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Saab 95 1967 Service Manual

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Page 6: Table Of Contents
Cars luau: .- . GENERAL Saab 95 MEGS—1975 95753000001 — 95753003018 CHASSIS AND ENGINE NUMBERS Model 19758 95753060001 — 95753061838 assis Model 1976 95763000001 — 95763003838 illustrations below show the locatlons oi the ch orrect identlflcatlon I and engine numbers. To ensure c.
Page 8: Model
GENERAL DATA Model 1967—1968 Monte Carlo Saab 96 Saab 95 13 ft. 13 ft. 14 ft. Overall length, incl. bumpers (4170 mm) (4170 mm) (4270 mm) 5 ft. 5 ft. Overall width 5 ft. (1580 mm) (1580 mm) (1580 mm 4 ft.
Page 9 Model 1969 Saab 95 Saab 96 Overall length, incl. bumpers 14 ft. 13 ft. (4300 mm) (4200 mm) Overall width 5 ft. 5 ft. (1580 mm) (1580 mm) Overall height (unladen) 4 ft. 4 ft. (1470 mm) (1470 mm) Ground clearance...
Page 10 Model 1970 3.9292 14 ft. Overall length, incl. bumpers (4300 mm) 5 ft. Overall width (1580 mm) 4 ft. 10.5 Overall height (unladen) (1490 mm) Ground clearance (2 people front) (130 mm) 4 ft. Track, front and rear (1220 mm) 8 ft.
Page 11 Model 1971 Saab 95 Saab 96 Overall length, incl. bumpers 14ft.1 13ft.9in. (4300 mm) (4200 mm) Overall width 5 ft. 5 ft. (1580 mm) (1580 mm) Overall height (unladen) 4 ft. 10.5 (1490 mm) (1470 mm) Ground clearance (2 people front)
Page 12 5322.99 Model 1972 Saab 95 13 ft. 9 in. 14 ft. (4200 mm) Overall length, incl. bumpers (4300 mm) 5 ft. 5 ft. (1590 mm) Overall width (1590 mm) 4 ft. 4 ft. 10.5 (1470 mm) Overall height (unladen) (1490 mm)
Page 13 Model 1973—1974 Saab 95 Saab 96 Overall length, incl. bumpers (4300 mm) (4200 mm) USA cars: USA cars: 14 ft. (4350 mm) (4250 mm) Overall width 5 ft. 5 ft. (1590 mm) (1590 mm) Overall height (unladen) 4 ft. 10.5 4 ft.
Page 14 Model 1975 Saab 96 Saab 95 13 ft. Overall length, incl. bumpers 14 ft. (4200 mm) (4300 mm) Overall width 5 ft. 5 ft. (1590 mm) (1590 mm) Overall height (unladen) 4 ft. 10.5 (1470 mM) (1490 mm) Ground clearance (2 people front)
Page 15 As from model 1976 Saab 95 Saab 96 Overall length, incl. bumpers 14 ft. 14 ft. (4410 mm) (4300 mm) Overall width 5 ft. 5 ft. (1590 mm) (1590 mm) Overall height (unladen) 10.5 4 ft. (1490 mm) (1470 mm)
Page 16 (USA cars as from No. 53921) Material Aluminium 2 compression and Number of piston rings, on each piston control rIng (tripartite) Permissible difference in weight (piston and connecting rod) in one and the same engine 0.46 oz. (13 g) SAAB 0204 1977...
Page 17 Piston ring groove width: 2030—2.055 Upper 3,030~3.050 4.000~4.020 Center 501 7—5.042 Lower Piston diameter: 89978—90002 mm (The piston is out-of-round and spherical) Standard 90.478—90502 mm oversize 0.5 90373—91002 mm Oversize 00011 in.—0.0024 Piston clearance (0.03—0-05 From the upper side of Piston, removal the cylinder block...
Page 18 Diameter crank pins: 53.98—54.00 Undersize 0.25 53.746—53.736 mm Undersize 0.50 53492—53482 Undersize 0.75 53238—53228 Undersize 1.00 52.984—52974 mm Clearance between bearing insert and crank pin: Standard 0.014—0.054 Undersize 0.014—0.064 mm CRANKSHAFT Crank pin diameter connecting rods Number of main bearings 56.980—57.000 mm Main bearing journal...
Page 19 CAMSHAFT Number of bearings Insert diameter: Front 41.516—41.542 mm Center 41.135—41.161 Rear 40.754-40.780 mm Bearing clearance, all 0.025—0.077 Inner diameter of bushings: Front 41.587-41.593 mm Center 41.186—41.212 Rear 40.805—40.831 "Camshaft end float 0.025—0.076 Spacer thickness: 4.064—4.089 Blue 4.089—4.1 14 Camshaft drive Gear pinion Number of teeth on pinion Number of teeth on camshaft gear...
Page 20 Model 1967 1.85 (47.0 Free length of springs 1.91 (48.5 1.78 (45.2 1.06 (27.0 mm) Fully compressed 1.13 (28.6 1.13 in. (28.6 Load for compression to 1.59 265—294 N 267—302 N (40.26 mm) 175—211 (59—66 lbs., (60—68 lbs., (39—47 lbs., 27.0—30.0 kp) 27.2—30.8 kp) 17.8—21.5...
Page 21 300 rev/min Stage 700—1 rev/min 700—1 rev/min Stage " 2 700—2 900 rev/min 700—2 900 rev/min Stage Nom0.59 i 0.04 in. Nom. 0.59 i 0.04 in. Float level when idling (1511mm) (15i1mm) from gasket level from gasket level re” SAAB 020—6...
Page 22 Model 1969 USA-cars, model 1969 Type FoMoCo CBGH—9510—G FoMoCo C8GH—9510—H Choke Automatic Automatic Main jet Float valve Acceleration pump capacity 0.33—0.45 cu. 0.33—0.45 cu. (5.5—7.5 cm3)/10 strokes (5.5—7.5 cm3l/1o strokes Idling speed rev/min 800—900 rev/ min Fast idling, third step 800—2 000 rev/min 900—2...
Page 23 Model 1977 Model 1976 Type Ford TF—9510—KDA Ford 75 TF—9510—KHA Choke Manual Manual Main jet (Sweden and Finland: 125) Float valve Acceleration pump capacity 0.135—0.256 cu. in. 0.24—0.30 cu. (2.2-4.2 cm3)/10 strokes (4-5 cm31/1o strokes Float level (Distance between the sealing edge of the carburetor housing and the bottom of the float with the valve closed.
Page 24 1976 Saab 95 L and 96 L approx. U.S. gal. (approx. 38 liters) Fuel transmitter: Type designation Saab 95 up to chassis 57.023 Veglia 67—8011 Type designation Saab 95 as from chassis 57.024, up to and incl. model 1975...
Page 25 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 all year round and renewed 2-year intervals. other...
Page 26 Electrical system BATTERY As from model 1971 (LHD-cars) Voltage Capacity 44Ah ALTERNATOR Type, up to and incl. chassis No 95773001663, 96773004488 and 96776001632 Bosch 14v35A20 Type, as from chassis No. 95773001664, 96773004489 and 96776001633 14V55A20 Bosch Rated voltage 14 V Rated speed rev/min...
Page 27 Model 1975— WV 1,1 PS Type designation 0 001 Number of teeth on pinion Number of teeth on ring gear 0.8 kW (1.1 Output Mechanic testing values: 11.3—12.8 N (405—46 02., Brush-spring pressure 150—1 0.0138—0.0236 in. (0.35—0.6 mm) Pinion backlash 0.0985—0.1 18 in.
Page 28 SPARK PLUGS USA-cars (1.7 Up to and incl. As from As from engine No. 59835 engine No. 59836 Motorcraft (resistor) (resistor) Bosch W 225 T35 175 T30 Champion UL 82 Y N—9Y N—11Y NG K BF 6 (12.7 Thread 14 x 1.25 14 x 1.25...
Page 29 Mont Saab 95 §E§b_9_§ BULBS model 1968 meet. SUMO W “ Headlights, Sealed Beam P45t 45/40 W Headlights, asymmetric BAY15d Parking light and direction indicator 21/5W light, front BA15S Stop light and direction indicator BA15$ light, rear Tail light BAY15d —...
Page 30 As from model 1976 991. Effect Saab 95 Saab 96 Headlights, Sealed beam 50/40 W — Headlights, asymmetric 60/55 W P 43 t/38 Parking light, front 15 S Direction indicator light, front 15 S Direction indicator light, rear Tail light...
Page 31 WINDSHIELD WIPER MOTOR As from model 1970 Type designation Lucas DL 3 Output rev/min and current consump- tion. Warm motor, loaded with ev/r'nin (10 kpcm, 8.7 in.lb.) and tension 13.5 V: rev/min 51374, 3P9" 1/2-speed 44-48 awn 1-5 appr. 2.5 1/1-speed eo—7o awn 2-3...
Page 32 Transmission GEAR capacity approx. quarts (approx. liters) Type of Oil EP-oil 80 W (alternatively SAE accordin Gear ratios, total: 1st gear 17.0:1 2nd gear 10.221 3rd gear 6.3:1 4th gear 4.1 :1 Reverse 15.5:1 Differential gear ratio, pinion/ring gear 4.88:1 Number of teeth, pinion/ring gear 8:39...
Page 33 CLUTCH Make Fichtel 8‘ Sachs Type Single dry Plate Clearance, release bearing—clutch measured slave cylinder 0'16 Clearance between release plate and flywheel apprOX- in- (26 mm) Pressure plate springs: 0.94 (23.9 Length compressed 600—660 N (134-147 lb., 61 ~67 kp) Tension when compressed 5-6.5 in.
Page 34 (max. 6.3" (160 mm) stroke approx.) Wheel cylinder: Diameter, front Diameter, rear: 5/8" Saab 96 Saab 95 up to model 1969 518', Saab 95 as from model 1970 3/16" Bundy-tube Brake lines Brake hoses: 81/2"...
Page 35 Front assembly, steering WHEEL ALIGNMENT 711° Front wheel alignment, no load: 211/20 "King-pin" inclination 1° Caster 1/2° 1/3«.~1/2o Camber 3/4 t 1/4° O i 0.04 in. (0 11 Toe-in at wheel rim 0.08 at 0.04 in. (2 i Turning angles: 20°...
Page 36 9 3/4 (250 Extended 15 3/8 (390 Stroke, fitted 1/3 in. (85 mm) Rear shock absorbers Saab 95 Saab 96 and Monte Carlo Arm, hydraulic Telescopic, hydraulic Type Length between centre hole and 10” (255 mm) shoulder for washer 7/16"...
Page 37 Light load 24 psi (1.7 bar, kp/Cm2) Fully loaded 27 psi (1.9 bar, kp/cmz) At full load the tire pressure of the rear tires on the Saab 95 should be 30 psi. (2.1 bar, kp/cm2). Tire pressure figures refer to cool tires. 020-22...
Page 38 Body Saab 96 Saab 95 Body dimensions (approximate): Overall length 12 ft. (3 930 13ft.7 (4160 Overall width 5 ft. 5 ft. Overall height 4 ft. 4 ft. Weight of body: Total (252 (293 Excl. hood, doors, fenders and luggage...
Page 39 l u l l - l l l I - I I I I - l u l l - I I - I - I l u l l - I l l l - I I I I - l u l l - I I I . . . l u l l - l l I l - I l l l - l u l l - I I I .
Page 40 ..II I I I I I I I I I I n I n I I I I I “I. Im-nl I n — u - - I I I - u u n l l n —Im- I I I — “ I I “Ea—E ..—...
Page 84 mshaft They are carried in the cylinder rectly by the c amit the movement to the valves via push CHAN KSHAFT block and trans tappets accessible upon remov. rods and rocker cast-iron crankshaft hardened ground bea- cylinder heads. ring journals. It runs in three main bearings, the middle which also...
Page 85 LUBRICATION SYSTEM pump, relief valve engine lubrication system forced feed type. pump bi-rotor type. shaft connected pressure generated rotor-type pump driven distributor shaft which driven camshaft the camshaft. pump mounted the oil under angle drive. When pump working, drawn crankshaft. pump rotor forces...
Page 86 withaniu..g-c.._, ’ pump is equPPed longer effective when a SUffIC|8ntly filter that pumping ”° ssure been attained. Ml." car. high Dre the fuel passes through a nylon filter housed m The oil filter is made as a unit complete with cartridge.
Page 87 Solex downdraught carburetor. is opened valve which is actuated the filler cap. incl. engine (chassis —434.173 the Saab 96 and Monte Carlo, —46.137 Saab Fuel tank ventilation When fuel is poured in, the tank will not be complete- Iy filled, and instead the level rises only slightly above...
Page 88 (chassis 434.174— for the Saab 96 and certain amount mixed but also drillings Monte Carlo, and No. 46.138— for the Saab 95),the de- early stage emulsion tube, with the fuel at sngnation is 32 PDSlT—4. eatures automatic...
Page 89 Wheel, thus enabling the latter to take up the position de- IDLING SYSTEM Idling Main jet Idling duct Air-regulating screw, idling mixture Throttle valve Adjusting screw. idling Idlin9 fut" 1'“ SAAB 200—7...
Page 90 noun IUD“ "EEK englnihese holes located immediately abOVe Low-speed system carburetor. sition of the throttle valve. As the valve the closed increased from idling, the mixture of To facilitate the transfer from the idling system ‘0 the opening IS.SI-0V;r:W" not only from the idling system but main system, from...
Page 91 High-speed system pressed into the carburetor body. higher speeds ‘ As the fuel passes through emulsion tube, amount avrer loads, fuel supplied determined emulsion mixed with engine through the main system of th fuel passes the main jet before re h‘...
Page 92 hamber cover. From the risgr fitted in the float c pipe which also press-fitted iUct Econostat system leads to the atomiz atomizer pipe place:- the cover. The openin order point where Slight full-load Spezg: mime to receive enough fuel higher neck of the carbure Speed sYstem...
Page 93 Acceleration system and the fuel forced past the ball inlet duct into throat carburetor acceleration injector tube. When 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.
Page 94 CARBURETOR FOMOCO, MODEL 1969—1970 As from model 1969 the car is equipped with a FoMOC0 down-draught carburetor. The fuel feeding is regulated by fixed jets mounted in the carburetor body. Only the main jet removable. In the body there are drilled fuel ducts, and also air ducts.
Page 95 cARBURETOR FOMOCO, MODEL 1971—1975 In order satisfy demands on Cleanin haust gases, engine is eqUipped With Q of-th-e ex. buretor. This carburetor differs from the n emission car. models that made With narrowVersmn in ear. each carburetor has been SUbiected t:;;‘|’;::a;c:s The following descriptions ar retors model...
Page 96 stable float level, needle valve “lumped ensu Float Svnem ed ball. with a spring-load ipped with a valve, Whlch goVEmS The carburetor is equ fuel level the float chamber is governed float chamber. When the throme the ventilation of the float.
Page 97 Starting automatics Automatic choke (Modulating choke) as from carburetor TW—JD USA cars as from carburetor 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 drawn downwards in a cylinder bore and,...
Page 98 receives more air "0m pressure~equalising strictlon,an. laced further down in the neck of the Car- Idling system hole. which I5 Prpose of this is to get the correct rela- buretor. The 9:" fuel and air, before the mixture — via When engine idling,...
Page 99 Main system order for the engine to receive enough fuel higher full-load speeds, the carburetor is provided with vacuum higher speeds and heavier loads, fuel is supplied regulated full-load-enrichment system. The system con- the engine through main system carburetor sists of a piston, which via a channel communicates with...
