Saab Sonett III Service Manual Download Page 54

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Summary of Contents for Sonett III

Page 1: ...utomotive group TROLLH TTAN SWEDEN Copyright SAAB SCANIA Endast f r spridning utomlands SPECIFICATIONS TROUBLE SHOOTING 0 TOOLS SERVICE MAINTENANCE 1 ENGINE 2 ELECTRICAL SYSTEM 3 TRANSMISSION 4 BRAKE...

Page 2: ...s with the sections where there are differences from the Saab V4 Thus this manual may actually be considered as a supplement intended for use together with the Service Manual of Saab V4 SAAB SCANIA Sa...

Page 3: ...Production Technical Publications Saab Scania Trollh ttan Sweden Printed by Gotab Surte...

Page 4: ...SPECIFICATIONS TROUBLE SHOOTING CONTENTS 010 General 020 Specifications 030 Trouble shooting See Service Manual Saab V4 Nov 1972 SAAB Ilf...

Page 5: ...EXTERIOR SAAB SONETT III Nov 1972 SAAB 010 1...

Page 6: ...o be avoided in the event that the car is subsequently used in a country other than that of regis tration As from model 1972 the chassis number consists of eleven digits Explanation of the digits is s...

Page 7: ...bumpers Overall width Overall height empty Road clearance fully bad Track front and rear Wheelbase Turning radius Curb weight without air conditioning with air conditioning Gross vehicle weight ratin...

Page 8: ...balance shaft bushings Cylinder bore Standard Oversize 0 02 in 0 5 mm Oversize 0 04 in 1 0 mm Diameter main bearing bore Thrust bearing width 600 Vee formation block and crankcase casted in one piece...

Page 9: ...5 in max max 3 76 mm Piston ring play in groove 0 040 0 078 mm Gap in position 0 250 0 500 mm Oil control ring tripartite Thickness total 3 824 3 974 mm Width segment 3 430 3 580 mm Piston ring play i...

Page 10: ...earings Clearance in bushing Balance shaft end float Inner diameter of bushings Bearing diameter of balance shaft Backlash new drive gear Backlash wearing limit 2 front 0 02 0 08 mm rear 0 03 0 07 mm...

Page 11: ...tappet diameter Clearance between tappet and bore 8 063 8 088 mm 0 020 0 063 mm 0 046 0 089 mm 1 46 in 37 mm 1 26 in 32 mm 0 38 in 9 7 mm 0 014 in 0 35 mm 0 016 in 0 40 mm 1 85 in 47 mm 1 06 in 27 mm...

Page 12: ...lts 98 10 0 72 Connecting rod nuts 34 3 5 25 Crankshaft gear bott 49 5 0 36 Flywheel retaining bolts crankshaft 69 7 0 50 Camshaft thrust plate block 20 2 0 15 Bott camshaft gear 49 5 0 36 Cylinder he...

Page 13: ...n the camshaft Feeding pressure 3 4 4 3 lb sq in 0 24 0 30 bar kp cm 2 at 4000 crankshaft rev min Fuel tank capacity 15 8 US gal 60 liters Fuel level transmitter VDO K 221 87 3 3 alt K 221 826 2 6 Exh...

Page 14: ...f teeth on pinion 9 Number of teeth on ring gear 138 Output 0 7 kW 1 0 hp Testing values Mechanic values Brush spring pressure 11 3 12 8 N 40 5 46 oz 1150 1300 p backlash 0 0138 0 0236 in 0 36 0 6 mm...

Page 15: ...length min 16 000 sparks minute 4 000 distributor revolutions Spark length min Primary winding resistance between connections 1 and 15 Bosch K 12 0 55 in 14 mm 0 24 in 6 mm 3 1 3 6 ohnns Spark plugs...

Page 16: ...and a voltage of 13V rev min 5 W 5 rev min 200 W 5 1 2 speed 2400 60 2400 56 1 1 speed 3000 80 3700 96 high speed 3950 125 Windshield wiper motor Model 1970 As from model 1971 Type designation Lucas...

