal 7 ...

Page 12: ...he associated components should be removed or disconnected in the follwing sequence 1 Disconnect battery earth lead 2 Remove the retaining clips from bonnet pivot pins Bend one ofthe stays inwards to release it from the ivot bracket and with the aid ofan assistant lift off the bonnet Fig A 29 3 Drain the cooling system including the heater 8 4 Disconnect wiring from headlights and side indicator l...

Page 13: ... and Fig A 20 Installing the front cover I Front cover 2 Aligning tool GC 6059 Fig A 23 Installing the fan pulley flanJe Fig A 22 Installing the fan bearing Fig A 24 Installing the fan bearing cover plate Fig A 25 Removina the tappets 9 ...

Page 14: ... 26 Measuring the camshaft thrust plate Fig A 29 Removing the bonnet Fig A 27 Camshaft thrust plate spacer washer and woodruff key Fig A 30 Front panel retaining screws Fig A 28 Tunin gear aligrunent marks 10 ...

Page 15: ...ent DO NOT use a caustic cleanmg solution or wire brush to clean the pistons Clean the ring grooves and make sure that the oil ring slots are clean Clean the connecting rods caps and bearing shells with solvent and dry with compressed air Inspect the pistons for fractures at the ring lands skirts and pin bosses and for scuffed rough or scored skirts A shining surface on either pin boss side ofthe ...

Page 16: ...lling the engine Fig A 31 Removing the front panel Fig A 33 Water distribution pipe Fig A 34 Removin2 installing the oil pre re switch Fig A 3S Removing installing the oil pump 1 lntermed14te plate 2 Plate retaining bolts 12 ...

Page 17: ...ng Fig A 38 Removing the crankshaft sprocket Fig A 40 Placing plastigauge on the bearing cap Fig A 39 Removing the balance shaft C D A B Fig A 41 Measuring the plastigauge width Fig A 42 Crankshaft out of round Fig A 43 Crankshaft taper 13 ...

Page 18: ...rear oil seal Fig A 47 Checking the piston ring gap Fig A 46 Checking the piston fit with a puU scale Fig A 49 Oil pump dismantled I Pump housing 2 Inner and outer rotor 3 Cover plate 4 Reliefvalve 5 Spring 6 Valve cap 7 Gasket Fig A 48 Removing the ring gear from the flywheel 8 Oil pick up pipe 14 ...

Page 19: ...n 10 mm longer than those for the cylinder head As from engine No 74900 the cylinder head bolts have been lengthened to make them the same thus eliminating posSibility ofconfusion The centre main bearing also serves as an axial guide bearing for the crankshaft Big End Bearings The big end bearing inserts should be inspected and the bearing clearances checked in the same manner as already described...

Page 20: ...cap Fig A SI Checking the rotor end float Fig A S2 Checking the rotor radial clearance Fig A S3 Tightening the centre main bearing cap Fig A SS lmtalling the balance shaft Fig A S4 Installing the piston and connecting rod assemblies 16 ...

Page 21: ...7 Installing the wedge shaped seals in the rear main bearing cap Fig A S8 Installing the flywheel Fig A S9 Installing the intermediate plate Fig A 60 Stop plate position on the oil pump drive shaft Fig A 61 Sump gasket location Fig A 62 Installing the sump 17 ...

Page 22: ...36 Temporsrily install two ofthe lower bolts as guide dowels and fully tighten the two retaining bolts Check that the lower edge of the plate is level with the mmp face ofthe block Remove the two guide bolts 18 Locate the woodruffkey in the front end of the crankshaft install the crankshaft gear wheel retaining bolt and washer and tighten to the specified torque Avoid tapping the gear as this may ...

Page 23: ... 820 56 830 nun 58 830 56 840 nun 0 014 0 054nun 0 014 0 064nun 0 040 0 008 nun 0 026 0 203 nun 0 250 0 500 nun 0 380 1 400 nun CRANKSHAFT Number of main bearings Main bearing journal diameter Standard red blue 0 002 in 0 05 nun undersize 0 010 in 0 25 nun undersize 0 020 in 0 50 nun undersize 0 030 in 0 75 nun undersize 0 040 in 1 00 nun undersize Inside diameter of main bearing inserts fitted St...

Page 24: ... 3 US qts 0 3 litres Grade of oil Ford spec ESE M2C 101 B Summer SAE 20W 20 lOW 30 lOW 40 Winter below 140F 100C SAE lOW lOW 30 lOW 40 20 BALANCE SHAFf Nwnber ofbearings Journal diameter front rear Inside diameter ofbushings front rear Bearingclearance front rear End float Maximwn gear wheel backlash TORQUE TABLE Balance shaft pulley bolt Big end nuts Cam shaft thrust plate bolts Camshaft gear whe...

Page 25: ...d to the correct strength Drain flush and refill the system with new antifreeze solution every two yean or as recommended by the antifreeze manufacturer COOLING SYSTEM Dniningand Refilling NOTE Three drainpoints are provided a tap at the bottom ofthe radiator and two hexagon plugs one on either side of the cylinder block Ifthe system contains an antifreeze solution and it is required for re use co...

Page 26: ...Drain points 3 Fig 8 1 Cooling system prior to 1969 L 1 Water pump 2 Radiator 3 Radiator cap non preiiSUre release type 4 Expansion tank 5 Pressure cap 6 Cooling fan 7 Temperature sender unit 8 Thermostat 9 By pass 10 Water jacket automatic choke carburettor JJ Heater core 12 Heater bleed valve 13 Blower motor 14 Side de mist hose 15 Main de mister outlet 16 Collector box 17 Frelh air intake 18 De...

Page 27: ...16 Collector box 17 Frtsh air Intake Q Warmair 18 De mister pipe 19 Blower fan Coldair 20 Air flow control f ilp 21 DI 1Jin point radiator 22 Dl tJin points cylinder block one either lide Fig B 3 Cooling system 1970 2 6 1 Radiator top hose connection 2 Thermostat 3 Automatic choke Ctzrburettor connections 4 Inlet connection to interior heater 5 Outlet connection from interior heoter 6 Water dutrlb...

Page 28: ...ting the drive belt tension 1 Adjustingbolt 2 Retaining bolts Fig B 7 Testing the cooling system Fig B 8 Testing the pressure cap Fig B 9 Removing the thennostat I Water outlet housing 2 Thermostat Fig B 10 Thennostat installation position J Gasket 24 ...

Page 29: ...epair kit and assembly tools 1 Tool No GC 8501 B 2 Tool No GC 8501 A Fig B 13 Removing the pump shaft and bearing Fig B IS Installing the pump shaft and bearing Fig B 18 Installing the drive pulley Fig B 16 Installing the pump seal Fig B 17 Installing the impeller on the pump shaft 2 5 ...