Page 100 ceases cuapnragm returns When injectio Acceleration system ball closes outlet duct fuei normal p05i again through open inlet fills the accelerating pum throttle valve opens quickly, the air-fuel that?” valve. f the acceleration system, there is _ tends to lean. reason this among...
Page 101 VIEW CARBURETOR,EXPLODED Float chamber Throttle flap 2' Float chamber cover 9. Choke flap Accelerating pump Fm“ Ball and weight, acceleration fuel passage 4‘ Flo-at‘vllW Fuel line connection Mm" I" Float chamber vantiletion Throttle screw, idling mixture ldlinll SAAB 200—19...
Page 102 Choke Float system To facilitate starting when the engine is cold, the carbu. is governed retor is fitted with choke valve Upper part of the The fuel level in the float chamber carburetor throat. As the valve closes, the vacuum below fuel Intake.
Page 103 Idling system. then passes through another constriction additional introduced from pressure equalizing hole, located ttle valve and opens lower down in the throat of the carburetor. of the carburetor This is to ensure a correct fuel-air mixture before the mix- ture passes through mixture control...
Page 104 ensulc W“ "" “ VVVVVV WI”. stem booster S yCluantity at full load. The system comprises a Main system cient fue' which connected carburetor throat piston hrottle valv e by means of a passage. The piste" higher speeds and heavier loads, fuel is supplied jow the t d by the vacuum below the throttle valve.
Page 105 Acceleration system into the throat of the carburetor. When Injection ceases and the diaphragm returns to When :ormal position the ball closes the outlet duct and fuel denc :Z'Ottle Velve ls Opened rapidly pr:;1pthe open Inlet valve once again fills the acceleration the cht trh e fuel‘air flows...
Page 106 (freewheel locked), the vacu- leration During engine dece Deceleration system, cars for the USA as from model f the diaphragm is sufficiently high to acting 1970 and cars for Sweden model 1976 and 1977 the spring, thus drawing the diaphragm exceed the force of This actuates the valve spindle and the valve...
Page 107 CARBURETOR SOLEX, AS FROM MODEL 1977 B Float system The carburetor comprises three main parts: The carburet- The level of fuel in the carburetor is regulated by the cover, carburetor housing throttle section float. bottom. carburetor ‘Stage type. When fuel enters the float chamber, the float will rise, with primary and secondary stages.
Page 108 lant rises. automatic mechanism also of the cm the function of which is to increase Starting system dudes." stepeed during cold starting. The step cam is re- 'dlmg sfneans of a bimetallic spring. A vacuum-regu- The carburetor is fitted with automatic choke to facil- gulated th a m opens the choke soon after starting by...
Page 109 Idling and transition SYStem from idling jet past the idling mixture screw to engine. ensure smooth transition 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 open.
Page 110 the carburetor throat. When the throttle valve in .the pri- Main system mary stage approaches full—throttle posmon, actu. ates the throttle valve secondary stage by-means Under increasing engine speed and heavier loading, the of a lever, thereby bringing the secondary stage into 0p- engine is supplied with a greater quantity of fuel/air by...
Page 111 ‘ 5 \—M A m y / i l ’ t r f f a g g g g g g d "up u : _ , a - s \ \ \ \ \ \ \ \ \ t ‘...
Page 112 | _ r . _ s I/V/IV/ MAIN SYSTEM, FULL-LOAD Spray pipe Throttle valve Emulsion pipe Main Main jet Emulsion pipe Throttle valve Primary stage Secondary stage 200—30...
Page 113 Acceleration system chamber through an inlet valve in the acceleration pump. Pump strokes cause the inlet valve to close, and the fuel When the throttle is opened quickly engine is sup- is forced through the outlet valve at spray pipe into plied with additional fuel by means of the acceleratio throat of the carburetor.
Page 114 function of this valve is to regulate the vacuum in the Booster system vacuum control unit distributor when engine is hot and idling. This will increase the ignition timing, provide additional power high engine speeds and thereby reducing the temperature of the engine. under heavy loads,...
Page 115 CLEANER During model 1972 an air cleaner made of plastic was in- troduced. When altering the preheater position loosen Thehair clleaner is mounted on top of the engine and serves clamp around preheater snorkel turn 2:: to ean the Induction air and as an induction silen. snorkel the desired position.
Page 116 ter distribution pipe to rear part cylin- COOLING SYSTEM (1A: blzgtgng passed the engine, the water flows up by the The cooling system is of positive-pressure type with a cir- by-pass line s'de'Of trig: r(fthe pump. The cooling Jacket of the auto- mostat throug culation pump.
Page 117 uhnl‘nvnvn— L!“ ILA] Semi-enclosed crankcase ventilation The air is admitted through filler cap on the hand valve cover. It passes through the crankcase andJ via a hose the air filter carburetor without passing the air filter insert. TOTALLY ENCLOSED CHAN KCASE VENTILATION Control valve...
Page 118 ustion exhaust emission control system and eva. Comb nit, USA-version EXHAUST SYSTEM porative loss control u satisfy the regulations governing exhaust emission on aust emission control regulations To comply with the exh certain markets, cars intended these markets are in the USA, cars attended this...
Page 119 REMUVAL AND INSTALLATION Back four screws for front panel Removal of power unit detach the two radiator supports from the car body. Detach the clamping straps from the ra- diator remove the control wire. If the entire power unit is to lifted out, see group 4...
Page 120 ION OF Pom" INSTALLAT Disconnect the upper coolant hose from the eng'"e engine compartment Lift thesjgntuztthetr with gearbox. lifting lower coolant hose from radiator. eassem Back off and remove the two |0Wer radiator retam- hookk7fvif: a filtering arbor that the disc assembly ing screws and remove the radiator, and the eXPan' Choc ntered...
Page 121 :l‘uIII— va-I Take out the spark plugs. Remove the oil pressure gauge. DISASSEMBLY OF ENGINE Remove the valve covers. Release the rocker arm assembly by slackening the two bolts alternately Install the engine on a work stand. P P N T ‘ remove rocker assembling and...
Page 122 Remove induction mani nuts. necessary front rear ends with mallet order break seals. screwdriver between “f head. move induction Side Remove bracket Back remove CW" heads cylinder block. lnsp head gaskets signs leakage. wire Remove the tappets with the aid of a keep them in the correct order.
Page 123 “WW” “" Its drive shaft Back off and remove the camshaft thrust plate, re- mOve spacer pull camshaft carefuny out of the bearings to the front. NOTE As the bearings have different diameters, the cam- shaft can only be removed to the front, even if the rear cover...
Page 124 REASSEMBLY OF ENGINE serts position after having Place all bearing 5” [y with engine oil. coated them Iight 7862" $2414 REMOVAL CRANKSHAFT GEAR Tool 62188 Remove the flywheel. INSTALLATION OF CRANKSHAFT NOTE Before removing the flywheel, this item and crankshaft flange must marked relation...
Page 125 NOTE The arrows on center and front main bearing caps must point to the front. Tighten the front and rear bearing ca DS to of 98 (72 ft.Ib., 10.0 kpm). Finger-tighten She bolts for the center bearing cap. NOTE Do not confuse the screws for cylinder heads and main bearings.
Page 126 of sealing compound to the Apply a thin coat washer drive into Install piston together with connecting balance shaft sealin Install washer with using tool 78 62 287 by carefully pressing the piS- block until it bottoms 0 With handle hammer.
Page 127 CAMSHAFT BEARING AXIAL INSTALLATION FLYWHEEL NOTE spacer little thicker than camshaft thrust plate. difference measurement corre- sponds to the axial play in the camshaft. To indi- cate size group, spacers have blue Locate the in the crankshaft. Secure the gear markings.
Page 128 and secure it with the nine retaining 2147 78 6 Hate installation of the water pump, cured to the transmission Turn crankshaft until mark cran boItS- fa“ shaft gear faces the camshaft. the I ‘ ‘ haft so that Pass the camshaft gear onto the cams tailed ark on the crankshaft cover...
Page 129 Install the 0“ pump, Tighten the actual first then suction line bolt. bolts Insert the rubber seal in th bearing cap. e groove in the rear main Apply a coat of sealing compound to the two C joints where transmission Cover, int:- mediate...
Page 130 IMPUH IAN i ctive sealing, the bolts must be tight- Install bracket for the engine side stay. ensure e ges to prescribed torque DIP the push ends engine oil install ened In two Sta push rods in their original positions in the tappets- rice indicated.
Page 131 Install ciutcn atter havin aligned disc with tool 78 40 648. FITTING OF PISTONS Install the carburetor, together wit For fitting of pistons in cylinder bores, a feeler gauge Connect the fuel lines to the carbu fuel pump. Fit the hose clamps_ with a width...
Page 132 FITTING PISTON RINGS redrilled bore Pass the piston rings one by one down into the bore. piston turned upside down that ring takes Proper position. Measure the piston ring gap with a feeler gauge. The cor- rect figures given group the gap is too small,...
Page 133 cYLINDtH HEADS $513” the Cylinder head on the locating sleeves. DISASSEMBLY Ighten the bolts in three stages to the prescribed torque In the indicated sequence. (Engine removed) Ni" king ft.Ib. Remove the air filter. nition cables. p and dlsconnem the Take distributor ‘...
Page 134 ends in engine an arm "man the Dip the 9”“ heir original positions in the tappets, Apply sealing compound the surfaces Of the cy push rodS ends of the rocker arms with engine inder heads indicated illustration 0" page Lubricate return plate rocker arm...
Page 135 VALV I: IVIEUI'IHN ISM Disassembly RocKER ARM ASSEMBLIES Drive the roll pins out of the shaft with a drift. Remove the spring washers, rocker arms, springs and rocker shaft Removal brackets. Remove the air cleaner. Disconnect the ignition cables from the spark plugs and valve cover.
Page 136 VALVE STEM SEALS Installation Install new valve stem seals valve stems. Removal Position valve spring valve spring washers press with tool 279 down the Sprlng,' (Engine installed in the car) Install the valve retainers then relax Sprlng tension. Check that the retainer has adopted the cor. Remove the rocker assembly.
Page 137 Beaming of valve guides After prolonged running, the valve guides become worn rocker side. reaming thereforeovi- work must always be done from the Valve 5 side. size Of reamer to be chosen depends o amount wear gUIde valve oversi available (see depth of the bigger diameters is too large.
Page 138 Valve honing Apply a thin coat of grinding paste to the valve seat and insert the valve cylinder head. Make a few honing passes with tool, carefully clean grinding paste seat check surface with marking dye. necessary, repeat this procedure and also do further DRIVING milling if this should prove to be required.
Page 139 CHECKING THE COMPRESSION PRESSURE VALVE COVER Removal and installation Remove the air cleaner. Detach the ignition cables from the plugs and valve cover. Remove the screws. Lift off the valve cover. If a new gasket is to be installed, press the gasket tabs into the recesses in the cover.
Page 141 TRANSMISSION TRANSMISSION COVER Removal Engine removed (can also be done in the car) Install engine work stand. Remove the alternator and its bracket. (Removed connection with lifting out the engine.) Remove the belt pulley. prevent sludge impurities from entering the engine, the oil pan must always be removed down.
Page 142 195. Place support under short REPLACEMENT BALANCE SHAFT SEAL pump tool flange onto shaft shaft end and Pres figure. refit sealing dimension shown I Transmission cover removed washer. Drive seal, using tool 147. 7862” 57er SEAL, TRANSMISSION COVER REMOVAL Tool 62147 REMOVAL BEARING...
Page 143 Transmission cover mOUnted in car TRANSMISSION GEAR Remove the radiator and, necessary, the front body paneL Clean the transmission cover, NOTE The transmission gears can be replaced separately. Rapidly heat the part of the transmission cover sur- rounding the bearing using a gas torch. backlashes (side play) valid for the transmission gears CAUTION specified...
Page 144 186218 S2414 REMOVAL GRAN KSHAFT GEAR Tool MARKS, TRANSMISSION GEAR INSTALLATION Installation Apply sealing compound mounting surfaces of the transmission cover. Position the gasket. on the insert the in the crankshaft. Tighten the gear transmission cover and center it with tool 78 62 shaft with bolt and...
Page 145 Remove rocker assemblies alternat slackening of the two bolts a ‘ remove nstallatmn turn plates. Remove the push rods keep them cornea 1‘ Llulbricate the camshaft bearings with engine sequence. pass the camshaft carefull into engine block. Remove the CYlinder heads, Pass on the spacer with the countersunk...
Page 146 Connect the water hoses to the water pump, Lightlv oil the pu||ey shaft. Put on the pulley and Turn crankshaft until mark crank— shaft gear faces camshaft. tighten it with a bolt and washer. bber seal 9" Pass camshaft gear onto camshaft that...
Page 147 Install the complete cylinder heads, insert the b and tighten them in the sequence in ‘ 0 ts Install the induction manifold. Tighten the screws nuts with the tightening torque specified group 0. IMPORTANT To ensure effective sealing, the bolts must be tight' ened stages to prescribed...
Page 148 1241 INSTALLATION GASKET VALVE COVER Install the carburetor and gasket. Reconnect the fuel and vacuum lines. Install the distributor cap and attach the ignition cables. Install the air filter. NOTE Retighten the cylinder head bolts and adjust the valves when the car has been driven for about 1,200 miles...
Page 149 LAWN" III I.Ul‘ll"\l\| cRANKSHAFT DisassembIY Install engine on work stand Drain the engine oil, if this done. been down- wards With the engine normal position Remove the pump with its drive shaft. Remove the balance shaft pulley. Disconnect the water hoses from the water pump.
Page 150 Check that the crankshaft runs coolly me uearlng seats. [JUN the connecting reds against the crank webs shaft. bearing caps with inserted and oiled bearing inserts. Make sure that the marks coincide. Tighten the new bolts to the prescribed torque. NOTE very time...
Page 151 Install the oil pump. Tighten the actual pump bolts first and then the suction line bolt. Insert the rubber seal in the groove in the rear main bearing cap. Apply a coat of sealing compound to the two cor- joints where transmission cover,...
Page 152 NOTE Replacement of disc-shaft bushing passes through the ring gear Make sure that the drill into the flywheel. only an Fill bushing with grease. Introduce centering tool into bushing and tap gently with a plastic mallet in order to drive out Place the new ring gear on a plate with thickness Of...
Page 153 Reassembly If n ecessary, clean the Piston ring grooves (using a 2:“ of a worn piston ring). Lubricate pistons, cylinder bores with engine oil. Place p'St°"_"I"9$ in the following manner: Lhe 011 control ring center spring gap 180° from wiihnllk on the top of the piston; the oil segments side of thgaps staggered (25 mm) on either...
Page 154 0.|pan. I'UDILIUII tun. LVVU UUIlS secure the 10‘ "man rear balance shaft with the rubber washers bearing. ASSEMBLY FITTING BOLTS WITH RUBBER WASHERS PISTON Tool Lubricate tappets and their bores with engine install the tappets same sequence as bearings are installed check that the correct...
Page 155 5‘1132. TORQUING CYLINDER HEAD INSTALLATION INDUCTION MANIFOLD GASKET NOTE outer, rear bolt righthand cylinder head is specially adapted for the engine earth cable. Install the induction manifold. Tighten the screws nuts with the tightening torque specified group O. Apply sealing compound to the surfaces of the cyl- inder heads as shown in the figure.