Page 17: ...Bolts Tightening torques Quant Size Nm kpm ft lb Transmission case end cover CO Kt CsJ r e 5 16 25 2 5 18 Differential bearings 3 8 39 4 29 Ring gear bolts 5 16 25 2 5 18 Pinion shaft nut First tighte...

Page 18: ...55 mm approx 3 55 in ca 90 mm 0 16 in 4 mm BRAKE SYSTEM General Make Type front Type rear Footbrake Handbrake Brake fluid Dimensions Lockheed Disc brake Drum brake Hydraulic twocircuit type Mechanical...

Page 19: ...r 0 1 4 Toe in at wheel rim 0 04 0 04 in 1 1 mm Turning angles Outside wheels 20 Inside wheels 22 1 2 1 1 2 Steering gear Steering gear adjustment Pinion axial clearance max 0 005 in 0 12 mm Radial cl...

Page 20: ...h of drop center Permissible out of round of rim see fig A Permissible rim throw see fig B or 4 5 JFHA x 15 1 77 in 45 mm 0 06 in 1 5 mm 0 06 in 1 5 mm MEASURE POINTS ON THE RIM Tires Size Tire prevsu...

Page 21: ...19 Blue Sadolin Holmblad 56197 3044 Orange Nordsj up to and incl model 1972 56197 3045 Yellow Nordsj _ _ 56197 4022 Red Nordsj 56197 6016 Green Nordsj 56191 3044 Orange Nordsj as from model 1973 56191...

Page 22: ...TORQUE M WEREEEE E EE EEEREEIE EEEEEEE EEEEEEE EEEIEWE EEC EM EMEREEE EEEEEEE MEIMEE EM EIEEEEEE EEEEEE eliemEE EEEEEEEN W MIN EEE EEE1 E ME EEE EI EEEEEEER E E E1E EEEEE ENE EEEEEEE mg MEM EE EE MENE...

Page 23: ...ts 101 Special tools 102 Various tools1 Service inspections 110 General 120 Lubrication 130 Washing and polishing 141 Underbody and rustpreventing treatment See Service Manual Saab V4 Nov 1972 SAAB TO...

Page 24: ...this prevents dirt and grit from getting into bearings and other susceptible parts 4 Before removing a spark plug carefully clean the recess around its head 5 One of the basic prerequisites of good s...

Page 25: ...similar jacking point is provided under the rear part of the car where the floor is reinforced This point is located on the center line of the car immediately in front of the rearaxle tunnel Most sho...

Page 26: ...33 in or 237 mm diameter 2 09 in or 53 mm for a manual grease gun and in drums Various makes of manual grease gun designed to take these grease cartridges are available e g Tecalemite model 2840 Ta wi...

Page 27: ...TRIBUTOR LUBRICATING FELT UNDER DISTRIBUTOR ARM The felt pad in the upper end of the shaft under the distributor arm which must be removed first shall be lubricated sparingly NOTE Avoid excessive lubr...

Page 28: ...l SAE 80 to specifica tion API GL 5 1 8 US quarts 1 7 liters Follow instructions on page 120 2 Grease gun Grease gun Steering wheel turned fully to the left Oil can Check intervals of max 3 months Ch...

Page 29: ...ide windows sparingly with vaseline Laying up If the car is to be laid up for any length of time e g during the winter months it should first be lubrication serviced To avoid corrosion and other inter...

Page 30: ...Crank mechanism 217 Oil pan Lubricating system 221 Oil pump 222 Oil filter Fuel system 231 Carburetor Deceleration valve 233 Fuel pump 234 Fuel tank with fittings and fuel lines Inlet and exhaust syst...

Page 31: ...The engine in the Sonett I I I is identical with the V4 en gine installed in the Saab V4 except that it is provided with harder valve springs See the Service Manual for Saab V4 tot ENGINE AND GEARBOX...

Page 32: ...rt ment It absorbs the vapor from the tank when the en gine is not running The charcoal is purged when the en gine is running This is achieved by fresh air which is sucked through the filter in the bo...

Page 33: ...o expand inside the tank instead of being pressed up through the filler pipe 2 As the fuel level becomes lower in course of driving air is drawn inta the tank via the ventilation hose 6 S 2951 FUEL TA...