Page 30: ...pipe from the tube at the radiator filler neck Unscrew the four mounting bolts and lift out the radiator Fig B 11 If the radiator is being exchanged transfer the drain tap to the new radiator Install me radiator and secure it in position with the four mounting bolts Connect the top and bottom hoses and tighten the hose clips Refit the over flow pipe to the tube at the radiator filler neck Check th...

Page 31: ... ignition and remove the test lamp Dynamic Stroboscope Disconnect the vacuum pipe at the distributor Connect the stroboscope to the ignition cable of the No l cylinder and start the engine Check and adjust if required the ignition setting at starter r p m or with the engine running at approximately 500 revs per minute The mark on the crank shaft pulley should be adjacent to the 6 mark on the front...

Page 32: ...taining clip II Olpacitor I2 Skew getu 3 5 9 11 10 8 6 7 Contact breaker points Fig C 2 Basic ignition setting I Vacuum unit 2 Adjustment mtuk 3 Vacuum control tum 4 Earth lead 5 Felt lubricating pad 6 A11embly mark 7 Distributor cap retaining clip 8 Bearing 9 Capacitor IO Primary L T terminal II Fibre lug I2 Adjustment lugs fixed contact plllte 13 Breaker points 14 Locking screw IS Fixed contact ...

Page 33: ... Fig C 6 Distributor shaft cam assembly Fig C 7 Vacuum unit 1 Felt lubricating pod 2 Retaining ring cam assembly 3 Bearing washer 4 Cam usembly 5 Spacing washer 6 Governor spring 7 Retainingc ips governor weights 8 Governor weights 9 Distributor shaft and action plate 29 ...

Page 34: ...s securing the distributor cap retaining clips de tach the two clips and lift out the breaker plate assembly Drive out the retaining pin securillR the skew gear to the distributor shaft and using a suitable puller pull out the gear Fig C 5 Withdraw the complete shaft assembly froni the distributor body Unhook the governor springs from the cam assembly The cam assembly is held on the distnllutor sh...

Page 35: ...et for damage and renew if necessary Install the filter screen Install the ffiter screen Install the gasket ring and cover and secure with the centre bolt ensuring that the fibre washer is fitted under the bolt head DO NOT over tighten the centre bolt otherwise the washer may be damaged or the cover distorted Testing If the fuel pump is suspected of being defective the following tests should be ca...

Page 36: ... Retaining pin Compre sswn spri Diaphragm ng Pump bod Filter y upper part Gasket Cover Cover centr b e olt t Fig D 2 Secti onal view of the fuel pump 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cover Fuel inlet Inlet valve Diaphragm R taining pin Duzphragm rod Lock washer Spring retainer Return fP St IJI nng Compre rsion Outlet valve spnng Fuel outlet Filter Cover centre bolt ...

Page 37: ...of the Solex 28 32 PDSIT 7 carburettor Fig D 8 Right hand view of the Solex 28 32 PDSIT 7 carburettor I Fuel inlet 2 Acceleration pump 3 Idling fuel jet 4 Idling mixture adjusting screw 5 Vacuum connection 6 Idling speed adjusting screw 7 Throttle controllever I Choke water connections 2 Fast idling control link 3 Main jet access plug 4 Acceleration control link 33 ...

Page 38: ...ke control diaphragm Idling air jet drilling Acceleration pump Acceleration pump inlet IIQlve Acceleration pump outlet valve Float chamber Float chamber cover Carburettor main body Automatic choke housing Main jet Emulsion jet Idling fuel jet Float Chok tube Float valve Fuel inlet connection Vacuum connection Idling mixture adjusting screw Idling speed adjusting screw Throttle plate Choke plate Ec...

Page 39: ...idling fuel jet from the outside of the carburettor body and the emulsion jet from the carburettor body top face Blow out the float chamber jets and passages with compressed air A drill wire or other sharp instrument must NEVER be used for cleaning jets or passages as this may cause damage and affect the carburettor calibration Clean the needle valve in the float chamber cover Inspect the cover ga...

Page 40: ...5 26 5 122429 9 Acceleration pump diaphragm 10 Vent actuating lever II Idling speed adjusting screw 12 Idling mixture adjusting screw I3 Throttle plate 14 Acceleration pump operating link 15 Acceleration pump operating lever 33 34 2827 Sectional view of the FoMoCo C8GH 9510 Carburettor 26 Vacuum passage 27 Acceleration inlet valve 28 Pres lUTe equalisinghole 29 Acceleration pump discharge pa sage ...

Page 41: ...on position for choke plate pull down setting FoMoCo Fig 0 17 Checking the choke plate pull down setting FoMoCo Fig 0 18 Choke plate puU down adjustment FoMoCo Fig 0 19 Correct stop cam position during choke plate pull down FoMoCo Fig 0 20 Step i am adjustment FoMoCo Fig 0 21 Step cam stop A and choke plate arm B FoMoCo 37 ...

Page 42: ...e paid to 1he following points 1 It is recommended that new gaskets should be used throughout when reassembling 2 When assembling the automatic choke mechanism great care should be taken to ensure that the components are correctly located in the water housing 38 3 Centralise the choke and throttle plates with the plate in the closed position before finally tightening the clampingscrews Lightly pee...

Page 43: ... 26 Float chamber valve adjustments FoMoCo Fig 0 23 Adjusting the fast idle setting FoMoCo Fig 0 2S Float chamber valve settings A 0 32 0 40 in 8 10 mm with throttle wide open B 0 008 0 012 in 0 2 0 3 mm with throttle valve fully closed Fig 0 27 Float and fuel level settings FoMoCo A 1 08 in 27 5 mm B 1 34 in 34 mm 39 ...

Page 44: ...Co Fig 0 32 Vacuul l piston position for choke plate pull down setting FoMoCo USA version 1970 onwards Fig D 29 Accelerator pump ball valve and weights FoMoCo Fig 0 31 Choke plate installation position FoMoCo Fig 0 33 Ch the choke plate pull down setting FoMoCo USA version 1970 onwards ...

Page 45: ... Fig D 19 If necessary adjust by choke connect ing link at its existing bend Fig D 20 De choke Setting Open the throttle fully so that the arm B on the throttle control lever contacts stop A on the step cam and forces the choke plate to open Fig D 21 Using a drill of suitable diameter check the clearance between the lower edge of the choke plate and the carburettor wall Fig D 22 The clearance shou...