Page 156 Removal Using press, press the piston of the plston POSITION DOLLY (use a drift with a diameter a few millimeters smaller). Scrap the piston and piston pin. Measure the connecting means of a gauge and surface plate. 1977 216—8 SAAB...
Page 157 installationr ensure that the k on the from of the piston and lubricating hole i connecting rod are aligned as shown in the illus tration. CONNECTING POSIT ION PISTON STALLATION MOUNTING POSITION OF THE PISTON Heat the small of the connecting rod to a tempera.
Page 158 onto drive shaft install Slide the oil CRANKSHAFT BEARINGS Tighten the two bolts for the actual with the gasket. suction line bolt. pump first and the Disassembly the groove rear main Insert the rubber bearing cap. Install engine on work stand.
Page 159 Make sure mat crankshaft is Shortl lower dead center (about 300). With Conicity of a crankshaft journal this position, install bearing With insert and Plastigage and tighten the bearin C°"I°ItY Of a crankshaft journal exists if one end of the nuts to prescribed torque.
Page 160 Apply a coat of sealing compound to the two corner REMOVAL hints where the transmission cover, the intermediate plate and the edges of the oil pan meet. Position the install engine work Stand, 0“ Dan gasket block insert tabs prevent sludge ImpUrIties from enterin...
Page 161: Oil Pump
OIL PUMP P95“ the 0“ Dump onto the drive shaft and install Tighten the actual pump bolts first and then the suc- REMOVAL tion line bolt. Install engine work stand. APPIY a coat of sealing compound corner Egg: ghesgggggggugggng l..:::.*::.::::T;:':l:2:::.’r::.:::::d:::e OlntS ‘...
Page 162 OVERHAULING WITH REPAIR Disassembly Unscrew the suction line from the oil pump. Unscrew the oil pump cover. Remove the inner and outer rotor from pump housing. Make a hole in the relief valve cover plate with a drift. Pull out the cover plate with a suitably sized selftap-...
Page 163 I—ll GHANGING OF FILTER CARTRIDGE use tool 52 014 to remove the oil filter cartridge. screw the cartridge. cartridge cannot be cleaned and sh ould therefore renewed at the prescribed intervals (everY 6.000 miles or 10,000 km). Apply a little oil to the rubber gasket on the new cartridge.
Page 165 -— — 9° cOlilnlact the hoses from the automatic choke. Carburetor d 1,968 ke SOIex' models . Disconne urn “he. Ct the throttle control linkage and the vacu- REMOVAL Disconnect the fuel line Remove the carburetor.- Drain some cf cooling wat grburetor PDSIT_4: possnble to remove the...
Page 166 DISASSEMBLY INSTALLATION Remove the retalnlng rlng from the control rod be- Carburetor PDSlT—4Z Bween the automatic choke and the throttle vlave. Fit the intermediate flange, with new gaskets. etach Ilnk from the throttle valve arm. Install new gasket, carburetor tighten Unscrew and lift off the float chamber cover.
Page 167 ADJUSIMENI AUTOMATIC CHOKE Fast-idling adjustment Adjustment of the automatic Choke invol opera. Remove the air cleaner. tions, viz. setting of the choke lights and fast-idling ad- Operate the engine until it reaches normal working justment. These two tasks are described below.
Page 168 Carburetor, make FOMOCO, models 1969—1975 REMOVAL Remove the air cleaner. Detach coolant hoses from the automatic choke. Remove the throttle control. Detach fuel- and vacuum hoses. Remove the carburetor. Cover the orifice of the suction pipe. THERMOSTATlC SPRING HOUSING BOLTS REMOVAL DISASSEMBLY Remove the...
Page 169 WEIGHT, ACCELERATING PUMP FUEL BALL CHANNEL LOCATION FITTED THROTTLE VALVE Unscrew the bolts the accelerating pump cover. Fit the following screws of the idle device: mixture Remove cover, diaphragm spring. control, and idle adjusting. Fit the springs too. Remove accelerating pump rod from the lever of Fit the accelerating...
Page 170 CHECKING AND ADJUSTMENT OF FLOAT LEVEL When checking the measurement A, which shall be (275 mm), hold float chamber cover per- pendiculariy, with a view not to press in the spring. loaded ball of the float valve. When adjusting, bend stop gently arrow.
Page 171 measured amount fuel does w‘th' the stipulaIEd tolerances, adjust the acceleratir't setting by bending or straightening the connectsI pump lever- Bending lever increases 'ng'md Conversely, If the lever is traightened out Iihel-‘acitv. ” capacity is reduced. pump \Q’ U“ Slur ADJUSTMENT OF MEASUREMENTS “A”...
Page 172 mostatic spring housing. See to It that the Fit the ther correct posmon. Setting the chok valve vacuum adjustment spring takes (<38 ~86. this position. mark °at°h W~JB. 71 TW—JC and USA-cs GH—HI pm" Remove thermostatic r‘n step Shall exactly stop throttle valve...
Page 173 USA carburetors 0.08—0.10" (2.0—2.5 mm). Check the opening with drill similar. POSITION STEP CHECKING Adjust by bending the link rod. 5.95m CHECKING THE CHOKE VALVE OPENING I’ tongue. AdIUSI by bending the thermostatic spring lave ADJUSTMENT OF LINK ROD SAAB 231 —9...
Page 174 Setting of the mechanical opening of the choke Valve Checking the automatic choke Open the thrOttle valve fully. This forces the choke (Carburetor installed in the car) valve to open, in the way that an arm (8) on the rattle spindle contacts stop...
Page 175 FAST IDLE ADJUSTMENT engine until reaches normal working tem- perature. Remove the air cleaner. Connect tachometer. Hold the throttle valve shaft and the step cam 50, that the stop dog contacts the mark on the third catch of the step cam. The engine speed shall now be...
Page 176: Model 1971
ball weight Carburetor, make Ford, models Remove the gaske massage by inverting the 1976 and 1977 from the acceleration fue housing. REMOVAL Remove the air cleaner. Disconnect the fuel line, the ventilation hose and the vacuum hose from carburetor. Unscrew the choke control from the carburetor and unhook the throttle cable.
Page 177 EXPLODED CARBURETOR, INSTALLING THE THROTTLE VALVE Float chamber with throttle valve Float chamber cover with choke valve Main Float valve Install idling screw and mixture screw complete Float with springs. Model 1977: After the carburetor Ball weight, acceleration fuel passage Acceleration pump been adjusted, reseal...
Page 178 3lzlmm l.22i0.01o BALL WEIGHT PLACED ACCELERATION FLOAT LEVEL PUMP PASSAGE Fit the carburetor housing with a new gasket and To adjust the distance, carefully bend the lever stop replace the float chamber cover. Insert the bolts at the arrow. The (“Stance can be measured by means mount the choke cable...
Page 179 funny Checking and adjusting of fast idling Using funnel hose connecte to the inlet pipe, fill the float chamber with fuel. Remove the air cleaner. Completely unscrew throttle valv Run the engine until hot and check the idling setting. screw that pump strokes are obtained.
Page 180 Checkin adJUStment eh°ke valve Stop model 1977 modified mixture adjusting screw been introduced which sealed means plastic mzvsigzeocnhthEJEV: limit travel against plug. Before adjustment made, plastic Using drill checlft: Cable braCkét' plug must removed (and thereby destroyed) then Open 0.15 Valvemth.s position replaced,...
Page 181 DECELERATION VALVE, MODEL 1977 (5WEDEN-VERSION AS FROM MODEL 1976 AND usA-VERSION AS FROM MODEL 1970) Removal and installation Remove carburetor. Disconnect the crankcase ventilation hose and remove intermediate flange with the deceleration valve 5530/ DECELERATION VALVE WITH BOTTOM COVER REMOVED Undo the top cover retaining bolts and remove the REMOVAL...
Page 182 valve open, vacuum passing valve, adjusting screw deceleration valve has to screwed further until valve closed. Can. nect hose. deceleration valve working idling speed, will very fast idle 200—1 r/min). possible adjust this normal way. Connect a tachometer adjust the idling speed accordance with the specifications...
Page 183 12:37-73 ' “I” “WW” “5 tl'Om model REMOVAL Remove the air cleaner. 9 3 9 1 9 9 1 » : Disconnect the coolant hoses from the aUtomatic Choke Disconnect the throttle from the carbu rotor. Disconnect the fuel and vacuum hose;...
Page 184 Remove the float lever spindle and remove the float. REMOVING ACCE LE RATIO Remove the acceleration pump cover retaining bOIts and disconnect the linkage between the accelera- REMOV'NG FLOAT SP'NDLE ottle valve lever. Remove tion pump and the thr spring and diaphragm. Remove the bolts securing the throttle valve sec- tion to the carburetor housing.
Page 185 lever float chamber ventilation. From above, push float chamber ventilation carburetor, with soft spring. Then stiffer spring connect push lever. Bolt throttle valve section carburetor housing. Use a new gasket. Connect the control linkage for the acceleration pump system throttle valve lever install...
Page 186 CHECKING AND ADJUSTING OF FLOAT LEVEL Remove the top section of the carburetor if this has not already been done. Twist the top section to an angle Of 45° to the horizontal. Note! not depress the ball at the end of the float valve while measuring.
Page 187 CHECKING AND ADJUSTING OF VACUUM CONTROL (PULL-DOWN) OF CHOKE VALVE Remove the bi-metallic spring housing. Press diaph- ragm vacuum control hold this posi- tion. Turn primary choke valve towards closed position until obvious resistance is felt. By means of a drill, measure the distance between the upper edge of the choke valve disc and the carburetor...
Page 188 HECKING AND ADJUSTING OF THROT'L‘ VALVE ADJUSTING IDLING SPEED AND CO-SETTING DAMPER desagned Checking and adjusting should be made with the engine The throttle valve damp overrun. Cheeking warm, the headlamps switched to low beam and within Of the throme V3 d out with the engine warm and With...
Page 189 ULIZHNtH Checking HERMOS I A ICALL Y REGULA ED A To carry out the following check, disconnect the cold air intake from the valve assembly and observe the position (Sweden-version model 1976 and 1977 USA- of the valve. from model 1970) Vel‘Slon as With the engine switched off and...
Page 190 USA-version, as from model 1970 ‘0 Place flap valve under running water with tem~ perature 82—85°F (28—30°C). Note! The valve should be kept at an angle of 15° against manouvre give thermostat strength to move the valve. HM“ “w ‘5‘ FLAP VALVE HAS MOVED LEFT...
Page 191: Fuel Pump
FUEL PUMP Disassembly Screw off cover and remove the gasket strainer. REMOVAL AND INSTALLATION Make a mark over the flange on lower and upper part of the pump so that they can reinstalled Separate the fuel line from the fuel pump.
Page 192 CHECKING THE FUEL PUMP PRESSU T-nipple and a suitable pres. Apply little grease diaphragm con- carry out this check, Connect up as shown in the nect with diaphragm. throughout the en- sure gauge WI”. spring. figure. Measuring ca Pass lower part pump against the spring...
Page 193 Remove the rear seat cushion and backrest. Saab 95: Remove the sheathing over the tank by un- hooking the two spiral fasteners. Saab 96: Lift out the spare wheel and remove the front part trunk floor.
Page 194 CLEANING FUEL SYSTEM impurities found fuel tank, both tank and line must cleaned. This done emptving tank and flushing it out with pure gasoline or spirit. Make sure that tank horizontal, that impurities foreign matter do not collect at one corner. To flush the. system more thoroughly, remove the fuel gage sender unlt...
Page 195: Inlet Manifold
INLET MANIFOLD Up to and incl. engine No. 91279, the following tightening torques must be applied: REMOVAL Remove the air cleaner. Drain coolant through tap at the bottom 3.9—7.9 2.9—4.9 radiator. (2.9—5.8 ft.lb.) (2.2—3.6 ft.lb.) Disconnect the earth cable from the battery.
Page 196 Install the distributor engine block just it in accordance with the instructions in group 3, section 342. Install the valve covers, with new gaskets neces- sary. Tighten bolts evenly prescribed tor- qua. Install the distributor cap and attach the ignitlon cables.
Page 197: Exhaust System
EXHAUST SYSTEM NOTE Exhaust pipes of later design having interme- exhaust system contains three main parts: from diate suspension, is to equipped with inter: mefmr' exhaust pipe and rear muffler. mediate suspension shown in fig. in connection with changing the exhaust system.
Page 198 CAUTION From this position, possible withdraw right‘ 1973, the guard pipes between spacers were discontinued. During hand pipe through hole the engine compartment front muffler fitted when a muffler is re- floor. These should cars which previously placed. This also applies to had guard pipes- Assembly...
Page 199 REAR MUFFLER Installation Removal Pass the muffler onto exhaust pipe. Don't forget clamp. Jack up the R.H. side car. Remove the rear Fit the muffler bracket wheel house wheel, and loosen the exhaust pipe clamp at the rear wall. muffler. Tighten clamp at the...
Page 200 Removal Exhaust pipes of later design having intermediate sus- pension, are to be equipped with suspension kit 72 85 182. This work is facilitated if the right side of the car Place the mounting 2.36 behind the rear edge jacked uliltz‘Ienthe exhaUS‘ pipe rubber cushions from the right rear Whee...
Page 201 RADIATOR, COOLING SYSTEM ‘8 — Water Warm $1104 Cold COOLING HEATING SYSTEM, UP TO AND INCL. MODEL 1968 Water pump Water jacket, automatic choke Cold-air intake Radiator Heat exchanger Defroster hose Bleeding nipple wheel Water distribution pipe motor distributor Temperature transmitter Side defroster...
Page 202 Water Warm air ‘ Cold air COOLING HEATING SYSTEM, MODEL 1970—1975 Water pump By-pass Cold-air intake Radiator Water jacket, automatic choke Defroster pipe Radiator Heat exchanger wheel Expansion tank Bleeding nipple distributor Pressure trap motor Thermostat valve Side defroster hose Drain valve Temperature...
Page 203 COOLING SYSTEM Cleaning Draining Drain off the water. Flush the system with clean water. Remove filler radiator. from Fill the system with clean water to which a suitable 1969 model, remove also the pressure cap of the ex- commercial solvent been added.
Page 204 Pressure testing is often difficult discover leakage cooling SYS‘ tern, as the pressure system reaches its full value 00W while the car is being driven. One good method avoid damage system under pressure with pres- Remove hood. sure tester, whereupon radiator, hoses seals...
Page 205 WATER DISTRIBUTION PIPE AND WATER HOSES Removal Drain coolant through the tap lower part radiator. Slacken three hose clamps that hoses main on the water distribution tube. Slacken the clamp which h0|ds the water pipes togeth- Remove water distribution tube from engine together with the hoses.
Page 207: Water Pump
WATER PUMP REMOVAL Drain coolant through bottom radiator. Remove the alternator and its bracket and take off the belt. Slacken the water pump bolts, but allow them to re- main the transmission cover. Remove the water pump. INSTALLATION Remove all residual gasket fragments from the gasket surfaces.
Page 208 196 and press with Place housing with tool 196 and Install Pulley tojmp Shaft into pulley respectively in the reverse position on the pressing aid of a mandrel to 81:10 08 in. (0.8—2.0 mm). table. Position the seal press firmly with that protrudes...
Page 209 The thermostat retaining bracket must be perpendi- NOTE REPLACING TENSIONING BELT cular to the longitudinal axis of the car, as other- wise bracket will squeezed water out- ‘ Back off the alternator retaining bolts and remove the let tailpiece. belt. belt tension with...