Page 34: ...th water This tank con sists of a tubular brace mounted between the wheel houses Apart from having a slightly bigger radiator than in the standard version the cooling system is identical with its coun...

Page 35: ...Crankcase ventilation The engine has totally enclosed crankcase ventilation The principle is described in Section 200 in the Service Manual Saab V4 Nov 1972 SAAB 200 5...

Page 36: ...ning the sup port from the induction pipe and pulling out the connection link to the throttle valve shaft 11 Remove the two front engine cushions working from above 12 Back off and remove the exhaust...

Page 37: ...e T pieces of the drive shafts in the inner universal joints Do this with the T pieces located vertically and with the power unit pushed over as far as possible in the opposite direction Assemble firs...

Page 38: ...and reconnect all coolant hoses Start with the lower hose 18 Full the radiator with cooling water and ventilate the system through the venting nipples on the ther mostat housing and heat exchanger Ch...

Page 39: ...transmitter 2 Disconnect the venting tube 3 10 Lift the tank out through the rear lid ELECTRICAL CONNECTIONS FOR FUEL LEVEL TRANS MITTER AND UPPER TANK VENTING TUBE 1 Fuel level transmitter earth wire...

Page 40: ...h Fuel lines The fuel lines consist of the following parts The front pipe mounted on the floor of the engine compartment The rear pipe which is mounted on the floor inside the passenger compartment Bo...

Page 41: ...ubber bushing in the dash panel 4 Refit the rubber wedges and the plate washer 5 F ill up the fuel tank Check the tightness 6 Refit the pedal plate the transmission casing and the seat Replace the wal...

Page 42: ...gaskets must be fitted Tighten the bolts carefully to avoid damaging the flanges Cracks pip es rrluffierr must 1 re 3 cecc or repaired by welding Make sure that there are no residual stresses or perm...

Page 43: ...ent also against the normal di rection of circulation 8 Check the function of the tap in the line to the heater element 9 Ref it the thermostat water neck and hoses Test the system for leaks When clea...

Page 44: ...move the horns 4 Remove the screws holding together the upper and lower front stays Bend the upper stay out of the way to provide access to the upper retaining screws of the radiator 5 Disconnect the...

Page 45: ...tem 341 Ignition coil 342 Distributor 344 Spark plugs 346 Suppression of interference 351 Lighting Electrical equipment other 361 Direction indicators 362 Horns 363 Windshield wipers and washer 364 El...

Page 46: ...s comprise the retractable headlights direc tion indicators flashers and parking lights side position lights number plate lights rear lights with parking lights and back up lights which light automati...

Page 47: ...current intensity through the microswitch will be as low as possible The light relay is so designed that it can also be used for so called high beam signalling but on the Sonett III this possibility c...

Page 48: ...30 5 1 Light May 0 Manouvre teint I i I I 4 5 L J 86 850 87 30 510 86 85 87 30 51 0 86 85 87 03 Ignition lod 0 Bal ttni WIRING DIAGRAM FOR LIGHTING S 3612 SAAB 300 3 Nov 1972...

Page 49: ...nized to give a high penetration signal The Sonett III is equipped with a hazard warning signal switch located in the middle of the instrument panel When the button is pulled out all direction indicat...

Page 50: ...work The wiring connections consist of solderless AMP connec tors Fuses are provided to protect wiring etc from abnormally high current intensities due to short circuits for instance and to reduce fir...

Page 51: ...ed as the rectifier diodes may otherwise be dam aged IMPORTANT The generator must not be run with the battery dis connected The battery cable connections must not be reversed as this will result in se...

Page 52: ...lternator is internally ventilated It has a 12 pole rotor and six silicon diode rectifiers An exciter diode is connected to each of the three stator wind ings with a common grouping point at terminal...

Page 53: ...e rises to 14 V or above the magnetic field of the coil becomes so powerful as to overcome the spring resistance of the regulating contact and break the circuit The current to the exciter winding is t...