Page 46: ...42 Fig 0 34 Choke platepull down adjustment FoMoCo USA version 1970 onwards Fig 0 35 Explodes view of the decel valve FoMoCo USA version 1970 onwards I Adjusting screw ...

Page 47: ...y adjusted every 6 000 miles 10 000 km To check the function ofthe deceleration valve with the air cleaner fitted run the engine up to normal operating temperature Check that the valve is working at idling speed by disconnecting one ofthe hoses between the valve and the carburettor and checking that no vacuum is passing the valve Ifthe valve is open and vacuum is passing the valve screw in the adj...

Page 48: ...Fig 0 36 Apply sealing compound to the locations marked Fig 0 37 Installation of inlet manifold gasket Fig 0 38 T Jgbtening the inlet manifold bolts Fig 0 39 Front silencer Fig 0 40 Rear silencer 44 ...

Page 49: ...ITION SYSTEM section Reconnect the spark plug H T leads ensuring that they are replaced in their correct order Install the carburettor using a new gasket and reconnect the fuel pipe vacuum pipe and throttle control linkage Re connect the water hoses to the inlet manifold and the choke housing Connect the temperature gauge sender unit lead Refit the rocker covers and the air cleaner The rocker cove...

Page 50: ...l fully open float valve Idling speed Fast idling speed third step FoMoCo 70 1W 9S10 AA Mainjet Float needle valve Float level fully closed float valve Float level fully open float valve Idling speed Fast idling speed third step headlights on low beam 46 2S Smm 12S 110 so l S so 0 6 0 12 cu in 10 2 cu cm per 10 strokes l S 7 3 gms 0 59 0 04 in 1S O 1 0 mm from gasket 800 900 rev min llOO 1300 rev ...

Page 51: ...ol Release Bearing Pull the release lever forward remove the two spring clips retaining the release bearing to the release fork and remove the release bearing Fig E 8 Ifthe bearing is of the graphite ring type and the ring is worn level with its retainer it must be replaced When fitting a new release bearing check whether the bearing has a graphite ring or Teflon coating on its pressure face Ifthe...

Page 52: ...sassembled view of the clutch pressure plate assembly I Clutch cover 2 PrerltUI e plate 3 Clutch relefllt Ieven 4 PrerltUI e rprings 5 Release plate 6 Retllining rpring 7 Releue lever ptvotr Fig E 3 autch release mechanism 1 Master cylinder 2 Slave cylinder 3 Adjurtment screw 4 Locknut 5 Bleed valve ...

Page 53: ...hecking the releaae ann free play A 5 31 in 4 inm Sectional view of the clutch disc Fig E 6 Checlting the clutch disc throw out Fig E 7 Dismantling the pressure plate lllleDibly Fig E 8 Outch release ann and bearinl 49 ...

Page 54: ...sher 6 Piston 7 Piston secolldary cup 8 Stop washer 9 Rubber dust cover 10 Push rod 11 Clevis pin to pedal 10 11 10 11 1213 Fig E 10 Exploded view of the master cylinder Models prior to 1969 1 Cylinder body and reservoir 2 Hydraulic hose 3 Valve seal 4 Valve stem 5 Spring washer 6 Valve spacer 7 Spring 8 Spring retainer 9 Piston seal 10 Piston 11 Rubber dust cover 12 Push rod and retainin g washer...

Page 55: ...of the slave cylinder l orrT 1 I 1 2 345 6 7 89 Fig E 14 Exploded view of the slave cylinder 1 Push rod 2 Rubber du t cover 3 Retaining circUp 4 Piston seal 5 Piston 6 Piston retum spring 7 Cylinder body 8 Bleed valve 9 HydnzuUc hose Fig E 1S Bleeding the hydraulic system Sl ...

Page 56: ...y type master cylinder Lubricate the bore of the cylinder with clean hydraulic fluid and insert the return spring largest coils firSt and the spring seat Fit the secondary cup to the piston flat side towards the nearest end ofthe piston Dip the piston in hydraulic fluid Insert the primary cup lip first into the cylinder Next install the dished washer with the convex side towards the piston Fig E 1...

Page 57: ...oth ends remove nut and transfer to other end ofpin T ten nut to loosen pin 17 From inside car tum back floor mat and remove rubber plugs to provide access to engine rear mounting centre bolt Fig F 27 Ifmounting is jammed free by tapping with an arbor inserted through upper hole Fig F 28 18 Raise car on stands placed at front edges of sills so that front wheels are clear of ground 19 Remove larger...

Page 58: ... shaft universal joint RHD models 2 3 4 5 Fig F 2 Diagrammatic arrangement of the free wheel 1 autch shaft 2 Free wheel hub 3 Free wheel sleeve 4 Rollers 5 Coil springs Fig F S Gear shift shaft universal joint LHDmodels 1 Gear shift rod 2 Conical pin with lock nut 3 Rubber boot 4 Rubber disc 5 Operating shaft gearbox 6 Spring ...

Page 59: ...Fig F 3 Exploded view of the transmission 55 ...

Page 60: ...d 56 Fig F 7 Speedometer drive gear 1 BeDring sl eve 2 Spindle 3 Driven gear 4 Retaining pin 5 Gasket Fig F 9 Transmission case cover and shifter mechanism 1 Operating shaft 2 Tl rlnsmission case cover 3 Retaining pins 4 Shifter levers 5 Lock lever shaft 6 Lock lever 7 Screw cover to case 8 Plug ...

Page 61: ...haft seal wid double sealing lips A The space between the lips to be filled with chassis grease B This side to face inwards towards the tnuumission case Fig F 13 Installing die clutch shaft seal Fig F l4 Differential unit and inner drive shaft 1 Spa 2 Btzll be ring J 0 own wheel 4 Dlff ntilzlthaft J Loclcrlng Diffm ntilzlddeg 1 Btzll beanng 8 I1111er dme lhtzft 57 ...

Page 62: ...universal joint ss Fig F 19 Fig F 16 Installing the new inner drive shaft oil seal 1 Oil seal 2 Arbor Tool No 784033 3 Handle Tool No 784030 Fig F 18 Removing installing the drive shaft Tapping out a broken inner drive shaft I Arbor Too No 784142 2 Inner drive shaft ...

Page 63: ...r drive shaft 6 Joint bt lls 7 Hub 8 Rubber bellows 9 Connecting drive shllft Fig F 21 Pressing out the outer drive shaft Fig F 23 Installing the baD bearing in the steering knuckle Fig F 22 Removing the outer universal joint from the drive shaft Fig F 24 IJIStaDing the lock ring using tool No 784161 59 ...