Page 211 SUNDRIES SERVICE ENGINE Service engines supplied as a spare part will consist of a cylinder block with pistons and axles. These engines will be delivered with provisional plastic plug hole the cylinder block where the hose for the air filter is con- nected in the case of semi-enclosed crankcase ventilation.
Page 212 CONTENTS GENERAL 31 1 BATTERY GENERATOR STARTER IGNITION COIL DISTRIBUTOR SPARK PLUGS SUPPRESSION OF INTERFERENCE LIGHTING DIRECTION INDICATORS HORNS, SIGNALING DEVIC -WASHERS. HEADLIGHT WIPERS AND -WASHERS WINDSHIELD WIPERS AND ND SWITCHES ELECTRICAL CONTROLS A WIRING AND FUSES...
Page 213 The headlight inserts can easily be adjusted both vertical- As from model 1976 all L.H.D. Saab 96 cars are equipped ly and laterally. Lights on/off by means of a switch on with electrically heated rear window. the steering column stand.
Page 214 As from model 1976 all L.H.D. Saab 96 (as from model 1977 even Saab 95 L and R.H.D. Saab 96 L) are equipped with electrically heated rear window. The switch WARNING FLASHER...
Page 215 Inna SPECIFIC GRAVITY OF ELECTROLYTE GENERAL T?’ IDIClIlc utevily of the electrolyte can bu checked I" 'Yl‘lnno-lvilu liyilioniutiii. result them" in‘ battery volt lead accumulator with cell die-m tho chaining cuiidltlun oi the buttery. the working voltage cell being ioughly volt: Tl‘...
Page 216 VOLTAGE CHARGING must adapted capacity aCCUrate test state battery made charglng " by using a cell teste resustance, connected parallel, giving a load of 80—100 The battery is fully charged when 09" voltage amounts amps. volts without load remained constant —...
Page 217 ULI‘hIIl alte Carbon ggaSEJSVTSIres very little maintenance, because Output Current commutators are not needed for the Prescribed -for tconsequence, periodical attention alternatOr shomd b is type of generator. Repair of the most made specialized service garage, portant that disassembly and testing "lade in th...
Page 218 nnected to a ground contact, re- INTERNAL WIRING from ground direct co carriers is located insulated spectively. Between these two The alternator is for internally air-cooled, has a the carrier of the exciter diode. The stator windings are star-coupled (see Wiring diagram)_ 12-pole, fork-type rotor and is equipped with sex silicon The rotor carries the ring-shaped exciter...
Page 219 DEsiuwAi iuni DISASSEMBLY The Bosch designation Of the alternate, 35 A Hold the belt pulley with a suitable tool, and loosen the nut with a 0.87 open end wrench. The meaning of the type designation Loosen the belt pulley. On the drive end plate, mark out the location of the L x 100 = 2 000 r/min...
Page 220 REASSEMBLY RENEWAL OF CARBON BRUSHES Fill —- 222:?er with BF’SCh grease Press Remove brush holder plate, fig, carbon side facing thegdlr?::::;:dme plate, enCIOSEd brushes are going with Detach cable connectionS, Ease the drive heating, then possible to remove the carbon presSing fastengh the rotor.
Page 221 Ital IIIU charge indicator light of 12 V and minimum 2 W must be General FOnnected between terminals 61 and 8+ according to wir- "‘9 diagram. pre-exciting current will then flow through the charge indicator light, D+/61 on the alter- Please note the following points before t esting the alter-...
Page 222 f diodes with OHM-meter Mn an Ohmmeter. Testing 2/3 of maximum output current Similarly, diodes can Switch on battery load the alternator. Adjust the resistance of a good diode very small In the conducting speed to exactly 2 000 r/min. The alternator output must direction (e g a few Ohms), whereas the resistance in the maximum...
Page 223 The alternator requires very little maintenance, be- the Saab 95/96 disc. A new alternator stay introduced cause carbon brushes commutators which interchangeable with earlier design. The alter- needed for the output current.
Page 224 DESCRIPTION INTERNAL WIRING When ignition is turned ignition position, alternator is for internally air-cooled, has a circuit is closed. 12-pole;fork-type rotor and is equipped with six silicon The current goes from ignition lock charge indi- diodes rectification. To each of the three stator wind- cator light, connection...
Page 225 through the resistance and is thus reduced TERMINALS the magnetic field strength diminishes, and witeiiéupon strength of the alternating Current generated in “I: the Output of exciter diodes, connection of regulator Winde' Thus' the mum regulator limits the volte Stator maximum approx.
Page 226 WARNING engine at a higher speed than 2 000 r/min as there is a risk of damage to the power c0n- sumers being caused overvoltage. indicator light goes out immediately, the charging and must be renewed. regulator is defective flashes or lights continuously, the If the indicator...
Page 227 ASSEMBLING Insert the rotor and screw the assembly together. Make length of the brushes must checked before the al sure that the arm bearing housing correctly posi- ternator is assembled, minimum is 0.354 i tioned relative to the slip ring bearing housing.
Page 228 REMOVING BRUSH UNIT ASSEMBLY Disconnect the wires with the help of a soldering iron; DISCONNECT'NG BRUSH UNIT ASSEMBLY M“ brushes then removed. When resoldering the wire connections, make sure that solder flows into the wires. Undo brush unit assembly retaining screws and move assembly.
Page 229 TESTING dicator light of V and minimum 1.2—2.0 W must be COnnected between terminals D+ and 3+ according to Please note the followmg pomts before testing the alter- wiring diagram. The pre-exciting current will then flow nator parts thereof. t"""NJ'SIh the charge indicator light, 0+ on the alternator, aggzsciay only be tested With D.C.
Page 230 Testing alternator parts Testing of stator windings Short Circuit to Ground (diodes unsoldered), Short circuit to ground of stator Winding tested Use only a test lamp not exceeding 24 v or an Ohm-me- usual with test lamp max. ter. Also with diodes connected, short mount to ground Always disconnect the silicon diodes from the stator wind-...
Page 231 STARTER DISASSEMBLY (See fig. overleaf) REMOVAL Disconnect solenoid feeder cable. 9 9 2 ° : - Disconnect negative cable from battery. Remove the solenoid retaining screws. Disconnect supply cable from the solenoid switch. Unhook and remove the solenoid. Disconnect positive cable from starter. Undo the retaining screws from capsule...
Page 232 3481 STARTER, DISASSEMBLED Screws, commutator frame Steel washer Solenoid switch Field Winding Pinion housing Starter housmg Bearing bushing, drive side Armature Protective Rubber washer U-shaped washer Steel washer Shims Engaging lever Rubber gasket Starter pinion Bearing bushing, commutator side Bearing, bushing, starter pinion...
Page 233 Installation Hook solenoid switch in engaging lever and secure With the two retaining screws. Connect supply cable. Test starter. See group 0, Specifications. STOP RING PRESSING CARBON BRUSHES Starter removed Removal Fit the engaging lever arm to the cog engaging ring insert the assembly, together with the rotor Remove the two screws from the capsule bracket.
Page 234 Installation Assembly rotor shaft Lubricate the spiral spli Wire brushes brush plate field silicone grease. winding by soldering. the pinion engaging ring wi lock ring on the Mount the pinion, stop ring brush plate Position. Lift springs with wire hook insert the brushes.
Page 235 IGNITION con. TEST REMOVAL 1. Disconnect leads. Connect test equipment proceed as follows: 1’ Disconnect leads from coil. ter- Measure resistance primary Winding betwee Back off retaining screws and remove coil_ minals Measure coil performance volts mmimetefs of spark length. See group 0, Specifications.
Page 236 UIDI IIqu REMOVAL GENERAL Remove ignition cables from spark plugs. . U ‘ P P ’ N . “ Release retaining springs and remove cap- The distributor, make Bosch, mount rear Remove primary cable. the engine block. Remove vacuum hose. The distributor rotates clockwise and is driv...
Page 237 DISASSEMBLY, UP TO AND IN CL. CHASSIS NO. 49.092 RESP. 453.129 With the aid of two screwdrivers, press away the from centrifugal governor weights. Remove the rotor Remove the lubricating felt, the lock ring and wear- ing washer from the breaker cam. Remove the lock ring and the washers from the breaker arm pivots.
Page 238 breaker plate distributor housing (turn spring with ball toward. Primary terminal.) Screw on retaining spring with (that determines position) primary terminal side. Screw on retaining spring on other side. Fit the fixed breaker point or breaker unit and sert retaining screw without tightening...
Page 239 CHANGING OF BREAKER POINTS. REMOVED 5. Smear the breaker cam and fiber peg with Bosch Ft 1 v DISTRIBUTOR grease. Turn distributor shaft until breaker arm lifted Disassemb'Y way from the fixed breaker POim- a screwdriver between the two adjusting lugs and slot.
Page 240 CHANGING BREAKER POINTS, INSTALLED DISTRI- BUTOR Disassembly Release retaining springs and remove cap. Remove rotor. Disconnect breaker arm lead. Remove clip and washers from breaker pivot (app- lies) to distributors O 231 146 044 and O 231 146 024). .0" PPN.‘ Press leaf spring out of hole in contact support and re- move breaker...
Page 241 Breaker point gap Dwell angle narrow Gap A too wide Gap A correct Angle S too wide Angle 8 too narrow Angle S correct MEASURING DWELL ANGLE Soak the lubricating felt in the distributor shaft VACUUM CHAMBER with oil and fit the rotor. (Distributor removed) Fit cap and secure with the two retaining springs.
Page 242 hose. Disconnect vacu DISTRIBUTOR and check dwell angle at starter Turn on ignitio" idling. Adjust required. and with the ens!In Removal $122k and adjust if required, ignition setting at ’ with engine running max. Remove all ignition cables with rubber protectors s;arter r/mm...
Page 243 CENTRIFUGA VACUUM ADVANCE 044 AND O 146 024 DISTRIBUTOR O 231 Saab 95 up to incl. chassis No. 46137 Saab 96 u incl. chassis 434173 Dwell angle 50 i 2° (400—530 D) Contact pressure 3.9—5.2 istributor rev/min r/min Centrifugal advance...
Page 244 “9 5 3547 CENTRIFUGAL AND VACUUM ADVANCE DISTRIBUTOR O 231 146 033 AND O 146 072 Saab 95 chassis 46138-49092 Saab 96 chassis No. 434171-453129 Dwell angle 1 2° Contact pressure 3.9—5.2 (400—530 p) Cemrifugal advance r/min Distributor...
Page 245 Degrees on distributor shaft 10.00 1500 r/mln CENTRIFUGAL VACUUM ADVANCE 3549 DISTRIBUTOR O 231 146 084 AND O 231 146 092 Saab 95 chassis 65001—95722006000 Saab 96 chassis 520001-96722017000 Dwell angle i 3° Contact pressure 4.9—6.2 (500—630 Centrifugal advance r/min Distributor rev/min Vacuum...
Page 246 Degrees on distributor shaft CENTRIFUGAL VACUUM ADVANCE DISTRIBUTOR 170 031 Saab 95 chassis No. 95722006001 —95752002048. —95753003018. —95756000281 Saab 96 chassis 96722017001—96752015165, —96756007419 Dwell angle i 3° Contact pressure 4.9—6.2 (500—630 Centrifugal advance r/min Distributor rev] min Vacuum advance mmHg...
Page 247 (i two seconds) and the ignition advance should be increased. FaUItV delay valve should be replaced. $3103 WITH DOUBLE ACTING VACUUM CONTROL DISTRIBUTOR UNIT Connection hose from carburetor CHECKING THE DELAY VALVE 2. Connection for hose from the intermediate flange 342-13 SAAB...
Page 248 IGNITION SETTING 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- advance works properly. 342—14...
Page 249 SPARK PLUGS REMOVAL Disconnect ignition cable. Blow cylinder head clean around spark plug Unscrew spark plug. INSTALLATION Screw spark plug hand. Tighten the plug with a torque wrench, 29-39 (3—4 kpm, 22—28 ft.-|b.). Connect ignition cable. TEST Spark plug removed Clean spark plug by sandblasting.
Page 250 REGULATOR INTER FERENCE SUPPRESSION OF INTERFERENCE ference occurs on medium vave band, radio with installation is available as extra equip- regulator inter n filter installed at Bosch suppressio ment. contains installation details suppreSSion regulator. components necessary for normal installation. If the sup- pression components does not work satisfactory the fol- lowing completions may be made.
Page 251 In the R.H.D. Saab 95/96, the ordinary symmetric light, for instance when travelling by changingover from high beam to dipped beam is, how- abroad, asymmetric section masked with...
Page 252 Changing bulbs A headlight bulb normally has full power for the first hours of the burning time. Even if the lamps work longer, light power decreases considerably after this time. order to have as much light as possible, is therefore ad- visable to change the headlight bulbs about once a year.
Page 253 Changing the Sealed Beam unit ChECk the other headlight similar manner. Disconnect the cables from the unit If dimcu'ty is encountered adjusting the beam, Remove the three nuts holding the Chromed check the light distribution on high beam. remove ring. Renew the Sealed Beam...
Page 254 3—3 or more than 4 in. (100 below line 3—3. III! VII/I4 ’II II. ’IIIIIIIII. {5227/ ALIGNMENT OF SEALED BEAM UNITS Center line of car 2—2. Vertical center line headlight 3—3. Horizontal center line of headlight (150 10.5116 (415 351—4 SAAB...
Page 255 HEADLIGHTS, AS FROM MODEL 1969 modify the asymmetric lights so that they produce ordinary symmetric light, for instance when travelling by General abroad, asymmetric section masked with untransparent tape or in some other suitable way. headlights are recessed front panel. left As from model...
Page 256 Changing headlight insert Open hood, pull out bulb connector. Close hood, loosen decor frame screw, remove decor frame. Loosen the four screws which retain the headlight. Lift out headlight along with mounting plate. Slacken the adjustment screws, until they can be PU" out of the headlight insert...
Page 257 Adjustment with beam aligning apparatus Check tire pressures load would normally be loaded and place the car at right angles to the apparatus. Set the lens of the apparatus to the correct height lative to the headlight and to the correct lateral posi- tion...
Page 258 Check the beam of the other light in the same way. Check that the high beam has an even spread. If the light pattern is irregular or if any difficulty is experi- TAIL LIGHT, SAAB 95 enced in setting the dimmed beam correctly, check Stop flasher light that the bulb...
Page 259 FLASHING BACKUP LIGHT TAIL- STOP LIGHT, SAAB 95 FLASHER PARKING LIGHT, FRONT, INCL. MODEL 1977 TAIL LIGHT, SAAB 96. AS FROM MODEL 1978 FLASHER PARKING LIGHT. FRONT. FROM MODEL 1978 3514 1977...
Page 260 INTERIOR LIGHTING General The ceiling lamp and switch are fitted on the ceiling rail. Saab 95 there are two interior lamps, one at the front and one at the rear of the passenger compartment. These lamps can be switched on either with the door...
Page 261 DIRECTION INDICATORS DIRECTION INDICATOR RETURN YOKE GENERAL The clearance between return yoke and projec- tion directional indicator switch should be 0.008- The direction indicators consist of flashing lights at front 0.024 in. (0.2—0.6 with the switch neutral. and rear. At the front, the flashers are combined with the just by inserting shims between the switch and the column parking lights and flash with white or (as from model stand.
Page 263 SIGNALING DEVICE MODEL 1967 SIGNALING DEVICE MODELS 1968 AND 1969 General On the 1968 and 1969 models of Saab 95 and 96, the horn is operated with same lever used windshield wipers and the electric windshield washer. sound...