Page 54: ...or lights continuously the alternator must be overhauled Removal and installation of alternator 1 Disconnect the battery negative cable Note that the engine must be stopped before the cable is detache...

Page 55: ...replaced See section on Changing brushes 1 Pack the ball bearings with Bosch Ft 1 v 34 grease Press the ball bearing into the housing with the en closed side facing the drive end 2 Press the drive bea...

Page 56: ...aining screws and remove the rotor with the bearing hous ing from the stator 2 Undo both nuts holding the rectifier bridge in place 3 Undo the terminal screw of the connecting wire to the brush unit a...

Page 57: ...UNIT TERMINALS 6 Push up the brushes and secure them with the brush springs Fit the brush unit assembly and make sure that the spring washer is in its correct place in the bearing seat 7 Insert the ro...

Page 58: ...odes is about 50 V Magnetization Unlike a DC generator the alternator does not demagne tize spontaneously after a long period of disuse A 12 V indicator lamp with a power of at least 1 2 2 W must ther...

Page 59: ...e Testing rectifiers with an ohmmeter The rectifiers can also be tested with an ohmmeter In a properly work ing diode resistance is low in the conduct ing direction e g a few ohms but much greater in...

Page 60: ...ts the vacuum advance so that the idling will be faster and the engine cooling will be improved Concerning removal disassembly etc of distributor see Service Manual Saab V4 ARRANGEMENT OF VACUUM ROSES...

Page 61: ...N 14 19 oz 400 530 p 1 Centrifugal advance r min Distributor rev min II Vacuum advance mm Hg Underpressure As from model 1971 S 3549 100 200 400 mm Hg 2000 300 500 1000 0 100 0 4 0 0 1 0 2 Q3 0 4 0 5...

Page 62: ...ove the ring 3 Detach the contact piece and take away the insert Installation 1 Press the contact piece on and fit the new insert making sure that the guide lugs fit into the respective grooves 2 Refi...

Page 63: ...6 Pull the pullrod all the way out and align finely both vertically and horizontally with the headlight adjusting screws See fig 7 Refit the headlight frames See Replacement of headlight insert MARKS...

Page 64: ...45 HEADLIGHT HOLDER 1 Intermediate shaft 2 Taper pin 3 Bushing 4 Pullrod 5 Microswitch 6 Headlight mechanism 7 Tensioning screw 8 Headlight holder Parking stop and back up lights direction indicator l...

Page 65: ...y prizing carefully at one edge with a screwdriver The bulb can then be removed 2 Press the new bulb in making sure that the two fasten ings close snugly so that the bulb sits firmly 3 Refit the lamp...

Page 66: ...rking If one of the flashers fails to operate the warning lamp will not glow and the remaining light will flash more rap idly If the flasher unit is in good condition and correct bulbs are fitted the...

Page 67: ...ear of the horn until a pure note is obtained Signalling device Model 1970 The horns are operated with the lever for the windshield wipers To sound the horn move the lever towards the steering wheel A...

Page 68: ...ND WASHER Both windshield wipers and windshield washer are of the same type as in the SAAB V4 The wiper shafts are how ever attached in a different way and the washer is fitted with two double jets Ju...

Page 69: ...the gearbox cover so that the cover can be turned 2 Adjust to the wanted parking position and tighten the cover Wiper mechanism Removal 1 Remove the wiper arms and the nuts of the wiper shafts 2 Unfas...

Page 70: ...tallation 1 F it the wire of the new wiper motor in the tube It might be necessary to tum n the motor and the wire somewhat anticlockwise to get the wire to enter the gears on the wiper spindles Tight...

Page 71: ...nism will be accessible Detachment of the instrument panel is described in Chapter 8 3 Loosen the two nuts on the wiper spindle of the right hand side Push both the wiper spindles from outside and div...

Page 72: ...e instrument panel Mounted on the instrument panel close to the heater controls is a switch for extra lights These light only when the headlights are switched on at high beam The relay is mounted in t...

Page 73: ...evice has been installed that switches on a warning light and a buzz er if the car is started when the driver s and or passenger s seat belts are not fastened The warning light is located on top of th...