Page 64: ...int Fig F l7 Releasing the rear engine moimting centre bolt 3 Fig F l6 Exploded view of the steering Imuckle assembly 1 InnerIM t seaL 2 Lock plates 3 Steeringarm 4 Steering knuckle houling 5 Ball bearing 6 Nut 7 Outer shaft seaL Fig F l8 Tapping loose the rearengine mounting ...

Page 65: ...ar fit safety stands and remove the relevant road wheel Remove the brake calliper disc and splash shield Unbolt the steering arm and upper control arm balljoint from the steering knucke Release the clamp bolt and detach the lower control arm balljoint from the steering knuckle Remove the larger of the two clamps from around the rubber boot at the inner universal joint Open up the inner universal j...

Page 66: ...r baU joint 3 Track rod outer baUjoint 4 Steering knuckle and steering arm 5 Pinion haft 6 Rack 7 Rack adJustment nut 8 Track rod A y 1 1 t 8 I Track rod locknut 2 Bellows clamp Fig G 3 Checking the toe in adjustment A Fig G S Track rod end setting type with key flats Fig G 6 Track rod end setting type without key flats 62 ...

Page 67: ... 4 Tighten the track rod lock nut and the bellows clamp The bellows must be slack enough to slide on the track rod After adjustment of the toe in dimension A Figs G S G 6 on the track rod must not exceed 1 6 in 40 mm on the type of track rod which has key flats and 1 2 in 30 mm on the type of track rod without key flats The difference in dimension A for the track rods on either side of the car mus...

Page 68: ...Balljoint and stud J Rubber dust seal 4 Steeringarm 5 Phlin washer 6 Casteihlted nut 7 Split pin 1 Housing 2 Rack J Pinion shaft bushing 4 Spacer lh eve 5 Pinion shaft 6 l Wnwasher 7 Shim 8 Pinion bt llringand cover p llte A 9 Rackdamper 10 Spring 11 Adjulting nut 12 Lock nut 1 J Cupped lock washer 14 Shim 15 Rack end nut 16 Spring washer 17 Ball inner set t 18 Ball outer llt llt 19 Track rod 20 L...

Page 69: ...oving the ball outer seat from the nut fonner type joint Fig G 13 Securing the inner balljoint Fig G IS Boring out the ball joint lock pin new type joint 7 6 5 4 2 3 Fig G l4 Sectioned view of the track rod inner ball joint new type 1 II outer letJt 2 II inner teat 3 Track rod 4 Lock pin 5 Lock nut 6 Spring 7 Rack Fig G 16 Removing the ball outer seat and locknut new type joint 65 ...

Page 70: ...whatsoever but is not so tight that it sticks or jams in any position The track rod with track rod end attached should remain in any position to which it is moved without falling under its own weight It should also be possibfe to move the track rod to its full limit of travel in any direction by applying light manual pressure Tighten the lock nut to the ball outer seat with tools Nos 783962 784071...

Page 71: ...gear Fig G l9 Removing Installing the rack end nut former type joint Fig G 20 Adjusting the gear shift twist stop Fig G ll Sectioned view of the twist stop 1 Clamping bolts internal hexagon hetJds 2 Adjusting holes 3 Twill stop 4 Gear shift 8htzft 5 Steering column shroud 6 Gear shift le er 67 ...

Page 72: ...e 8 Steering column Fig G Z Z Ignition Gear shift lock 1 Cotch pin 2 Lock ba el 3 Signpllzte 4 Lockbody 5 Locking tongue 6 Lockplug 7 Spring washer 8 Retaining screw 8 5 Fig G 23 Removing the hom button Fig G 2S Steering wheel hub assembly models 1968 69 1 Safety pod 2 Wheel retaining nut 3 Spring washer 4 Steering wheel 5 Cover 6 Indicator cancelling ring 7 Steering column 5 ...

Page 73: ...he gear shift lever in the first gear position and slacken the two clamping screws Access to the screws is obtained through the two holes on the under side of the steering column shroud Fig G 20 Engage reverse gear and turn the ignition key to the locked L position The stop screw on the twist stop can now be backed off through one of the holes The hole to use is dependant on whether the car is fit...

Page 74: ...r to 1968 D Steering wheel assembly models 1968 1969 E Steering shaft models 1969 onwards I Horn button 9 Rubbergrommet 2 Steering wheel 10 Steering shaft with univen41joint 3 Washer and direction indicator 11 Column lower bushes cancelling ring 12 Cardboard sleeve 4 Column upper bushes 13 P Qstic cone 5 Cover p Qte 14 Cover pillte 6 Lock ba el 15 Twist stop 7 Twist stop 16 Ignition IWitch Gear le...

Page 75: ... 41 Shim s 12 Return spring 42 Fibre washer 13 T11peredpin 43 Chromed fleeve nut 14 Universtd joint 44 Fibre washer 15 Gear shift lt ller 45 Snap ring 16 PitJstic ball 46 P iJin washer 17 Spring 47 Spring 18 Turn guard 48 Lt ller housing 19 Pin 49 Shim s 20 PltJstic bearing 50 Fibre washer 21 Lever housing 51 Chromed sleeve nut 22 Shims 52 Fibre washer 23 Fibre washer 53 Snap ring 24 Chromed sleev...

Page 76: ...ig G 32 Location of the gear shift lever in the gear shift shaft 1 2 Gear shift shaft Gear shift lever Fig G 34 Gear shift universal joint LHD models 1 Gear shift rod 2 Conical pin with lock nut 3 Rubber boot 4 Rubber disc 5 Operating shaft gearbox 6 Spring 2 3 Fig G 35 Sectional view of the direction indicator device models 1970 onwards 1 Horn contact 2 Safety pad 3 Steering wheel 4 Sliding conta...

Page 77: ...led downwards out of the steering column shroud and the washer spring bushing washer and felt ring removed from the bore in the shroud If required the clamping screws on the twist stop can be released and the twist stop removed from the shaft In this case the spring retainer and return spring can then also be removed from the shaft Reassembly is the reverse of the dismantling procedure with specia...

Page 78: ...nut Max permissible distance between LH RH Dimension Tightening torque ball stud to steering arm Toe in at wheel rim Toe out on turns 74 Technical Data Prior to 1969 Rack Pinion 14 0 2 1 4 turns 0 004 0 008 in O I 0 2 mm 0 012 in 0 3 mm max From 1969 15 5 I 2 7 turns 0 005 in 0 12 mm max 0 01 in 0 25 mm max 1 5 in 40 mm max 1 2 in 30 mm max 0 08 in 2 mm 25 36 LB FT 3 5 5 0 kg m 0 08 0 04 in 2 0 I ...