Page 264 nuts which hold horn contact move SIGNALING DEVICE MODEL 1970—1975 guard reverse order Reassembly takes place '" t removin Removal To remove the sliding contact, commence group the steering whee be detached from the casing 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- undoing the retaining screw.
Page 265 SIGNALING DEVICE, AS FROM MODEL 1976 Removal and installation Remove guard horn contact pulling unit straight from the steering wheel. unit is fitted steering wheel means three spring-fasteners. ELECTRIC CONNECTION DISCONNECTING Installation is made in the reverse order. See also group 6. REMOVING GUARD HORN...
Page 267 WINDSHIELD WIPERS AND MOTOR WIPER .wASHERS, HEADLIGHT Function WIPERS AND -WASHERS In the wiper motor the movement is transmitted to the General operating rods via a gear housing. Current for the wiper motor supplied battery through ignition con- The windshield wiper motor can be set for two wiper tact fuse...
Page 268 -‘.‘1III...I. 20 23 I270 WINDSHIELD WIPER MOTOR, INCL. MODEL 1969 Washer Thrust Limit switch moving contact Self-aligning spherical bearing Bearing retaining ring Yoke Grommet Armature Brush lever retainer Tab washer Field coil Worm gear Rotating output crank Self-aligning spherical bearing Drive bracket play...
Page 269 WINDSHIELD WIPER MECHANISM Removal and installation Left side, L.H.D. cars (Right side, R.H.D. cars) Remove the wiper arm, outer nut and sealings. Remove the combination instrument. This is attached with a bracket and two nuts. The accessibility will improved, if the speedometer is removed. Prize apart the ball joints...
Page 270 CONNECTION AND OPERATION, ELECTRICAL CONTROLS AND ELECTRICAL MODEL 1971 SWITCHES Switch in position 0 As from model 1971, the Saab is equipped for cer- tain markets with a cleaning device for the headlights. lock engaged, voltage available If the ignitio The device consists of a wiper and washer unit driven wiper motor connections 4 and 53a respectively.
Page 271 Switch in position 2 WIPER MOTOR Current goes to the windshield wiper motor (high speed) Removing and to relay via connections 54 and 53b on the switch. The current goes through the coil relay coil Remove the left grille plate (as from model 1974,...
Page 272 WIPER MECHANISM Removal and installation, up to and incl. model 1973 Remove the decor frames the grille plates. Model 1973, remove the plastic cover in front of the wiper mechanism. BUSHING FIXED WITH TENSION PIN, MODEL CENTRAL 1973 Prize apart push from crank...
Page 273 REMOVING PUSH FROM CONNECTING ADJUST'NG LENGTH SHORT PUSH Remove the protective plate, including the central Adjust the tension of the cords by slackening the lock- bushing and the wiper shafts, to the left. ing screw in the retaining bushings for the cords and then moving these order to...
Page 274 Changing wiper blades Remove the circlip from the wiper shaft and Du" the wiper blade. Fit a new wiper blade and refit the circle. 363—8...
Page 275 SPECIAL SWITCHES As from model 1969, back-up light switch has been CABLE CONNECTIONS, IGNITION LOCK troduced in the Saab 95. yellow The switch located by the gearbox and is actuated white the gear shift mechanism. 3. 4 green to Fun. one.
Page 276 beam connected through can- position and the big LIGHTING RELAY grounded through light switch. tact coil lighting relay contains devices for flashing the high beam switching high beam and low beam. Function (see wiring diagram): If the ignition switch light switch are on.
Page 277 9-10 ft.-Ib. Screw in transmitter. (12—15 Nm,1.2—1.5 kpm). P P N . ‘ Connect lead. Connect lead. Fill cooling system with coolant. Run engine until hot and check temperature gauge reading. Check coolant level replenish if necessary. 9‘ Fur m, SAAB...
Page 278 A warning lamp on instrument panel lights If the with electrically heat .0. Saab 96 are equipped with “or, drIver and/or the front seat passenger has not fastened switch heating his seat belt. The following components are included in the warning is placed on the instrument panel.
Page 279 WIRING AND FUSES WIRING The cables and wires lead the current from the battery or generator to the various items of consumer equipment. order protect the wiring reduce the risk shorting, the wires are gathered into harnesses wherever possible, i.e. a number of individually insulated wires are carried in an enc|05ing plastic sheath.
Page 280 Alternator WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1967 Starter motor Battery The range of the electrical system is shown by the wiring Fuse system on the next page. To simplify the identification, Temperature sender the wires have been covered with...
Page 281 DIAGRAM, SAAB 95 R.H.D., MODEL 1967 WIRING 371 —3 March 1979...
Page 282 Voltage regulator mm“ D'AGRAM, SAAB 95 L.H.D., MODEL 1967 Alternator Starter The range of the electrical system is shown by the wiring Battery system on the next page. To simplify the identification, Fuse box the Wires have been covered With...
Page 283 WIRING DIAGRAM, SAAB 95 L.H.D., MODEL 1967 371—5 March 1979...
Page 284 Starter motor WIRING DIAGRAM, SAAB 95 USA, MODEL 1967 Battery Fuse The range of the electrical system is shown by the Wiring Temperature gauge sending system on the next page. To simplify the identification, pressure sw1tch the wires have been covered with...
Page 285 2's" E's} cilia 23:21 «13 €69 — WIRING DIAGRAM. SAAB 95 USA, MODEL 1967 March 1979 371-7...
Page 286 Voltage regulator WIRING DIAGRAM, SAAB 96 R.H.D., MODEL 1967 Generator Starter motor The range of the electrical system is shown by the wiring Battery SVstem on the next page. To simplify the identification, Fuse box the wires have been covered with...
Page 287 ” WIRING DIAGRAM, SAAB 96 R.H.D., MODEL 19 371—9 March 1979...
Page 288 newcomers». was. unguoosl. 1967 State! “mammmsmwmm SysternmdrmxtmTosinuifymeda'lim. Faber: dumlnuebemmedmmirmhwiofdiflm Twew.mm Heaterfa'i mat“ “a III-per m Diection new room “9'15 Black 7.18. 19. 45. 46. 47. 49. 71, 105,109, 125, Him”: 135, 136, 133, 139, 140. "I" m if,“ Red: 5. 21. 28. 2812.23.32. as. 61. 63.155.67.68, 72. 2°...
Page 289 I I-IIIII :é no“? still WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1967 March 1 371—.1 1...
Page 290 Battery WIRING DIAGRAM, SAAB 96 USA, MODEL 1967 “- Fuse box ‘ Temperature gauge, sending unit The range of the electrical system is shown by the wiring Oil pressure switch :33: eosnhthe :ext page. To simplify the identification, Back-up light. switch...
Page 291 WIRING DIAGRAM, SAAB 96 USA. MODEL 1967 March 1979 371—13...
Page 292 Starter WIRING DIAGRAM, MONTE CARLO R.H.D., MODEL 1967 Battery Fuse box ature meter The range of the electrical system is shown by the wiring 13‘ 10‘?lm::rge “Stem °" the 99>“ page. To simplify the identification, ‘t the wires have been covered with insulation of different Back-up light‘...
Page 293 1967 RING DIAGRAM, MONTE CARLO R.H.D., March 1979 371—15...
Page 294 1 1. Battery WIRING DIAGRAM 1967 NTE CARLO Fuse box Temperature meter The range of the electrical system is shown by the wiring gauge SWitc :Zstem on the next page. To simplify the identification, Back luphtlgSWitCh Wires have been covered with insulation different...
Page 295 ODEL CARLO L.H.D., 1967 RAM, MONTE WIRING DIAG March 1979 371—1 7...
Page 296 BatterY WIRING DIAGRAM, MONTE CARLO USA, MODEL Fuse box 1967 Temperature meter Oil gauge The range of the electrical system is shown by the wiring 5‘ Back-up light switch sVstem on the next page. To simplify the identification, Stop light switch the wires have been covered with insulation of different Heater fan motor...
Page 297 1392 late: ~EEE DIAGRAM, MONTE CARLO USA, MODEL March 1979 371—19...
Page 298 Starter WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1968 Battery Fuse ding unit The '3099 of the electrical system is shown by the wiring Temperature gauge, sen system 0" the next page. To simplify the identification, pressure switch the wires have been...
Page 299 " EFTIII? -- l'-i WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 19 371 —21 March 1979...
Page 300 Starter WIRING DIAGRAM, SAAB 95 L.H.D., MODEL 1953 Battery Fuse box The range of the electrical system is shown by the wiring Temperature gauge, sending unit system on the next page. To simplify the identification, Oil pressure switch the wires have been covered with insulation of different Stop light switch shades.
Page 301 ‘ s I ‘ I O © “é l u: "III-lg! .ii.tas. “I m, . 1 - i L." M" 51111! E “i “ Illl team: .— DIAGRAM, SAAB 95 L.H.D. MODEL 1968 WIRING March 1979 371—23...
Page 302 Starter Battery WIRING DIAGRAM, SAAB 95 USA, MODEL 1968 Fuse box 1 I. sending unit Temperature gall The range of the electrical system is shown by the wiring Oil pressure switch system on the next page. To simplify the identification.
Page 303 1 553 ‘ "Elli"; .0 EEEEIE; e’ ".9151?Wll g. WE‘II' xiii -S:I gar i ii Ei__ WIRING DIAGRAM, SAAB 95 USA, MODEL 1968 March 1979 371—25...
Page 304 Batten! WIRIN MODEL 1968 DIAGRAM, SAAB 96 1.19.- T:::p:rature gauge, sending unit ‘ ‘ The range of the electrical system is shown by the wiring pressure SWItCh svstem on the next page. To simplify the identification, stop light SWitCh the wires have been covered with...
Page 305 371—27 March 1979...
Page 306 Starter Battenl WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1958 Fuse box ending unit Temperature gauge, 5 hown by the wiring The range of the electrical system is 5 ntification. Oil pressure switch system on the next page. To simplify the ide...
Page 307 EWEEEEE DIAGRAM, SAAB 96 L.H.D., MODEL 19 WIRING March 1979 371-29...
Page 308 Battery WIRING DIAGRAM, SAAB 96 USA, MODEL 1968 Fuse box 1 1. Temperature gauge, sending unit The range of the electrical system is shown by the wiring pressure switch system on the next page. To simplify the identification, Back-up light switch...
Page 309 "V 1 552 “i "II "l [Ill-Ill! WIRING DIAGRAM, SAAB 96 USA, MODEL 1968 371—31 March 1979...
Page 310 Temperature gauge, sending unit 1 3. WIRING DIAGRAM, MONTE CARLO L.H.D., MODEL Oil pressure switch 1 4. 1968 Back-up light switch 1 5. Stop lamp switch The range of the electrical system is shown by the wiring Brake warning contact 1 7.
Page 311 .“ sessil— WIRING DIAGRAM, MONTE CARLO L.H.D., MODEL 1968 March 1979 371—3:...
Page 312 Temperature Oil pressure swrtch WIRING DIAGRAM DE LUXE USA, MODEL 1968 Back-up light swrtch The range of the electrical system is shown by the wiring Stop light switch sVstem on the next page. To simplify the identification, Brake warning contact the wires have been covered with insulation of different Heater fan...
Page 313 'iiiiiii WIRING DIAGRAM, DE LUXE USA, MODEL 1963 March 1979 371 ~35...
Page 314 Components WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1969 Parkin light and direction indicators The range of the electrical system is shown by the wiring m e e w e w w d Headlights system on the next page. To simplify the identification.
Page 315 4 1 2 .mgz Cf)? ©® '4" 3': In *‘ll f" lIIliIIIl QEEEEEléz'? DIAGRAM, SAAB 95 R.H.D. MODEL 1969 WIRING March 1979 371-37...
Page 316 Co mp0 nents WIRING DIAGRAM, SAAB 95 L.H.D., MODEL 1969 ht and direction indicators parking "9 The range of the electrical system is shown by the wiring Headlights system on the next page. To simplify the identification. Horn wires have...
Page 317 MODEL 1969 WIRING DIAGRAM. SAAB 95 L. H. 371—39 March 1979 an“...
Page 318 WIRING DIAGRAM, SAAB 95 USA, MODEL 1969 ght and direction indicators Parking Ii The range of the electrical system is shown by the wiring Headlights P P N 9 S n P w M a symm 0" TI '9 "ext page.
Page 319 =EEEEEEIEE'u aggrim ‘ giamaaama Emu—Ill “‘ “i “W 45% ‘E ‘5‘ k“ WIRING DIAGRAM, SAAB 95 USA. MODEL 1969 March 1979 371—41...
Page 320 Components WIRING DIAGRAM, SAAB 96 R.H.D., MODEL 1969 d direction indicators Parking light 3" Headiights The range of the electrical system is shown by the wiring system on the next page. To simplify the identification. Horn the wires have been...
Page 321 “can m _ _ _ J s I MO when QEEBEEBE . Em DIAGRAM, SAAB 96 R.H.D.. MODEL 1969 WIRING March 1979 37143...
Page 322 Components direction indicators WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1969 Parking light and Headlights The range of the electrical system is shown by the W'r'"9 Horn system on the next page. To simplify the identification, ignition 60“ the wires have been covered with...
Page 323 'E” ééiflg‘giéii iijiiiiiEJ‘ g fea may? r“ “W — WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 371—45 March 1979...
Page 324 Components WIRING DIAGRAM, SAAB 96 USA, MODEL 1969 nd direction indicators Parking light a w s w w e w p a Headlights The range of the electrical system is shown by the wiring system on the next page. To simplify the identification.
Page 325 ” E" ‘_ a“ ii a tilts-ts ” ¢ .'" “a. 371—47 March 1979...
Page 326 Components WIRING DIAGRAM, LUXE USA, MODEL 1969 Parking light and direction indicators Headl 59h“ The range of the electrical system is shown by the wlrlng system on the next page. To simplify the identificatlon, Horn the wires have been covered with insulation of different Ignition coil...
Page 327 Willi 5‘ 1969 WIRING DIAGRAM, DE LUXE USA, MODEL March 1979 371 —49...
Page 328 WWW” WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1970 Parki light and direction indimmrs The range of the electrical system is shown by the wiring Hmwm 9 1 9 9 8 9 9 1 9 9 . ” ? system on the next page. To simplify the identification.
Page 329 'Ijzé-s mm ii ‘Fagéii WE'RE-[iii] III! Asaaeai as am W.“ ‘2“ ‘0 WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1970 March 1979 371—51...
Page 330 Components WIRING DIAGRAM, SAAB 96 L.H.D..'V'ODEL 197° Parkin light and direction indicators m u m g i - t h d Headlil»!hts The range of the electrical system is shown by the wiring Horn system on the next page. To simplify the identificat'on'...
Page 331 Emmmw In: 5111111111111 .5-5 iii? WlRlNG DIAGRAM, SAAB 95 L.H.D.. MODEL 19 371 —53 March 1979 -‘ ‘n...
Page 332 Components WIRING DIAGRAM, SAAB 95 USA, MODEL 1970 ction indicators Parking light and dire The range of the electrical system is shown by the wiring Headlights O p w w e w e w w d system on the next page.
Page 333 ‘ 3’. til? mamas {sesame " :JEE'! a? "A age: ‘ 115% — v_“ WIRING DIAGRAM SAAB 95 USA MODEL 1970 371 —55 March 1979...
Page 334 WIRING DIAGRAM, SAAB 96 R.H.D., MODEL 1970 “eh direction indicators Parking The range of the electrical system is shown by the wiring S O P N Q V I ‘ w a r ‘ system on the next page. To simplify the...