Page 74: ...ng 1 Screw in oil pressure switch and tighten to 12 15 Nm 1 2 1 5 kpm 9 10 ft lb 2 Connect lead 1 Drain off coolant 2 Disconnect lead 3 Unscrew transmitter 1 2 in wrench opening Installation NOTE Smea...

Page 75: ...ermissible voltage drop is 0 1 V Fuses The electrical system is provided with 16 fuses The fuses are located in two fuse boxes one under the engine hood lid on the left hand wheel housing and one unde...

Page 76: ...AKE WARN SWITCH CONN ENGINE BLOCK SPARK PLUG 3 DISTRIBUTOR 9731 HAZ WARN SWITCH RHEOSTAT DIR IND SWITCH WASHER MOTOR AUALIGHT HEAD LIGHT 0461 13CIOIN IN VEI DVICI DNIEIIM FLASHER UNIT 1 775k TACHOMETE...

Page 77: ...56 grey 1 5 30 red 4 0 56a blue 0 75 30a white 1 5 56a white 1 5 301 grey 1 5 56b red 1 5 31 black 0 75 56b yellow 1 5 31 black 1 5 56f blue 0 75 31b brown 0 75 56h yellow 0 75 31b brown 1 5 56s yell...

Page 78: ...RIBUTOR RHEOSTAT DIR ING SWITCH HAL NARR SWITCH TACHOMETER STARTER AUX LIOHT HEADLIGHT WASHER MOTOR B 41 t LIGHT DIR ING RE 1 PEATER LIGHT HIGH EAM IND SPEED METER HT 11111 1 11111 i i I ilLw IL WARM...

Page 79: ...30 red 4 0 56a blue 0 75 30a white 1 5 56a wh ite 1 5 301 grey 1 5 56b red 1 5 31 black 0 75 56b yellow 1 5 31 black 1 5 56f blue 0 75 31b brown 0 75 56h yellow 0 75 31b brown 1 5 56s yellow 0 75 49 b...

Page 80: ...R IND STOP TAIL LIGHT BACK4 11 LICENCE 1 nr RELAY 117z 71 75 j 53 ZL6 L 13CIOIN IN VH DVICI DNI UIM AUX LIGHT LY HEADLIGHT IGN COIL ALTERNATOR VOLT REGULATOR L HEATER FAN STARTER WAGNER MOTOR SPARK PL...

Page 81: ...56 grey 1 5 30 red 4 0 56a blue 0 75 30a vvhite 1 5 56a white 1 5 301 grey 1 5 56b red 1 5 31 black 0 75 56b yellow 1 5 31 black 1 5 56f blue 0 75 31b brown 0 75 56h yellow 0 75 31b brown 1 5 56s yel...

Page 82: ...LUM i I I F 4 4 IGN COIL HEATER FAN CL 6L 13 CIONI INV EIOVI CI DNI EI IM 6 VOLT REGULATOR ALTERNATOR CONN ENGINE BLOCK HORN TACHOMETE L WARN LIGHT CHDGE IND j LIGHT FUEL ING LIGHT FUEL TEMP GAUGES J...

Page 83: ...h III III 412 Clutch operation III III 432 Gear operation Gear box 470 Removal and installation Gear box 471 Disassembly and reassembly 473 Differential and pinion ring gear 475 Universal joints and s...

Page 84: ...ral Clutch operation is hydraulic and comprises a master cyl inder connected to the clutch pedal and a slave cylinder that actuates the clutch The master cylinder is connected to a reservoir which mus...

Page 85: ...er 3 Release the clutch pedal push rod by removing the cotter pin and shaft bolt 4 Release the return springs of the brake pedal and clutch pedal 5 Strike out all slotted pins and pull out the pedal s...

Page 86: ...ston return spring valve spacer elastic washer valve spindle and valve seal The open end of the cylinder is protected by a rubber dust cap When the piston returns to the position of rest the valve whi...

Page 87: ...and if it not scored or distor ted and feels smooth to the touch new seals may safely be fitted If on the other hand the slightest doubt is entertained about the condition of the bore a new cyl inder...