Page 79: ...hly the same time Whenever lyres are interchanged the inflation pressures should be re adjusted and if the lyres were balanced on the car they should be re balanced Wheel Balancing Unbalance of the road wheels may cause wheel tramp vibration in the steering or abnormal tyre wear To obtain the maximum ride confort and tyre life the balance of the wheels should be checked periodically It is recommen...

Page 80: ...front suspension assembly left side shown 1 Suspension coil spring 2 Rubber bump stop 3 Steering arm 4 Spring lower seat 5 Upper ball joint 6 Broke disc 7 Lower ball joint 8 Shock absorber 9 Stabiliser bar 10 Lower control arm 11 Connecting drive shaft 12 Rubber buffers 13 Upper control arm 14 Rubber insulator ring ...

Page 81: ...ster camber adjustment shims 6 Upper control arm 7 Upper ball joint assembly 8 Spring clip 9 Ring 0 Rubber dust cover Steering arm 15 12 Steering knuckle housing 3 Lock plates 4 Clamp bolt ball stud 15 Lower ball joint assembly 16 Reinforcing plate 7 Stabiliser bar end mounting bracket 8 Rubber bush 9 Lower control arm 20 Lower arm bearing bracket 77 ...

Page 82: ...g scat The compressed coil spring can now be removed Examine the rubber insulator at the spring upper seat and replace if necessary Similarly examine the two rubber buffers under the upper control arm which form the rebound travel limit Ifthe suspension spring is being exchanged fit the removed spring in spring compressor Tool No 784081 remove the restrainer tool and release the 78 compressor Fig ...

Page 83: ...earing 5 Sleeve nut 6 Drive shaft lock ring 7 Universaljoint balls 8 Universaljoint hub 9 Connectingdrive shaft 10 Rubber bellows 11 Bellows c 4mps 12 Upper balljoint assembly 13 Steering knuci Z housing 6 7 8 9 10 Fig H S Steering knuckle and control ann baD joints Fig H 6 Coil spring restrainer Tool No 784082 79 ...

Page 84: ...Fig H 7 Upper baD joint and spring lower seat J Fig H 9 Suspension coil spring and rubber bump stop right side shown 80 ...

Page 85: ...1 e Fig H 10 Coil spring compressor Tool No 784081 Fig H II Installing a control ann bush Fig H 12 Control ann to bearing bracket angles after tightening the shaft nuts Fig 8 13 Stabili er bar 81 ...

Page 86: ...ts need not be withdrawn from the control arm and ball joint Pass the bar out to the right hand side Installation Pass the stabiliser bar in from the right hand side Secure the body mounting first and then secure the end brackets to the lower control arms Mount the road wheel and lower the car Replacing the Bushes The stabiliser bar need not be removed from the car to replace the rubber bushes Jac...

Page 87: ...er using Tool No 784036 Mount the road wheel and lower the car SHOCK ABSORBERS On Saloon models the shock absorbers are of the telescopic type whereas Estate models are fitted with lever type shock absorbers Testing The condition of the unit can be checked by bouncing the corner of the vehicle by hand and noting whether the motion is damped by the shock absorber when the hand is removed Replacemen...

Page 88: ...ng upper seat Rubber bump stop Stop strap Spring lower seat Link body bracket Locating link Fig 1 2 General view of the rear suspension Estate 1 Centre bearing 2 Axle tube 3 Lever type shock absorber 4 Spring upper seat 5 Rubber bump stop 6 Stop strap Z Spring lower seat 8 Link body bracket 9 Locatinglink 10 Shock absorber link ...

Page 89: ...Fig l S Installing the hub outer bearing Fig l 3 Removing the rear hub Fig l 6 Installing the hub inner bearing Fig 1 4 Rear hub and brake drum assembly 85 ...

Page 90: ...Fig l 8 86 lD CD LJ Shock absorber Estate Fig l 7 1 Nuts 2 Washer 3 Rubb 4 W er bushings asher Ll 1 c __ _ JJ __ l Jf 1 l Shock absorber Saloon Fig l 9 Shock absorbe r mstall t 8 10 Estate ...

Page 91: ...Fig 1 10 Fig l l2 fitting dimension Fl g 1 11 Axle stop PIS mm A 0 6m bearing bracket axle centre Unbolting the tin link body bracket Unbolting the loca g 87 ...

Page 92: ...lling the rubber bushing in the locating link Fig I 17 Exploded view of the coil spring assembly Fig I 16 Correct angle between the locating link and body bracket I Fig I IS Exploded view of the rear axle assembly 88 ...

Page 93: ...Installation is the reverse of the removal procedure with special attention to the following points 2 3 4 If new rubber bushings have been fitted to the axle assembly the bearings concerned must not be tightened until the weight of the car is standing on its wheels The coil springs must be installed with the unground end facing down wards Turn the spring until it is correctly located in the lower ...

Page 94: ...ake adjulter Generalview of the braking system layout models I969 onwards 1 Malter cylinderand fluid rerervoir 2 Vacuum servo unit 1 Vacuum servo air ft ter 4 Handbralce lever 5 Brt1lce p al 6 Wheel cylinders 7 Stop light rwitch 8 Brt1lce warning light rwitch 9 MoPing piece bi Gice warning rwltch 10 Rear brake ad wter 7 2 Fig J 3 General view of the disc brake assembly 1 Brt kedlsc 2 Whee hub 3 Fl...

Page 95: ...d in position by the calliper mounting bracket and calliper assembly Movement ofthe piston for ces the inner friction pad outwards against the brake disc The moveable calliper assembly is then influenced and moves to press the outer pad against the disc as well Retracting ofthe piston is effected by the action of the piston seal which returns the piston only sufficiently to maintain a constant cle...

Page 96: ...Fig J 4 Exploded view of the front disc brake assembly 1 2 Fig J 6 Screw vice for the brake piston Tool No 786043 Fig J S Brake pad wear 1 New pads 2 Wornpads 92 ...

Page 97: ...t device 2 Shoe hold down spring 3 Handbrake link 1 Calliper assembly 2 Spring loaded steady pin 3 Calliper mounting bracket 4 Pivot pin 5 Pad retaining pins 6 Pad steady springs 7 Bleed valve 8 Wipersem 9 Piston 10 Friction pads 11 Brake cylinder 12 Piston seal 13 Retainer ring wiper seal 14 Shim Fig J ll Rear brake adjustment 1 2 Adju rtment device Adju rter 93 ...