Page 335 5 7 ‘ $1 “I "N miiI In "iI E111111111111 1" ‘ Hil— WIRING DIAGRAM, SAAB R.H.D., MODEL 1970 March 1979 371—57...
Page 336 Components WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1970 Parking light and direction indicators The range of the electrical system is shown by the Wiring Headlights system on the next page. To simplify the identification, Horn the wires have been covered...
Page 337 “m iijiiii MODEL 1970 DIAGRAM, SAAB 96 L.H.D WIRING March 1979 371-59...
Page 338 Comlm'“ants WIRING DIAGRAM, SAAB 96 USA, MODEL 1970 Parkin light and direction indicatOrs Headlights range of the electrical system is shown W the Wmng Horn system on the next page. To simplify the identificatlon: Ignition 00“ the wires have been...
Page 339 I—rmi‘l—llil e.e: 371—61 March 1979...
Page 340 WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1971 tion indicators Parking light and direc Headlights range of the electrical system shown W'r'ng Horn system on the next page. To simplify the identification. Headlight wiper motor the wires have been covered...
Page 341 J iii D., MODEL 1971 WIRING DIAGRAM, SAAB 95 R. H. 371—6 March 1979...
Page 342 Component; WIRING DIAGRAM, SAAB 95 L.H.D., MODEL 1971 irection indicators Parking light and d wiring Headlights 9 9 9 ° “ ? ? ? n g The range of the electrical system is shown by the Horn system on the next page. To simplify the...
Page 343 Iii! EEIEEEEE "jiiiii liIilli mm iiiiiiiiiiigija 371 —65 March 1979...
Page 344 Components WIRING DIAGRAM, SAAB 95 USA, MODEL 1971 ght and direction indicators Parking Ii wiring Headlights The range of the electrical system is shown by th identification, Horn system on the next page. To simplify the Ignition coil the wires...
Page 345 mmmi “4 n» 4% me 5= . . j {55.35, ‘ 371—67 Map-d. «nan...
Page 346 WIRING DIAGRAM, SAAB 96 R.H.D., MODEL 1971 ection indieators Parking “9” and dir The IWIS!!! Of the electrical system is shown by the wiring deiigh“ system on next page. simplify the identifieation. Horn the wlres have been covered with insulation of different Headlight mm“...
Page 347 . ._ .551. MEEF reiterate: ‘9 ESP?“ E % iiii,i%l, L WIRING DIAGRAM, SAAB 96 R.H.D.. MODEL 1971 March 1979 371—39...
Page 348: Parking Light
Component! WIRING DIAGRAM, SAAB 96 L.H.D., M0051. 1971 and direction indicators Parking light The range of the electrical system is shown by the wirlng Headlights m g ‘ a s n r h u w d svnem next page. simplify the...
Page 349 33 m WIRING DIAGRAM, SAAB SEDAN L.H.D.. MODEL 19 371 —71 March 1979...
Page 350 WIRING DIAGRAM, SAAB 96 USA, MODEL 1971 Cami” Parking light and direction indicators The range of the electrical system is shown by the wiring Headlights sVstem on tne next page. To simplify the identification, Horn the wires have been covered with...
Page 351 Etna-mil reiterate .— 4 In. WIRING DIAGRAM. SAAB 96 USA, MODEL 1971 March 1979...
Page 352 OF WIRIN AND DETAIL Sca' heating e 1972-197:i DIAGRAM’ SAAB 95 RJill. MODEL 51. 8-pin connector 3—pin connector 2-pin connector “911:3, :fmmbggeml SVstem is shown by the wiring 54. 1-pin connector Back-up llght contact Back-up lights AlternatOr 3’...
Page 353 3 ' or. I E : 1&an DIAGRAM, SAAB 96 R.H.D., MODEL 1972—1974 WIRING March 1979 371 ~75...
Page 354 Fuse holder WIRING DIAGRAM, SAAB SEDAN L.H.D., AND Headlight wiper mo Headlight wiper motor relay DETAIL OF WIRING DIAGRAM SAAB STATION 20- Seat heating element with thermostat WAGON L.H.D., MODEL 1972-1973 8min connector The range of the electrical system is shown In! the wiring 3—pin connector...
Page 355 "mm RING DIAGRAM, SAAB 96 L.H.D., MODEL 19 72—1973 March 1979 371 —77...
Page 356 8-pin connector WIRING DIAGRAM, SAAB USA AND DETAIL OF 3-pin connector WIRING DIAGRAM, SAAB 95 USA, MODEL 1972-1973 2-pin connector 1-pin connector range of the electrical system is shOWn wiring Back-up light contact system on the next page. Back-up lights...
Page 357 1'" DIAGRAM, SAAB 96 USA. MODEL 1972—1973 RING March 1979 371—79...
Page 358 Washer motor WIRING DIAGRAM, SAAB 96 L.H.D., AND DETAIL Fuse holder WIRING DIAGRAM, SAAB 95 L.H.D., MODEL Headlight wiper motor 1974 Headlight wiper motor relay Seat heating element With thermostat The range of the electrical system is shown by the wiring...
Page 359 l a w m a n ! “ Iii? y. “ MarCh 1979 371—81...
Page 360 Headlight Wiper ‘38? WIRING DIAGRAM, SAAB 96 R.H.D.. AND DETAIL OF WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 8-pin connector 1975 3-pin connector 2-pin connector The range of the electrical system is shown by the wiring 1-pin connector ‘ system on the next page.
Page 361 WIRING DIAGRAM. SAAB 96 R.H.D., MODEL 19 371 —83 March 1979...
Page 362 Direction indicator repeater light Instrument panel illumination Dome light Door contact, interior lighting Trunk light Trunk light contact Wiper system switch Windshield wiper Washer motor Fuse holder Headlight wiper motor $3310 9:7;AIL OF WIRING DIAGRAM, SAAB es L.H.D., MODEL 371—84 March 1979...
Page 363 ‘ H“ “I'M-i — I--ll---—'I.I;J‘f— 132323233211 WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1975 371 ~85 March 1979...
Page 364 3-pin connector WIRING DIAGRAM, SAAB 96 R.H.D., AND DETAIL 2-pin connector OF WIRING DIAGRAM, SAAB 95 R.H.D., MODEL 1-pin connector 1976 12—pin connector Resistance, dimmed lIght Service outlet, ignition Battery Warning light, choke P P N P ’ W P P I " ?
Page 365 ; m “as. WIRING DIAGRAM, SAAB 96 R.H.D., MODEL 1976 March 1979 371—87...
Page 366 1-pin connector WIRING DIAGRAM, SAAB 96 L.H.D. AND DETAIL 12-pin connector WIRING DIAGRAM, SAAB L.H.D., MODEL 1976 Seat belt warning light Seat contact range of the electrical system shown the wiring Belt contact, system on the next page. Belt contact,...
Page 367 WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1976 March 1979 371-89...
Page 368 Windshield wiper motor Washer motor 22 2513 Fuse holder Headlight wiper motor Headlight wiper motor relay w“ Seat heating elements with thermostat 81M connector 1:;A'L OF WIRING DIAGRAM. SAAB es L.H.D., MODEL 3-pin connector 2-pin connector 371—90 SALE: Marnie 1 070...
Page 369 WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1977 371—91 March 1979...
Page 370 Wiper and washers system switch Windshield wiper motor 22 2513 Washer motor Fuse holder Headlight wiper motor Headlight wiper motor relay Seat heating elements With thermostat WI RING DIAGRAM, SAAB 95 L H 0., MODEL 371—92 Morph 1979 A——...
Page 371 S 5769 1.911 E-m:--—JH. WIRING DIAGRAM, SAAB 96 L.H.D., MODEL 1977 8 March 1979 371.93...
Page 372 Headlight wiper niului ielnv WIRING DIAGRAM SAAB 96 L.H.D. MODE LS 1978 heating elements with Him iiiosiai 1979. AND DETAIL OF WIRING DIAGRAM mm Lonniicloi SAAB 96 L.H.D. MODEL 1978 52‘ 3.pin coiiiioctm The range of the also“ It»! system...
Page 373: Model 1975
WIRING DIAGRAM, SAAB 96 L.H.D.. MODELS 1978 AND 1979 371 —95 March 1979...
Page 374 CONTENTS GENERAL CLUTCH CLUTCH OPERATION GEAR REMOVAL, INSTALLATION DISASSEMBLY, REASSEMBLY DIFFERENTIAL AND PlNION/IRING GEAR UNIVERSAL JOINTS AND SHAFTS Febr 1977 SAAB...
Page 375 GENERAL clutch shaft is a ball bearing with radial clearance clutch cover locked axially means of retaining rings. CLUTCH Axial guiding of the clutch shaft is provided for by this bearing. The pressure plate is pressed against the clutch clutch single dry plate type, comprising...
Page 376 TRANSMISSION SAAB 400—2 Enh— 1&11...
Page 377 to the engine means of a clutch housing of light Syn chronizer unit alloy, which also encases the differential. All gear wheels, except reverse gear wheel, helical con- synchronizer unit functions as described in the fol- stant mesh with another. lowing: Shaft borne gears are either carried on needle bearings or When...
Page 378 — the primary shaft — is able to rotate faster than the clutch shaft. The freewheel is equipped with a blocking device by means which completely locked. DIAGRAMMATIC ARRANGEMENT OF FREEWHEEL Clutch shaft Roller Freewheel Coil spring Freewheel sleeve 400.4 SAAB «(117...
Page 379 CLUTCH DISASSEMBLY AND REASSEMBLY REMOVAL Before disassembling the pressure plate assembly, mark parts order ensure reassembly same Lift engine car, section 201. lative positions. This important view clutch bal- Slacken successively back off the bolts holding ance. pressure plate assembly flywheel.
Page 380 Remove the clutch release levers from the clutch cover. Reduce slowly the pressure press. Remove the clutch cover from the pressure plate. ATION CF FAC'NG “NETS Remove the clutch springs. Reassemble in the reverse order. having fitted new facings. the clutch disc should check with the aid...
Page 381 CLUTCH OPERATION ADJUSTMENT OF CLUTCH PEDAL FREE MOVE- MENT Up to and incl. model 1968 The clearance between release bearing and release plate gradually decreased by wear on the clutch facings. Ad- REMOVAL AND INSTALLATION OF CLUTCH PEDAL just the clutch pedal free movement with the screw on the clutch housing.
Page 382 RemOVal MASTER CYLINDER hose from slave cylinder pump out Detach clean vessel. General fluid into from clutch pedal remov. Separate the master cylinder cast unit containing the cylinder ‘ cotter, plain washer :19; off and remove the retaining bolts and remove fluid reservoir.
Page 383 pains are not taken to prevent it. Seals of natural rubber SLAVE CYLINDER highly susceptible, even minute quantities gradually cause considerable swelling. slightest General trouble in this respect is suspected, fit new seals through- out the system flush system clean with pure The slave cylinder is secured to the clutch...
Page 384 RELEASE BEARING Removal and installation car, section 201. Lift the engine 0 ever forward remove Turn the clutch l release bearing in the fork, clips retaining _spr ing SLAVE CY LINDE R, DISASSEMBLED Push Spring Rubber dust Cylinder body Lock ring Bleeder screw...
Page 385 As from model 1969 MASTER CYLINDER General REMOVAL AND INSTALLATION OF CLUTCH PEDAL The master cylinder consists of a cast body with a fluid Remove the protective cover of the steering wheel container of plate enclosing the cylinder housing. shaft. operating unit consists of the following main parts: push Remove the cotter washer,...
Page 386 Fit the push into cylinder, followed the Wash. lock ring, placing latter Cylinder hous. ing groove. Refit the seal bellows, or fit new ones if the old ones are damaged. Installation Disassembly Install master cylinder position. Attach the push rod to the clutch pedal inserting Ease the rubber dust cap back and remove the lock ring,...
Page 387 Disassembly BLEEDING THE MASTER CYLINDER AND SLAVE CYLINDER Ease the dust back remove the lock ring, using [ong nosed pliers. piston with seal attached Connect a hose (internal diameter approx. 0.25 removed, followed by the spring. Examine cylin- mm) to bleeding nipple of the slave clender- Place der bore and not scored or distorted, and...
Page 389 Back off the four screws for the front panel REMOVAL, INSTALLATION detach the two radiator supports from body. Detach the clamping straps from the ra- REMOVAL diatcr and remove the control wire. Bend upper bracket expanSIon tank If work is to be done on the transmission unit only, the backwards so that the headlight washer motor entire power unit must be lifted out.
Page 390 Disconnect the upper coolant hose from the en- Attach the lifting hook suitable hoist and lift lower coolant hose from radiator. the engine carefully about mm). Pull Back Off and remove the two lower radiator retain- transmission pin out of the rear engine bracket, I99 screws and remove the radiator and the expan- Open up the inner universal joints, first on the right SIOI'I...
Page 391 INSTALLATION Refit the air cleaner. Refit the radiator and the expansion tank. Connect Check that the inner universal joints are filled with the lower coolant hose before tightening the two appropriate grease. joints must comple- lower retaining screws. tely filled with grease upon assembly. Connect the upper coolant hose.
Page 393 DISASSEMBLY, REASSEMBLY Differential and freewheel DISASSEMBLY NOTE Proceed step by step as described in the following until Before continuing to dismantle the transmission unit, the part concerned has been removed. always check the location of the pinion and measure Clean outside transmission unit...
Page 394 Note the location of shims In the cover and collect the shims. Take care to prevent ejection of the poppet ball: in the gear shift forks. DISASSEMBLY REASSEM BLY FREEWHE Tool DISASSEMBLY COVER AND SHIFT FORK RAILS 471-2 SAAB Febr 1977...
Page 395 If only the rear pinion shaft bearing is to be re- moved, this can be done now as follows: Engage gears (reverse 3rd), release retainer back off the left hand threaded and nut on the shaft whereupon the bearing can be removed with the aid of puller 78 41 As from transmission...
Page 396 Primary shaft with bearings and gears Remove the left hand threaded from shaft and pull out the rear pinion shaft bearing With Back primary shaft remove the puller, tool 78 41 158, using the front press retaining washer. screw support shaft.
Page 397 Press the pinion shaft out in the The bearing should on no account be taken apart, drawing the shaft at the same ti is to refitted. it that the rollers do if necessary: fall refit retaining ring immedi- ately, expanding it first so that it springs proper- IV in the groove.
Page 398 Then press the bearing in, as described above. Fit a new tabbed washer and lock nut (NOTE! Left hand threaded) on the pinion shaft. Note that the should tightened until primarv- and counter shaft installed. position 7841 000 lelNG PINION SHAFT Tools 471—6 SAAB...
Page 399 Primary shaft with bearings and gears incl. gear 276503: Refit the front bearing (using tool 78 41 075) and place the retaining ring, locking pin, thrust washer and 4th speed gear needle bearing on the primary shaft. Check that the locking pin prevents the thrust washer from rotating.
Page 400 Countershaft with bearings and gears NOTE Place the countershaft [f the countershaft refitted complete with reverse gear bearing, use tool 091. This tool is al- used reverse gear seat with bearing are mounted separately. Reassemble the 1st and 2nd Engage two gears simultaneously, e.g. 2nd and 4th, and turn the 3rd speed gear...
Page 401 Gear shift forks Check that the rubber washer and plastic PM? have Return the synchronizer sleeve and t been mounted in the end cover and the oil collector he reverse in the transmission case end. neutral position insert gear gear shift forks.