Page 88: ...er body Replace the rubber dust cap or if it is damaged fit a new one Slave cylinder General The slave cylinder is secured to the clutch housing by means of a screw The inner assembly comprises the pu...

Page 89: ...and depress the clutch pedal Close the bleed nipple just before the bottom position and release the pedal Repeat this procedure until all air has been cleared out of the system i e until air bubbles...

Page 90: ...f gear positions Checking Put the gear lever in neutral position Move the lever to the left till you feel that it is touching the spring for the reverse gear catch Move the lever 1 2 measured at the k...

Page 91: ...he cylinder head 10 Remove the throttle control by unfastening the sup port from the induction pipe and pulling out the connection link to the throttle valve shaft 11 Remove the two front engine cushi...

Page 92: ...unit so far that the ou l pan rests against the lower cross member Transfer the left retaining iron of the lifting device to the upper screw for attachment of the gearbox on the left side This facilit...

Page 93: ...pressure and coolant temperature Check the coolant level after running up the engine to the warm condition 22 Refit the rubber boot on the gear shift rod Check that the dash panel is positioned in the...

Page 94: ...512 Replacement of brake linings 515 Brake drums 516 Brake discs 517 Friction pads Hydraulic footbrake system 520 Overhaul brake fl uid 521 Master cylinder 522 Brake lines 523 Wheel cylinders 524 Bra...

Page 95: ...t the front and drum brakes at the rear The Sonett I I I how ever has a different pedal stand and brake fluid reservoir See also the Service Manual for the Saab V4 BRAKE SYSTEM 1 Master cylinder 4 Bra...

Page 96: ...5 Back off and remove the retaining bolts for the master brake cylinder and lift the cylinder out Installation Reinstall in reverse sequence NOTE 1 Cover all openings to prevent the entry of foreign...

Page 97: ...n assistant pump the brake pedal and watch until escaping brake fluid is free of air bubbles Keep the hose ends below the fluid level in the glass vessel the whole time 7 Close the bleed nipples keepi...

Page 98: ...Compress the intermediate spring 18 together with spring holder 20 and drive out the retaining pin 19 using a suitable pin punch This will separate the two pistons 10 and 14 and allows the withdrawal...

Page 99: ...ole 8 Retaining plate 9 Spring 10 Primary piston 11 Rubber bellows 12 Primary cup 13 Piston washer 14 Secondary piston 15 Secondary cup 16 Body housing 17 Clip 18 Spring 19 Retaining pin 20 Spring hol...

Page 100: ...d pull out the pedal shaft 6 Detach the push rod from the rubber boot thereby enabling the brake pedal to be separated from the master cylinder When the pedal is then lifted out it will be accompanied...

Page 101: ...heel alignment Front assembly 631 Steering knuckle housing and ball joints 632 Control arms Steering column shift gear 641 Steering wheel steering column and steering wheel lock 642 Steering gear 643...

Page 102: ...are of exactly the same design as those installed in the Saab V4 The Sonett III however features a steering wheel lock and a leather covered sports type steering wheel See also the Service Manual for...

Page 103: ...g pin inclination Caster Camber Toe in and Wheel turning angles 1 Check that the tire pressure is correct and that the front tires are not too unevenly worn 2 Check the front wheel bearings control ar...

Page 104: ...difference will be 0 The correct setting is 0 04 0 04 in 1 1 mm toe in i e B A 0 04 0 04 in 1 1 mm 0 04 in 1 mm Dimension A should be 0 0 0 08 in 0 2 mm less than dimension B Checking and adjustment...

Page 105: ...ng value of toe in Screw tie rod in or out the following 1 4 turns 7 out 6 out 5 out 0 16 in 4 out 0 12 in 2 3 out 0 08 in 1 2 out 0 04 in J I WIE 1 1 l 0 1 OUt 1 0 01 Correct in value I 2 I I 1 in i...

Page 106: ...cal in which case caster is 0 In the Sonett III caster should be 2 1 2 positive Checking and adjustment If caster adjustment is called for this can be done by inserting shims under the bearing bracket...

