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Saab 95 1967, Руководство по обслуживанию

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OVERHAULING WITH A REPAIR

KIT

Disassembly

I.

Unscrew the suction line from the oil

pump.

2.

Unscrew the oil

pump cover.

Remove the inner and

outer

rotor

from

the

oil

pump

housing.

3.

Make a hole in the relief valve cover plate with a drift.

Pull out the cover plate with a suitably sized selftap-

ping screw.

CHECKING

AXIAL CLEARANCE OF

ROTOR

Correct clearance 0.004

in.

(0.1

mm)

2.

Check the clearance between the outer rotor and the

oil pump housing with a feeler gage.

If the maximum

I!

permissible clearance is exceeded, a new pump house

Ii

ing must be used.

S

12“

REMOVAL OF

RELIEF

VALVE COVER PLATE

4.

Remove the spring and the oil

relief valve.

CHECKING

RADIAL

CLEARANCE

OF

ROTOR

Correct clearance 0.012

in.

(0.3

mm)

NOTE

Take great pains to remove all grinding dust from

the parts before assembling. The inner rotor and

the drIve shaft constitute one spare part.

OIL PUMP, DISMANTLED

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

cover

plate

with

the

f|at

side

pointing

outwards. Press It In until

it bottoms out against the

stop.

5.

Using a blunt, round-tipped drift with a diameter of

“assembly

a

out-0.48 In. (12 mm), tap the middle of the cover

plate In order to press it home.

6.

Install the rotors and coat them with engine oil. Put

1.

Insert a new outer and

inner rotor in the pump hous-

th

e

cover

on

the

pump

housing

and

tighten

the

bolts

ing. Check the clearance between the sealing surface

of the pump housing and the front sides of the outer

to the Prescribed toque_

Insert the drive shaft in the

and inner rotor with a ruler and a feeler gage. If neces-

7

rotor shaft and check that the Pump runs easily

sary,

grind

the

sealing

surface of the oil

pump

housing

Install

the suction

""9 With

a

new gasket to

the oil

pump housing.

or

the

rotor

sides

with

a

fine

emery

cloth

on

a

face

plate.

991

-9

m

1077

Содержание 95 1967

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Страница 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...

Страница 7: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 42: ...6 2 2 0 3 3 3 8 2 5 1 3 8 8 2 2 R E S 0 3 5 6 0 5 0 3 0 3 0 3 2 0 0 2 3 8 3 3 8 u o m x m u m m a m n c c 3 0 0 3 3 0 2 c u n t g 3 0 3 3 a O y m n x 33 2 0 8 0 3 0 25m x 8 20 0 3 18 3 08 3 mclmomm 53...

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Страница 50: ...0 0 2 3 2 30 O m 2 m 2 r 1 2 4 H O O r m So w m w u m v a m 0 2 0 2 m awe P c w m _ o 2 0 2 C Z D m w a O 2 0 9...

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Страница 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...

Страница 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...

Страница 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 _...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 140: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 164: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 206: ......

Страница 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...

Страница 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...

Страница 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...

Страница 210: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 262: ......

Страница 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...

Страница 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...

Страница 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...

Страница 266: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 388: ......

Страница 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...

Страница 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...

Страница 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...

Страница 392: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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...

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Страница 414: ......

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Страница 424: ......

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 431: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 442: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 486: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 506: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 542: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 551: ...nil 13...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 610: ......

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