Page 402 nction of the gear shift mechanism, Check the fu Differential freewheel undamaged Check that th erted in the primary shaft/ needle bearing are Ins Refit the differential assembly spacers, hub should engage firmly freewheel sleeve. The tighten the bearing cap screws with a torque of tool 87 90 305 when twisted to the right.
Page 429 INNER DRIVE SHAFT Tool If the seal steering knuckle housing been removed, insert a new one. Pack the ball bearing with Saab Special Chassis Grease. Use only original ball bearings. Press the bearing into steering knuckle housing with the numbered...
Page 430 If the needle bearings have been removed, lubricate them with Saab Special Chassis Grease “mum them their journals. cover pro. tection for the needle bearings and pass the driVe shaft in through the wheel house.
Page 432 CONTENTS GENERAL BRAKE SHOES BRAKE LININGS BRAKE DRUMS BRAKE DISCS FRICTION PADS HYDRAULIC FOOTBRAKE SYSTEM MASTER CYLINDER BRAKE LINES WHEEL CYLINDERS BRAKE OPERATION HANDBRAKE SYSTEM s“, 19,,...
Page 433 GENERAL The mechanical handbrake acts on the rear wheels. brake lever is located between the two front seats and The car has disc brakes front and drum brakes at rear. braking effect is transmitted to the rear wheels by two hydraulic footbrake acts on...
Page 434 FUNCTION between pistons determined Spiriil spring wire clamp. semndary piston primary uép When the brake pedal is depressed, the master cylinder secondary cup at front rear respectively. rtteo pistons apply a force to the brake fluid, which is trans- behind the primary cup is a dished...
Page 435 MASTER CYLINDER, SECTIONED, LHD MODEL 1969—1970, MODEL 1969 No. 96722017570, 95722006474 $3.5 vvvvvv Iii/1.121114%”, WI" kE_I|— 3;..le 5.37%.:ng " / 5 591 3 MASTER CYLINDER LHD AS FROM MODEL 1971 SAAB March 1979...
Page 436 "Illll: Illll’l--.'-"-’l-ll"'.'l"llll’: ‘ ‘ 'ii: ‘ MWMW IIIII %E,EJ ll]! \“\*§s‘\\\\\\\\\“\\m\\\\\\\. S7076 MASTERCYLINDER FROM CHASSIS 96722017571 95722006475 FRONT WHEEL BRAKE braking forces to the knuckle housing. The brake body assembly is fitted to the support bracket The front wheels are equipped with disc brakes with only by means of a hinge pin and a friction unit.
Page 437 REAR WHEEL BRAKES AND HANDBRAKE The rear wheel brakes have one wheel cylinder mounted in the backplate. The cylinder is fitted with pistonS, each of which acts brake shoe. brake shoes manually adjustable. The braking movement is transmitted by sealed Bowden cables to levers for the rear wheel...
Page 438 SERVO UNIT Brake position The servo unit consists of a vauium cylinder which is ac- pedal, the valve piston is moved When pressing the brake closed atmo- mated brake pedal. cylinder connected left, vacuum channe the engine inlet manifold means of a hose.
Page 439 BRAKE SHOES shoes. If they are worn Examine the linings on thickness (2.5 mm), unevenly worn, REMOVAL OF BRAKE DRUM FOR INSPECTION OF covered with grease, linings must be fitted. BRAKE LINING, REAR WHEEL rear linings. then sufficient change rear linings only.
Page 440 DISASSEMBLY Use a piece of wire or a clamp to keep the brake pis- tons cylinder while carrying out this operation. Remove the springs which hold brake shoes against the backplate. FITTING HANDBRAKE LEVER Lift the rear shoe with the handbrake lever into the large hole.
Page 441 Jack up the car so that the rear wheels are clear of the be even. When changing brake linings, always use genu- ground. Be sure to locate the jack in the correct posi- Saab replacements or linings recommended Saab. tion. is possible to adjust the brake without remov- After adjusting the brakes, always make sure that the rear ing the wheels.
Page 443 NOTE Remove the old brake linings. To ensure optimal safety, use only genuine Saab Wash the brake shoes in gasoline or kerosene and blow linings or exchange shoes. clean with compressed air.
Page 444: Brake Drums
BRAKE DRUMS MACHINING REMOVAL AND INSTALLATION If the brake drums are moderately scored, more or less equally on both left and right sides, this will Remove the cotter pln and the sh fluence the braking effect or life of the brakes. Jack up the car.
Page 445 BRAKE DISCS NOTE disconnect brake hose. instead place REPLACEMENT brake housing in such a way that the hose not ex- posed to tension. When the brake disc shows signs of heavy wear after con- siderable mileage. it must be replaced. Moderate scoring, Pull off the wheel hub with the brake disc attached.
Page 446 =— ‘10 z" 7’ ‘2 I” full“: n-.%y9“i‘l‘ semi}! i?" was“ «1 ¢ WWW": _..::e'aI-Ma®%W‘H% =4W" "m 1301 FRONT AXLE UNIT WITH DISC BRAKE Brake disc Ball bearing Brake Shaft seal Brake piston Ball Brake housing Backing plate Clamp Wheel Inner drive shaft...
Page 447 FRICTION PADS Turn movable brake part towards the'wheel, and fit the outer friction pad. Make sure that movesd freely in its position in the yoke. Possrbly, protru GENERAL ing parts will have to be trimmed with a file. As the disc brakes are selfadiusting, possible to...
Page 448 disc. Top up with brake fluid the reservoir. WARNING not forget to pump repeatedly with the brake pedal, otherwise the pedal will go all the way down when the brakes are applied. 517—2 “I17 Ree-...
Page 449 HYDRAULIC FOOTBRAKE SYSTEM Even the best brake fluids deteriorate after prolonged use, OWing to oxidation and absorption of water, which low- OVERHAUL boiling point. For racing and rallying, and for driving mountainous is found necessary to dismantle the brake system territory, brake fluid should be changed at yearly inter- part thereof, this...
Page 450 BLEEDING Bleeding IS not a routine service measure and is necessary only when part of the brake system has been disassembled when brake fluid been drained off. Sure signs that entered system excessive pedal travel, springy pedal action or absence of braking effect until the brake pedal been...
Page 451 MASTER CY L' “DER off the locking nut and unscrew the push rod from the fork on the brake pedal. Up to and model 1968 3. Back off and remove the two master cylinder retaining ceNERAL bolts. The lower one is a stud bolt and the nut is acces- sible from the engine compartment.
Page 452 Inter- Withdraw the non-return valves. Take care not to dis- rubber parts should be replaced by new ones, which tort spring clip (44) when removing from available suitable kits. valve body. SAAB 521—2 Febr 1977...
Page 453 ASSEMBLY As from model 1969 Before reassembling the master cylinder, dip all parts in necessary to dismantle the brake system, brake fluid. part thereof, this must be done under conditions of scru- Locate the cups on the pistons and check that they pulous cleanliness.
Page 454 Model 1969—1970 Depress the spring retainer (30) and, using a small screwdriver, unwind the spiral clip (29) from the DISMANTLING groove of the primary piston, taking care not to distort the coils; remove the spring retainer (30) The master cylinder should only be dismantled if there is gether with the spring Remove the washer (28)
Page 455 Remove the circlip taking great care not to damage the surface finish of the primary piston Lightly tap the mounting flange of the cylinder body on the bench, and remove the nylon guide bearing the secondary cup (24) and the plain washer Using special circlip pliers with...
Page 456 East! the pistons gently into the cylinder bore am slide the piston stop (31) over the primsu piston Fit the circlip (22) inner groove. using New.“ circlip pliers whh long. narrow ism. tool 78 41 993, and check that it is correctly located.
Page 457 As from model 1971 Check all parts and exchange any that are worn or de- DISMANTLING fective. Rubber gaskets and seals should be replaced by new ones. Repair kits containing complete replacement sets of rub- Separate power assist unit from master cylinder her gaskets and seals are available.
Page 458: Brake Lines
BRAKE LINES front rear The brake system incorporates t unication between the brake hoses, affording comm hoses diffe- body and the wheel cylinders. The The brake pipes are of 3/16 Bundy tube. The ends of sed. Install the hoses rent lengths must confu...
Page 459 Remove the rubber boots from cylinder. location of their steady pins differs from that of the Saab 95 — with a view to avoid misfitting. Pull out the pistons. Take the rubber seals off the pistons. As from model 1970,...
Page 460 Reassembly Scrupuious cleanliness must be observed when reassem- bling the wheel cylinder. Lubricate the cylinder bore, seals, cups and pistons with brake fluid before reassem- bling. Reassemble as shown in the illustration, making sure that piston seal facing right way. fingers only.
Page 461 Remove friction pads described previously. Bend retaining plates remove mining bolts which hold the brake housing to the steering knuckle housing. Lift brake housing away from brake disc. disconnect brake hose, but place the brake housing so that the hose does stretched.
Page 462 tl'ng of brake body assemb'Y 3"" supp“ “met Disman Replacement of complete brake cylinder brake body assem‘ essary to items disassem- bracket. these Disassembly bly or the SUPP“ Remove the friction pads as described earlier. bled as follows: brake from the steering knuckle housing Bend retaining plate...
Page 463: Brake Pedal
BRAKE OPERATION Remove clutch pedal return spring from shaft. UptoandincLInodel1968 od at the adjusting Unscrew the master cylinder push nut. brake ped- Pull out the shaft leftwards and remove BRAKE PEDAL ings if Check the bearing for wear bush brake pedal carried same...
Page 464 As from model 1969 BRAKE PEDAL brake pedal carried same shaft clutch pedal and is equipped with self-lubricating bushings. Removal installation Remove protective cover steering wheel shaft. Remove bracket brake light brake warning contacts. COTTER REMOVAL Loosen clutch pedal spring. Remove the cotter from R.H.
Page 465 HANDBRAKE SYSTEM Removal GENERAL Remove one of the front seats and the rear seat cush- ions. Jack up the car. Remove the rear wheel. mechanical handbrake acts rear wheels only. hand- Back off and remove adjusting under When the handbrake lever is pulled, the movement transmitted by the handbrake cables to levers on the rear...
Page 466 been dislocated. Refit the adjusting nut. illustration which shows the handbrake lever Reconnect the clevis to the brake lever and secure the its component parts. pun. Removal Push back th them to provide bet Remove the rubber Back off and remove the adlustlng nuts.
Page 467 Check that the braking effect is equal both wheels. done manner described below with ,justing nuts, which are accessible from the driver's seat. NOTE Always adjust the brake shoes before adjusting the handbrake. SAAB 5514 Fair 1011...
Page 468 CONTENTS GENERAL WHEEL ALIGNMENT STEERING KNUCKEL HOUSING AND BALL JOINTS CONTROL ARMS STEERING WHEEL AND COLUMN SHIFT GEAR STEERING GEAR TIE-ROD ENDS ‘ebv 1917...
Page 469 GENERAL ouuhly the medium 0! ball joints in two veeahapnd, trans- verse control arms. innor ends those curried 5" 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 the whealou In Ilmltod bJIrubbor bump”...
Page 470 ‘Z‘EEMW angry-19:72:? .— (rig—Dr "e":1'ti££"0‘a was; e‘farcammz-g't‘ 'ol'rsa't: mfemy "12mm; (.‘xg'xeiy'w52‘1neiwre 72211: :FED‘TE-PEEL"; “pray-711'“ “rt are. :WJm magazaa'n; 'aasuguu' amWf'mrwr tar. rmrzrrc rear-'5 a" war; "E mag—Winn: $271372“. szzr'e; mags“ 3.3;? nmrsa Zr" 352:: :09: manta" nrnmg-a—E‘Twmmam :errnz'asn; "e *zrrazphzT-g 9:3: art: 9‘...
Page 471 TE: :2: side is conneczagvgi: 02mpnses a separate Unit :Tngs and rubber bumpers. the ends of the control arms Ther:|;10|tnts mud] form ianIe tv;:o |ower control arms are on Saab 96 “p to and <10f a stabilizer bar. Contro| arms assis 96722013535...
Page 472 connected tie-rous unuugn omel- knuckles and STEERING AND COLUMN SHIFT GEAR ball joints Bil-mp“, with a column shift gear. The gear The car IS eq ivoted to the operating rod In the transmis. The steering gear made in two versions, one for right- shift shaft I5 P...
Page 473 WHEEL ALIUNIVItNT Check the steering gear and adjust any faults - see cENERAL section 642. Check the function of the shock absorbers and renew any defective shock absorbers and rubber bushings. is of the utmost importance that the front wh If the car has been involved in an accident, driven...
Page 474 Turn the tie-rod right left’ search until TOE-IN 'nin the right toe-in. E'stezring gears of earlier desrgn. the tie-rod has a key Viewed from above, the wheels should have a certain rela- later design there grip and then tionship to each other, expressed as the difference be- fie-prod must be turned with a pair of pliers.
Page 475 The camber should be 3/40 t 1l4° if the car is fitted with the term in the Saab car, and the term king-pin inclina- diagonal tires (5.20 x 15 or 5.60 x 15) and 1/3° i 1/2°...
Page 476 3mm!) angles have been adapted to the most com. WHEEL TURNING ANGLES drum tslight'Y inwards relation ‘ pain As the “e (driving straight ahead), steering Wheel alignment which allows perfect running of all four direction :Lagvliéfihe inside wheel on a bend Will be slightly greater. wheels on bends varies somewhat depending on speed the sharpness of the bend owing to suspension...
Page 477 3+0, 3—2,5 3—3 F—O,5 F—4,5 3—o,5 F—4,5 I”? 0 1 6 1 3—7,5 In the event of the adjusting possibilities being too allow obtain prescribed values, there special bearings with better adjusting POSSibi‘ities' See the Spare Parts Catalogue. SAAB 601—5...
Page 478 T "m RADIAL .M4+ 75 5I3I C O M E - 5 . 1 m 5 I 5 I “WM B I Z — r m . . . - . l I 1 I 5 I s I O I Z I 5 ' 5 I 5 5 F .
Page 479 Twin (toe-out) at wheel rim tie-rod Screw adjusting toe-in (toe-out), remember that: Reading the following turns When Measurement ""151 “Gt exceed figures men- Value of tioned in the illustrations. Diagonal Radial tires tires 1/4 out —0.28" T o e — o u t in m m a n d i n . 1/4 out —2 3/4 out...
Page 480 NOTE REAR-WHEEL ALIGNMENT wheel-angle measuring equipment is needed Special Checking establish faults to-in (toe-out). If the rear axle been subjected abnormal stresses, instance connection with collision or other acci- NOTE dent, it must be carefully checked for signs of fracture If the difference wheelbase exceeds 0.2 deformation.
Page 481 STEERING KNUCKEL HOUSING AND BALL JOINTS DOW"! mammacrs‘l"e 36-7155— :mmt‘armmt mt‘emnmmr. memmm Serf-Em smahmlfnmm Mxmmmmnam dehu- EMF“ II.“ km“ 12.8th 2.3“. t“ Ilmhihh" 3*” gun-chi III-R F“ lawn“ Stilt...
Page 482 NOTE The hub, ball holder and balls can be removed from the dome if the hub is turned through 90° certain position. These items should only moved, however, if absolutely necessary. SAAB 1977 Fain...
Page 483 If the seal in the steering knuckle housing has been removed, insert a new one. Pack the ball bearing with Saab special grease. only original ball bearings. Press the bearing into the steering knuckle housing with the numbered designation on the outer race facing outwards.