Page 107: ...ngles is commenced the toe in must be correctly adjusted To measure the turning angles use is made of two standard type turn tables with arc graduations or optical measuring equipment see fig Position...

Page 108: ...ithin the following limits Camber 0 1 Toe in toe out must not exceed per wheel 0 3 40 both wheels together 0 10 both wheels together measured rim to rim 0 0 28 in 7 mm Max difference in wheelbase left...

Page 109: ...2 0 6 mm with the switch at neutral Adjust the clearance by inserting shims be tween the switch and the column stand F it the return yoke so that its center line coincides with that of the switch hou...

Page 110: ...a screwdriver to loosen the steering column Reassembly 1 Check that the steering wheel shaft bush ings are correctly mounted in the grooves of the rubber bushings Mount the upper bushing in the steer...

Page 111: ...eering wheel The wheel must not be knocked off or on STEERING WHEEL LOCK General The ignition switch and steering wheel lock has four posi tions 0 Locked The key can only be withdrawn from this positi...

Page 112: ...TS 700 Description Suspension 731 Coil spring suspension front 732 Coil spring suspension rear Shock absorbers stabilizer 761 Shock absorbers Wheels and hubs 771 Wheels 772 Tires 774 Hubs See Service...

Page 113: ...e Saab V4 except that different coli springs are used See also the Service Manual for Saab V4 Wheels and hubs See the Service Manual for Saab V4 Rear suspension The coil springs are made especially fo...

Page 114: ...BODY CONTENTS 800 Description 810 Body assembly 820 Hood and engine lid 830 Doors 843 Glass 850 Upholstery and interior fitment 860 Bumpers and grille 890 Body finishing Nov 1972 SAAB...

Page 115: ...the seats The floor is flat and at the sides rigidity is provided by the box shaped sills A roll bar of tubular steel is located between the roof and the partition wall The luggage compartment compris...

Page 116: ...RS S 1212 Body shell repair procedure Materiels Fiberglass matting type 300 g 1 brush Sandpaper coarse Sandpaper fine Acetone Trichloroethylene Plastic of good quai ity e g Soredur H43 containing an a...

Page 117: ...cables from the floor panel 6 Back off and remove the nuts at the rear edge of the rear wheel houses above the silencers one on each side 10 Remove the upper part of the weather strip for the apertu r...

Page 118: ...chment to the dash panel The cover of the heater box must be removed 15 Release the instrument panel see group 8 Pull it out so that the support plates for the instru ment panel are uncovered Back off...

Page 119: ...lly Refit the cover on the heater box 4 Rivet the body on with the aid of a pair of pop rivet pliers at the rear door pillar remaining rivets the upper brackets for the cover plate on the front door p...

Page 120: ...opened by pressing up the lock with a suitable pin through a hole in the right wheel hose See illustrations mod el 1970 only LOCATION OF HOLE MODEL 1970 iffert yamo eme TO OPEN THE LOCK PRESS AGAINST...

Page 121: ...ay attachment to the bumper 5 Back off and remove the screws 5 at the hood attach ment to the body frame 1 screw on each side Note the rubber washers between the hood and the body frame 6 Rennove and...

Page 122: ...the cooling fan will hit the cross bar for the head lights and it may also make a proper head l ight adjust ment impossible CAUTION These blocks must on no account be forced into position since this c...

Page 123: ...2 Refit the washers and hinge nuts to the inside of the door 3 Test cautiously to see if the door fits into the opening Replacement of door hinges 1 Lift off the door see Removal of door 2 Lift off th...

Page 124: ...ary the control rod of the door locking catch can be removed from the door lock REMOVAL OF DOOR LOCK Reinstall in the reverse sequence Before refitting the lock check that all its moving parts and loc...

Page 125: ...This treatment however ruins the lock cylinder and a new one must there fore be fitted Reassembly takes place in the reverse sequence LOCK CYLINDER EXPLODED VIEW MODEL 1970 1 Key 7 Gasket 2 Lock cyli...

Page 126: ...ration strip lightly with a rubber mallet so that its flange enters the groove in the rubber weather strip properly S 2888 8 Refit the windshield wiper arms A Section A A FITTING TOOL VVINDSHIELD Not...