Page 98: ...nd must be renewed After adjustment is completed check that the free movement at the pedal is 3 6 mm 0 12 0 24 in Depress the brake pedal release it and then check that the rear wheels still rotate freely Inspecting the Linings An inspection hole is provided in the brake drum for this purpose Fig J 33 If the thickness of the linings is 0 1 in 2 5 mm or less the shoes must be replaced Replacing the...

Page 99: ... 11 10 9 Fig J 14 Exploded view of the rear wheel cylinder Fig J IS I 2 3 4 5 Rubber boot Piston Piston Sell Spring retaining clip Bleed valve 12 Rear brake back plate Left hand side shown I Handbrake cable 2 Coil spring 3 Clevis 4 Hydraulic union 5 Bleed valve 6 Cylindu retaining clip 7 Split pin 8 Cotter pin 9 Plain washer I 0 Rubber boot II Handbrake operating lever I2 Adjuster 95 ...

Page 100: ... 3 By pals port secondary circuit 4 Fluid inlet port secondary circuit 5 Fluid reservoir 6 By pals port primtlry circuit 7 Fluid inlet port primary circuit 8 Boot retaining plate 9 Piston return spring I0 Primary piston 11 Rubber boot I2 Prlmtlry cup secondary piston I3 Piston washer secondary piston 14 Secondary piston I5 Secondary cup secondary piston I6 Cylinder body 17 Clip I8 Spring I9 Clip r...

Page 101: ...ork on the brake pedal Place rags under the master cylinder to prevent damage to the paint work Unscrew the two hydraulic pipes from the master cylinder and fit blanking plugs to prevent the ingress of dirt and loss of fluid Unscrew the two master cylinder retaining bolts and remove the master cylinder The lower one is a stud bolt and the nut is accessible from the engine compartment The upper one...

Page 102: ...outlet Ddaptor 16 Piston seDls 17 Piston wDsher 18 SecondfiT piston 19 Qip retDining pin 20 Spring 21 Spring holder 22 Piston stop ring 23 Stop ring retDining clip 24 Plllin wtlsher 25 SecondfiT cup primtzry piston 26 Nylon guide beDring 27 Primary piston 28 Piston return spring 29 Spring retDiner 30 Spii Olox circ lp 31 Boot retDining plDte 32 Rubber boot 33 Push rod ...

Page 103: ...dtJry piston 14 I Broke fluid reservoir 2 Non return valve 3 Body 4 Primary cup secondary piston S Piston wtzsher llt COndary pilton 6 Secondtzry pilton 7 Connectm link 8 Link retllining pin 9 SecondtJry cup secondary piston IO Spring II Spring holder I2 PrifTIIlTy cup primary piston I3 Piston wtzsher primary piston 14 Piston stop ring IS Retllining clrcllp stop ring I6 Pltzin wtzsher I7 Secondtzr...

Page 104: ...ston and compress the spring until the link clip is visible Locate the end of the clip in the primary piston and secure with the retaining pin Release the spring and spring holder and check that the holder is correctly positioned 100 Dip the assembly in clean brake fluid and insert it into the cylinder Slide the pison stop ring over the primary piston and using long nosed pliers fit the retaining ...

Page 105: ...rcuit 7 Fluid Inlet port primary circuit 8 Piston rerum spring 9 Primary piston 10 Primary cup secondary piston 11 Piston washer Jecondary piston 12 Secondary piston 13 Secondary cup secondary piston 14 Cylinder body 15 Connecting link 16 Spring 1Z Link retaining pin 18 Spring holder 19 Primary cup primary piston 20 Piston washer primary piston 21 Piston stop ring 22 Retaining circlip stop ring 23...

Page 106: ... 0 N Fig J 28 Bleeding the rear brakes Fig J 27 Rear bleed valve p Fig J 29 Exploded view of the vacuum servo unit ...

Page 107: ...d dimension models 1967 68 A 2 3 in S8 mm Fig J 32 Brake pedal free movement Non servo models A 0 12 0 24 in 3 6 mm Fig J 31 Minimum pedal to toe board dimension models 1969 onwards A 2 3 in S8 mm Fig J 33 Rear brake inspection hole 103 ...

Page 108: ...erating cylinder bore Min permissible friction pad lining thickness Brake hose length 104 Disc front drum rear servo on LHD models from 1969 Operates mechanically on rear wheels only Dual circuit diagonal wheels paired Lockheed Disc single operating cylinder 10 5 in 266 7 mm 0 08 in 0 2 inm 2in 0 06 in 1 5 mm 8 1 2 in BRAKE HOSE LENGTH 96 Monte Carlo 95 MASTER CYLINDER Cylinder bore Prior to 1969 ...

Page 109: ...nections may damage the alternator diodes Never allow the alternator output cable to ground if it is disconnected at the alternator If this cable grounds with the ignition switched on the voltage regulator and the associated wiring may be damaged 6 7 8 9 10 II 12 13 14 Never allow the alternator output cable or terminal to ground as damage to the alternator and I or the alternator circuit may resu...

Page 110: ...em Saloon models Fig K 2 General view of the electrical system Estate models Fig K 3 Checking the battery speciftc gravity To t fli1Wtt comurrwn I _ 1 N 1 _ l l _ I J I ICI 14 v36A 20 I i I I i L_______ ________ __j Fig K 4 Alternator wiring diagram ...

Page 111: ...ploded view of the alternator Early type 1 Alte1 111ltor 2 Front hou ing 3 Stator 4 Rear housing 5 Protective cover 6 Rotor 7 Voltage regulator Fig K 7 Removing the brush holder plate Early type alt Fig K 8 Removing the front housing and rotor Early type alt 107 ...

Page 112: ... electrician A cure MAY be effected by replacing the alternator brush assembly and or substituting the voltage regulator for a known good unit otherwise the alternator must be removed for further inspection and testing If the indicator bulb is dimly lit with the engine running at speed a high res1stance in the circuit is indicated Check for loose or corroded terminals 108 or damaged wires Otherwis...

Page 113: ... tfon l l l 1 Diodoho D Fig K ll Checking the current flow in the rectifier diodes 3 2 4 Fig K 10 Soldering the brush connections Early type alt Fig K 12 Alternator tenninals Late type alt Fig K l3 Exploded view of the alternator Late type 1 F1ont houring 2 Stator 3 Rearhousing 4 Rotor 109 ...

Page 114: ...cting the brush holder leads Late type alt Fig K 15 Releasing the brush holder retaining screws Late type alt Fig K 17 Unsoldering the brush connections Late type alt Fig K 16 Removing the brush holder Late type alt 110 ...

Page 115: ...g from the stator and rear housing The brushes can now be inspected from inside the rear housing If the brushes are worn to a length of0 34 in 9 mm or less they must be replaced To replace the brushes undo the two nuts securing the diode heat sink plate to the rear housing Release the screw securing the brush plate lead Fig K 14 Release the two screws securing the brush holder plate to the rear ho...