Page 127: ...in and press it firmly into the retainer channel 2 Refit the rear run channel Make sure that the window moves smoothly in the run channels 3 Rivet the plastic door shell on using a pop rivet tool and...

Page 128: ...w retainer channel to the door frame and fill it with a suitable adhesion compound e g Epoxy resin As from model 1971 The joint between the retainer channel and door frame must be sealed with suitable...

Page 129: ...eats The seats are built on a frame of fiberglass reinforced plas tic The seat backrest and head retraint are made as an integral moulding The backrests are provided with an adjustable cushion The sea...

Page 130: ...be allowed to dry but should be removed immediately with cold water Unidentified stains Try the following solvents in the order named Cold or lukewarm water Lukewarm soap solution Before making furthe...

Page 131: ...move the ash tray bracket 5 Detach the heater control wires from the dampers and thermostat valve and remove the headlight control handle 6 Pull the instrument panel out Removal of instrument panel 1...

Page 132: ...on the inside and with a stainless steel bracing strip on the outside Provision has been made on the front bumper for the attachment of I icense plates and additional lights The bumpers is mounted wi...

Page 133: ...ely Do not mix more than you are likely to use with in about four hours The body work must be perfectly dry before you start painting Spraying Spray three times wet on wet at a viscosity of 18 19 sed...

Page 134: ...til the next day allowing about 16 hours for thorough dry ing Drying can however be forced by using the oven after one hour at 80 C 176 F the paintwork will be bone dry and can be pol ished as describ...

Page 135: ...MENTS HEATING SYSTEM ACCESSORIES CONTENTS 900 Description 911 I nstru ments 920 Accessories mechanical 930 Accessories electrical 941 Heating and ventilation system See Service Manual Saab V4 Nov 1972...

Page 136: ...d ventilation controls 3 I nstrument lighting rheostat 14 Ventilator fan switch 4 Instruments and indicator lights 15 Gear lever 5 Combined ignition switch and steering wheel lock 16 Handbrake 6 Winds...

Page 137: ...h off the engine immediately and investigate the cause UPM Tachometer The electric tachometer is coupled to the LT circuit of the ignition system MPH Speedometer odometer and trip meter The speedomete...

Page 138: ...t I ighting rheostat 15 Gear lever 4 I nstruments and indicator I ights 16 Handbrake 5 Combined ignition switch and steering wheel lock 17 Free wheel drive control 6 Windshield wiper and washer contro...

Page 139: ...ut If it lights up when you are driving switch off the engine immediately and investigate the cause UPM Tachometer MPH Speedometer odometer and trip meter The speedometer is graduated in MPH and the o...

Page 140: ...lighting rheostat 14 Cigarette lighter 4 Instruments and indicator lights 15 Gear lever 5 Combined ignition switch and steering wheel lock 16 Handbrake 6 Windshield wiper and washer control 17 Free w...

Page 141: ...gone out If it lights up when you are driving switch off the engine immediately and investigate the cause UPM Tachometer MPH Speedometer odometer and trip meter The speedometer is graduated in MPH and...

Page 142: ...damaged which could cause unwanted noise after instal I ing 1 Back off and remove the four screws holding the instru ment insert Pass the speedometer cable in from the en gine compartment Take out the...

Page 143: ...two jointing pieces mounted one on each side of the radiator A switch is fitted in the instrument panel The most suitable position for installation of the head lamps is in the space provided for this...

Page 144: ...the fan and heat exchanger and on through the damper housing into the passenger compartment The fan and the heat ex changer have separate but communicating c asings The air is warmed up as it passes...

Page 145: ...ve the screws for the heat exchanger cover and remove the cover 4 Back off and remove the retaining screw for the fan casing Disconnect the cables and note their respec tive locations Lift out the fan...

Page 146: ...ger com partment on the left side of the dash panel LOCATION OF THE RMOSTAT VALVE 1 Drain off the coolant 2 Disconnect the hoses from the heater cock 3 Remove the distributor casing for the outlet to...

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