Page 116: ...ive end bracket 4 Drive end buring bush 5 Endcover 6 U shaped washer 7 Shims 8 Rubber sealing ring 9 Commutatorend bush 10 Commutator end cover 11 Brush plate a11emb y 12 Fibre wlllher 1 J Steel washer 14 Field winding 15 Frrzme 16 Armature 17 Rubber plug 18 Steel washer 19 Pinion engagement lever 20 Drive pinion 21 Pinion buring bush 22 Circlfp retaining ring 23 Circlip Fig K 20 Tapping down the ...

Page 117: ...6 Wormgear 7 Self aligningspherical bearing 8 End pltzy adjuster and thrust pad 9 Through bolts and Insulating sleeves 10 Pole piece securing screws 11 Brush gear 12 Bushing 13 Washer 14 Limit switch moving contact 15 Bearing retaining ring 16 Grommet 17 Brush lever retainer 18 Field windings 19 Linkage operating crank 20 Drive end bracket 21 Drivegear 22 Limit switch fixed contact plate 23 Porous...

Page 118: ...ploded view of the wiper motor Models 1970 onwards 8 Cover retaining screws 9 Parking contact screws 10 Gearbox 11 Flat washer 12 Linkage operal il g crank 13 Crank retaining nut 14 Parking contact Fig K 26 Fuse block Fig K 27 Alignment diagram for left dipping asymmetric headlights models prior to 1969 H Height of headlight centre line ...

Page 119: ...Vertical adjustment screw Fig K 29 Alignment diagram for sealed beam headlights I 2 3 Vehicle centre line Headlight vertical centre line Headlight horizontal centre line A 2 in 50 mm B 6 in I50mm C I6 5 6 in 4I5 mm Fig K 31 Alignment diagram for right dipping asymmetric headlight models 1969 onwards H Height of headlight centre line 7 9 Fig K 33 Asymmetric headlight assembly Models prior to 1969 I...

Page 120: ...rior to 1969 I Retainer ring 2 Sealed beam unit 3 Adjusting ring 4 Retaining nut 5 Cradle 6 Adjusting screws 8 6 7 5 6 Fig K JS Asymmetric headlight assembly Models 1969 onwards I Bezel 2 Bezel retaining screw 3 Reflector unit 4 Cradle 5 Twin filament bulb 6 Spring 7 Bayonet ring 8 Rubber sealing cap Fig K 37 Changing the bulb asymmetric type headlights models 1969 onwards Q Fig K 38 Rear light as...

Page 121: ...69 onwards Fig K 41 Rear light assembly USA version estate car models 1969 onwards Fig K 43 License plate light Estate models Fig K 44 Front light assembly standard and export versions models prior to 1969 Fig K 42 License plate light Saloon models Fig K 4S Front light 8llllembly models 1969 onwards 117 ...

Page 122: ...haft once fitted using a suitable puller Fig K 22 Remove the brushes from their holders before fitting the armature into the starter frame Once installed refit the brushes in EXACTLY the same positions o ally and lift the spring ends onto the brushes Insert the steel washer first at the solenoid mounting flange and then the rubber plugs with the lug turned to face the starter frame 118 Overhaul Di...

Page 123: ...AD I 14 V non supressed Bosch EF R 12 V 0 8 PS 0 001 208 029 Bosch GF 12 VI 0 PS 0 001 311 024 pinion 9 Number of teeth on flywheel ring gear Brush spring pressure Output Early type Late type Armature shaft end play Flasher unit Horn FUEL GAUGE SENDER UNIT SAAB 95 up to chassis No 57 023 SAAB 95 as from chassis No 57 024 SAAB 96 up to chassis No 475 599 SAAB 96 as from chassis No 475 600 WINDSHELD...

Page 124: ... 104 green 0 75 105 black 0 75 109 black 0 75 110 green 0 75 111 red 0 75 112 blue 1 0 115 yltllow0 7S 118 white 1 0 122 white 0 75 130 brown 1 0 131 white 1 5 136 black 1 0 138 black 1 0 139 blKk 1 5 139a black 1 0 139b black 1 0 140 black 1 5 141 brown 0 75 141e brown 0 75 142 grey 2 5 147 black 0 75 190 yellow0 75 191 grey 0 75 192 black 0 75 Saab 96 Saloon RHD 1967 1 Parking light and direc ti...

Page 125: ...asa regulator I Alternator 9 Starter 10 Ballory 11 Fuso box 12 Temperature gauge Mnding unit 13 Oil preasure switch 14 Stop light switch 15 Heater fan motor 16 Wiper motor 17 Direction indicator repeater lights 11 Charge indicator light sii hp i t t Saab 96 Saloon LHD 1967 21 Electric clock 22 Temperotur gauge 23 Speedometer will odometer 24 Fuol gaugo 25 Dimmer switch 16 Flashor 0 Control rolay f...

Page 126: ...d 0 75 136 black 0 75 tion indicators 25 Speedometer with 2 Headlights odometer 3 Horn 26 Temperature gauge 4 Ignition coil coolant 5 Spark plugs 27 Electric clock De Luxe 6 Distributor only 7 Voltage regulator 28 Flasher unit 8 Alternator 29 Dimmer relay 9 Starter 30 Ignition and starter 10 Battery switch 11 Fuse box 31 Headlight switch 12 Temperature transmit 32 Instrument illumination ter rheos...

Page 127: ...ck 0 75 30 brown0 75 68 red 1 0 137 brown0 75 32 red 0 75 69 black 1 0 137c brown0 75 33 yellow1 0 70 black 1 5 138 black 1 0 35 grey 1 0 71 black 1 5 139 black 1 5 39 red 2 5 72 red 1 0 139a black 1 0 41 blue 0 75 72e red 1 0 139b black 1 0 42a blue 1 5 73 yellow1 0 140 black 1 5 42b white 2 5 74 grey 4 0 142 grey 1 5 1 Parking light and direction 25 Temperature gauge indicators coolant 2 Headlig...

Page 128: ...Starter 11 Bottery 12 Fuse bo 13 Temperature meter U Oil gauge 15 Back up light switch 1 Stop light switch 17 Heater fan motor 11 Wjndshield wastter pump 19 W1per motor 20 Direction indicator repeater hghts 21 Charge indicator light 22 ln_ dicolor light oil pre11ure 3i o jigih i j light 25 Flos er 32 1 d33 1 I j _ tl Saab Monte Carlo RHD 1967 26 Tochometer 11 Temperature gouge 28 Fue auge feectri ...

Page 129: ...1 lottery 12 fuse box 13 Temperature meter 14 o l gauge 15 lock up l ght swHch I Stop ltght switch 17 Heater fan motor II Windthield wosher pump 19 Wiper motor 20 Direction indicator repealer lights f t O h 0 i igph essure r i a iiaih i i light 25 Ignition and starter switch Saab Monte Carlo LHD 1967 26 Electric cloc lr 71 Speedometer odometer and trip meter 28 Temperature gouge 29 Fuel gouge 1 To...

Page 130: ...11 Y 12 _boa JJ r it 1 t Oil switch 15 lact P litlhl switch 16 Sto P aw tch 17 lrole wor 4 1 c ct wt dahield woaher W i 21 Directiofl i di tof re W 22 i li t D i icator Z t h Cticotot liehf oil 2S _ 1 le11iltoft and awitcll 21 Electric clock 29 SptedCNHter oclowteter ctttd trip _ 3D Tew pet otVte _ 32 Toc 1e 33 flasher 3 Mo 35 Di et relay l6 Cig rettc light 31 SPotlight switch 11 t og hoht switch ...

Page 131: ... CO Gb 66 82 83 118 122 122e 128a Yellow 17 23a 24a 33 43 c cb 73 8 4 128b Brawn 1 4 30 30e 130 137 1 41 Blue 13 25o 25oe 41 Go 112 1 j r 1f Fig L S Saab 9S Estate RHO 1967 1 o t Miion indKator htl ond do lighh 2 Heocmvht 3 Horn f Ignition coil i x gulotor 9 Stort IIIOior 10 BoH 11 Fv box 12 Toraperature do 11 Oil preuure witch 14 Stop 1 ght sw h h 15 Hooter IIIOior ld Windshield wiper otor 17 Dir...

Page 132: ...stributor 7 Voltage regvlotor I Alternator 9 Starter 10 lottery 11 Fuse bo 12 T otvf e gouge Mndi unit 11 Oil pressure switch Stop l ght nnlch IS Heoter fan olor 14 Wiper MOtor 17 Direction indicator repeater lights II Charge indicator hght i h i 21 Electric clock 71 Temperature gauge 23 Speedometer with odometer 24 Fuel gauge 2S Dimmer switch 26 flasher 27 Control relay for headlight flasher f h ...

Page 133: ...115 yellow0 75 24eo yellow0 75 61 red 0 75 116 red 0 75 24b white 0 75 62 grey 0 75 118 white 1 0 24be white 0 75 63 red 0 75 122 white 0 75 25o blue 1 0 64 grey 0 75 124 block 0 75 25ee blue 1 0 65 red 0 75 125 black 0 75 25b grey 1 0 66 white 0 75 126 white 0 75 25bogrey 1 0 67 red 1 5 129 whitt 0 75 28 red 1 0 68 red 1 0 130 brown 1 0 28e red 1 0 69 black 1 0 131 white 1 5 281 red 0 75 70 block...

Page 134: ... 1 0 61 red 0 75 115 yellow0 75 23be white 1 0 62 grey 0 75 116 red 0 75 24a yellow0 75 63 red 0 75 118 white 1 0 24ee yellow0 75 64 grey 0 75 122 white 0 75 24b white 0 75 65 red 0 75 124 block 0 75 24be white 0 75 66 white 0 75 125 block 0 75 25 blue 1 0 67 rod 1 5 126 white 0 75 15 Stop light switch 37 Courtesy light with switch 16 Brake warning contact 38 Switch for windshield 17 Heater fan mo...

Page 135: ...g h Compression leak i Air leak at inlet manifold j Restriction in exhaust system lc Poor valve seating I Sticking valves m Leaking cylinder head gasket n Worn camshaft lobes o Incorrect tappet clearance p Worn or damaged cylinder bores pistons and or piston rings q Worn valve guides r Damaged valve stem seals s Leaking oil seal or psket t Incorrectly jnstalled spark plug u Cr eked cylinder v Brok...

Page 136: ...ISF1RES ON ACCELERATION AND FAILS TO REV ROUGH IDLE ENGINE RUNS ROUGH AT IDGH SPEED LACK OF POWER POOR ACCELERATION LACK OF TOP SPEED EXCESSIVE FUEL CONSUMPTION PINKING a b c d e f 1 h kl mncpqr PROBABLE CAUSE a Battery discharged or defective b Contact breaker points need cleaning or renewing c Incorrect contact breaker points d Contact breaker spring weak e Spark plugs need cleaning or renewing ...

Page 137: ...t leveL m Carburetter icing n Air leak at inlet manifold o Incorrect grade of fuel p Carburetter accelerator pump defective q Throttle linkage mal adjusted r Incorrect adjustment of idling mixture s Air filter clogged t Incorrect ignition timing u Carburetter piston sticking v Wrong carburetter jets fitted SYMPTOMS b c d e f I h k I m n o p q r I t u I b c d e f g h k I mn o p q r I u REMEDIES a F...

Page 138: ...O ONE SIDE POOR RECOVERY OF STEERING WHEEL TO CENTRE EXCESSIVE OR ABNORMAL TYRE WEAR PROBABLE CAUSE a Tyre pressures incorrect or uneven b Lack of lubricant in steerina par c Lack of lubrication at steerina linkaae ball joints d Incorrect wheel alignment j Replace clutch disc k Fit new parts I Replace cover m Take up play n Renew disc o Replace hub p Renew bearing q Straighten or renew r Top up hy...

Page 139: ...l function in the brake pedal linkage k Unequal tyre pressures I Brake disc or drum distorted or cracked m Brake back plate or calliper mounting bolts loose or looseness in the suspension n Wheel bearings incorrectly adjusted o Weak broken or improperly installed shoe return springs p Uneven brake lining contact q Incorrect brake lining adjustment r Pistons in wheel cylinder or calliper seized s W...

Page 140: ...T FAILS TO a b c d e f g h k I mnopqr ILLUMINATE WHEN IGN S SWI TC H E D O N IGNITION WARNING LIGHT STAYS ON WHEN IGN IS SWITCHED LIGHTS DIM OR WILL NOT ILLUMINATE BULBS BLOW FREQUENTLY AND BATTERY REQUIRES FREQUENT TOPPING UP DIRECTION INDICATORS NOT FUNCTIONING PROPERLY PROBABLE CAUSE a Stiff engine b Battery discharpd or defective c Broken or loose connection in circuit d Starter pinionjammed i...

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Saab 95 Estate, Workshop Manual

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Summary of Contents for 95 Estate

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