Page 484 POSITIONING SPRING SCISSORS SPRING CUPS, LEFT SIDE them with Saab special grease mount them their journals. Fit the cover 736 to protect needle bearings, pass the drive shaft through the wheel house. Make sure that the inner...
Page 485 REPLACEMENT BALL JOINT DUST EXCLUDERS Remove the ball joint from the steering knuckle. upper ball joint has two screws and the lower ball foreign matter, protect the ball joints from wear joint one. (boots). Dam- Remove the ball joint from the control arm. they are fitted with rubber dust excluders aged boots must be replaced by new ones- Fit a new ball joint and...
Page 487 cONTROL ARMS Detach the steering arm and upper ball I'Dint from the steering knuckle. holds the lower coNTROL ARMS AND STEERING KNUCKLE Back off the clamping screw whic ball joint to the steering knuckle. Removal Open up the inner universal joint and remove the entire front axle assembly.
Page 488 73 23 736 to protect the needle bear. necessary, remove steering gear, section 642. 't that inner driver clean NOTE fresh Saab special chassis grease, section 475, conjunction with overhauls of the front suspen- Then fit the inner universal...
Page 489 NOTE Compress coil spring, using spring scissors 89 95 847. See section 631. no circumstances may oil or grease be used Back remove screws holding ball facilitate insertion of rubber bushings- If 'Ubr'ca' joint and lower spring seat to the upper control arm. tion is needed, use soft...
Page 490 Distorted arms must rejected new ones fitted tact surface brackets should 2°. their place. ANGLE BETWEEN LOWER CONTROL BEARING BRACKET 632—4 SAAB...
Page 491 5TEERING WHEEL AND COLUMN WARNING introduced as The collapsible steering wheel sh care. from model 1969 must be handled jolts or other must subjected impacts. General length rough treatment liable to alter the adjust bsorbing of the telescope joint or impair its shock-a The car...
Page 492 STEERING WHEEL AND HORN BUTTO ASSEMB MODEL 1967 REMOVAL OF HORN BUTTON, MODEL 1967 Disconnect the horn wire from the contact plate. H E ’ S - " : 5 9 Back off the nut and remove the retaining washer. Remove the horn ring.
Page 493 TEERING WHEEL WITH SAFETY PAD, MODEL Removal Remove the safety pad by turning it counter-CIOCk’ wise. Unscrew the nut and remove the spring washer. Lift away the steering wheel. The return yoke for the directional signal switch removed. WARNING The collapsible steering wheel shaft introduced from...
Page 494 Reassembly WARNING The collapsible steering wheel shaft must handled with care. must be subjected impacts, jolts other rough treatment liable alter adjusted length of the telescope joint or impair its shockab- sorbing effect. The wheel must not be knocked off Ol‘...
Page 495 Removal Remove safety padding horn contact finger by lifting the unit up and away from the steering wheel unit secured steering wheel means three spring-type fasteners. REMOVING STEERING WHEEL Lift off the steering wheel. The direction indicator switch actuator removed. Assembly SAFETY PADDING...
Page 496 STEERING COLUMN STAND WITH STEERING WHEEL WARNING SHAFT AND GEAR-SHIFT MECHANISM collapsible steering wheel shaft introduced as from model 1969 must handled with care. Disassembly must subjected impacts, jolts other rough treatment liable to alter the adjusted length Disassembly of the steering column also involves removal of the telescope joint or impair its shockabsorbing...
Page 497 Fit the return spring, spring holder and gear shift lever twist stop on the gear shift shaft, with the marking on the latter facing upwards. Then slide the gear shift shaft into the steering column stand from underneath. SAAB 641—7...
Page 498 GEAR SHIFT MECHANISM Bracket Return spring R.H.D. Rubber bushing Fiber washer 13. Tapered Screw Bushing Snap ring Universal joint Gear shift lever Rubber ball Washer L.H.D. 3. Spring L.H.D. Later design 28. Spring Gear shift lever Fork Lever housing Bushing Ball Washer Washers...
Page 499 Note! Apply gear shift mechanism as described above. moderate coating Saab special chassis grease If only the gear shift lever and gear shift shaft are to the fiber washer and the internal bearing surfaces...
Page 500 Reassembly Insert felt bushing stand. Lubricate GEAR SHIFT SHAFT UNIVERSAL JOINT, L.H.D. the bushing with Saab special chassis grease. Gear shift Place the spring and the washer on the fork nut. Conical with lock Screw in the fork nut far enough to...
Page 501 Saab special chassis grease before Starting. This position has a spring return action. fitting the new dust excluders. The steering column stand...
Page 502 Removal of twist stop of twist stop Adjustment Engage gear, thus providing access clamp- After adjustment of gear positions, readjustment of the ing screws on the twist stop through the holes (2) on twist stop is called for. procedure is the following: bottom steering column...
Page 503 LOOK CYLINDER, UP IO AND INCL. CH When the key is in this position, the catch pin in the 95773000341 AND 95773000960 SIS No. lock cylinder can be pressed in by inserting a wire Dicklock in a hole on the underside of the steering column stand.
Page 504 LOCK CYLINDER, AS FROM CHASSIS NO. Disassembly when key is missing 95773000542 AND 96773000951 If the been lost or necessary to remove Removal lock or the lock cylinder, the cylinder must be drilled before the catch pressed Drill 0.12 Put the gear lever reverse turn...
Page 505 check that the driver correctly positiOned lock sleeve. Adjust as necessary u In the sing flat-nose pliers. 6168 POSITION OF DRIVER INSTALLATION OF CYLINDER Hole for locking Driver Insert the cylinder in the lock sleeve. Insert the locking pin. 641—15...
Page 507: Steering Gear
R H. 09 Saab special chassis grease cars. Use hand drive" U} as the steering gear for cars with right To ensure satisfacmry funmo".
Page 508 Pass the steering gear out a little through right REMOVAL, UP TO AND INCL. MODEL 1968 (R.H.D. hand (resp. left hand) wheel house until the left CARS UP TO INCL. MODEL 1969) tie-rod clears the wheel house wall. Lift the steering gear out forwards and upwards between the Wheel following description...
Page 509: Model 1970
WAR N | NG The collapsible steering wheel shaft introduced as If necessary, grease the tie-rod ends, from model 1969 must be handled with care. Reconnect the battery cable, must subjected impacts, jolts other Refit the engine hood. rough treatment liable to alter the adjusted length of the telescope joint or impair its shock absorbing...
Page 510 Lubricate the rack and pinion, rough treatment liable to alter the adjusted length of the telescope joint or impair shockabsorbing bearing points and other sliding surfaces with Saab specia| effect. chassis grease. When installing the steering wheel shaft, take spe- removed,...
Page 511 REASSEMBLY, LATER DESIGN Exercise the greatest cleanliness when reassembling. Lu— bricate the rack and pinion, bearing points and other sliding surfaces with Saab special chassis grease. removed, press the pinion bushing into steering gear housing. Fit the inner ball...
Page 512 play in the pinion (the column) can be Excessive axial INSPECTION erting shims under the pinion cover. The corrected by ins pinion cover should clearance between t After considerable mileage, especially lubrication ‘n. (0.12 mm). 3.03:;er out the adjustment, which can be done with. is unsatisfactory, the rack may wear unevenly.
Page 513 MEASURING SHIMS Check that the washer position, apply a blob of Saab special chassis grease around the pinion stub. Refit the cover and shims, and tighten the bolts. member to fit the retaining washers. After adjustment,...
Page 514 Refit the nut to the rack. Pass the outer bearing cup onto tie-rod, fill with Saab special Later design chassis grease. Fit the spring and the inner bearing steering gear must be removed before the...
Page 515 Back off the two retaining bolts at the end farthest away from the pin- insert spacer under steering gear bolt where it does not lie flush. On some cars, a spacer has al- ready been fitted. “"1977 SAAB 642-9...
Page 516 SAAB 6,34...
Page 517 RUBBER SEAL REPLACEMENT with» lined in with ball joint. this is dam aged m that it no Iowan attends an effective seal. it must rejected new one titted. piowduie lul» lows. Jack up the car and ioniove the wheel. Remove the cotter pin.
Page 518 CONTENTS GENERAL COIL~SPRING SUSPENSION, FRONT COIL-SPRING SUSPENSION, REAR SHOCK ABSORBERS STABILIZER WHEELS TIRES HUBS Fab: 1917...
Page 519 The lower control arms on Saab 96 up to and incl. chassis —I 0 (lil' {II é: ‘ m m . " ( E m i l «...
Page 520 In addi- They are bolted to the body and connected to the rear tion, it is braced to the body at the sides through the me- axle links. REAR SUSPENSION, SAAB Center bearing Rear axle tube Shock absorber Upper spring seat...
Page 521 Saab 96 are of telescopic shock The rear connected means rubber bushed hear type T body rear axle at the bot- ings ‘0 t SUSPENSION, SAAB 96 REAR Center bearing Rear axle tube 3. Shock absorber Upper...
Page 522 WHEELS TIRES The dished wheels and wide base rims are manufactured The tires are tubeless equipped with balancing pressed sheet steel riveted welded together to mark the form of a colored circle. marking shows form integral unit. lighter side of the tire, when the tire...
Page 523 78 40 812. Alternative 2 is removal and installation of the front coil springs using spring scissors 89 95 060 (also designed for Saab 99 up to and incl. model 1972) and spring cups 78 61 248. Removal, alternative 1...
Page 524 joint to the upper control arm. Remove the lower Apply the spring clamp, tool the Spring spring seat. and withdraw the spring from the compressor. Check that the rubber sealing ring and metal washer fitted upper spring seat that rubber buffers are mounted under the...
Page 525 The lower end of the spring coil should butt up against the stop spring support. Fit the shock absorber on right side. NP’ Mount the wheel lower the car. 1977 SAAB...
Page 526 Unfasten the stop strap at its rear bracket and allow Project 0.6 in. (15 mm) beyond the bracket. the axle to fall down, thus enabling the Spring to removed without the use of tools. On the Saab 95 first remove the shock absorber link, If the rubber buffer...
Page 527 Disconnect the shock absorbers. On the Saab 95, unfasten at the rear axle. On the Saab 96, discon- nect upper connection. Detach the brake cable clamps from the shaft and the wire connections from the rear brake levers.
Page 528 Center bearing Drive a new bushing using the same tool. Locate the bushing in the center of the bearing. If the bushing in the center bearing is to be changed, the Refit the center bearing, but do not tighten the entire rear axle assembly should be removed.
Page 529 SIDE LINKS Refit links to rear axle but do not tighten the nuts These nuts must never tightened until Replacement of rubber bushings resting on the wheels. Insert the bolts from the out. side towards the center bearing. Disconnect the links from the brackets on the rear Lower the car, and tighten the nuts on the...
Page 530: Front Shock Absorbers
anvvu‘ “I, NOTE GENE Before reassembling, provide new rubber items in mace of any defective ones. Defective shock absorbers must be rejected, and new hen a shock absorber ' ‘ ‘ refitted, sure ones fitted. ThIS Is a matter of the utmost ImpOrtance, genuine rubber bushings at the...
Page 531 REAR SHOCK ABSORBER, SAAB 95 Disconnect the shock absorber from the body and rear axle. Remove the shock absorber, collecting the washers rubber items. Reassembly Fit new rubber items in place of any defective ones. ways genuine replacement parts. Refit...
Page 532 “ism: hole. Negligence this and rubber items. grease befOre n 058' Smear the threads with screwmg on the nuts. Tighten the nuts hard. ARTS. SAAB 96 SHOCK ABSORBER AND CONNECTING P REAR Nuts Washer Rubber bushings Washer 5. Spring washer...
Page 533 Refit the wheels and lower the car. STABILIZER BEARINGS Bracket, control Rubber bushing Rubber bushing Bracket, body Stabilizer 762—-1 SAAB 1977...
Page 534 wHEhLD tJeznc‘t’L'eeslr‘journaled rotating rim, the difference be- FITTING oF WHEELS illustration)lg est and lowest point measured at A (see Model 1976 :last not exceed 0.059 in. (1.5 mm), as from From the viewpoints of comfort and safety, it is impor— illustration) h.
Page 535 TI R ES Wheel alignment. Faulty alignment of the wheels can cause heavy wear tires. MAINTENANCE Speed. Tire mileage diminishes sharply with rising speed, mainly due to the greater friction heat gener. The working life of a tire depends very much on the care ated.
Page 536 HUBS FRONT WHEEL HUB GENERAL L: :S‘Sheel hub is splined to the outer drive shaft 3'1] brake drum rear wheels made slid‘ meansvofa castle cotter pin. mg surface on insude must well pro- against scratches and blow marks when mtegfa casting.
Page 537 REAR WHEEL Ball bearings are fitted rear wheel hubs. These, gether with the shaft seal, accompany the hub when it is removed. ill-ll 2495 WHEEL REAR Feb: 1977...
Page 538 REMUV’“ INSTALLATION Before starting work, make sure that the car is thor- Clean the hub thoroughly and make sure that there is no oughly deemed under the fenders. Scrape off all dirt dirt in the shaft seal. that might loosen and enter the bearings. Bafore installing, grease the tongue and sliding...
Page 539 Spacer sleeve Inner bearing Lock ring Sealing ring Refit the circlip. NOTE ‘i. Pack the ball bearings with Saab Special Chassis The circlip is of a special type and must always be mounted as shown figure. Grease. See section 120, "Lubrication".
Page 540 CONTENTS GENERAL BODY ASSEMBLY HOOD, FRONT PANEL AND FENDERS DOORS AND LIDS GLASS UPHOLSTERY AND INTERIOR FITMENT BUMPERS BODY FINISHING F'bvtsrv...
Page 541 The luggage compartment of the Saab 96 comprises the rear most part body limited front by the removable back cushion of the rear seat. The com- Partment floor consists of a...
Page 543 BODY ASSEMBLY dent that correction by beating or realigning is not suit- eENER AL able should be replaced by new ones. In many cases, even minor damage more quickly cheaply repaired. with better results, if the affected parts 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.
Page 544 Saab 95/96 and Saab 99 cars has been designed portions of the car body. It con5ists of a lever w facilitate repair bodies damaged road secured at the bottom by a chain to two of the legs of cidents.
Page 545 tended! will intersect at the same point on the floor Application of draw aligner, earlier version, principle will almost parallel. Adjust chain lengths as necessary, prize apart the The draw chain and hydraulic cylinder must be placed so quick-release extension of the pressure cylinder, and that the extended lines drawn through them intersect at wrap the safety chain...
Page 546 stors secured PUIIH. secured to the jig by means of a Alignment jig, later version mounted on ca frame of the Jlg. king pin. It is of the utmost im- forked bracket and a Ioc locked securely during Opera. alignment later version has the...
Page 547 Alignment jig, later design Wheels 3. Side support Draw aligner SIDE Extension MOUNTING USE WITH A 4-TON HYDRAULIC CYLINDER Support set, Saab (also alignment of earlier design) Support set, Saab 95 (also alignment earlier design) ,(Jssm NWARD ngIEDMOUNT'NG USED APPLICATlON...
Page 548 " draw aligner Mounting the car in the jig Descriptlon Of alignment "9 Simplest method mounting the the jig A description Of the alignmen srde liftin With ‘ or two pillars. Scania draw aligner Nykoping available under ordering number 101733. MOUNTING The car can also mounted...
Page 549 Skew Or asym- :IEI’EI III-§]I-|=!_ BODY MEASUREMENTS, SAAB 95 810—7 “m...
Page 550 Body measurements, Saab 95 mn— “ Underside sill 84.17 10.08 213812 13.66 1 0.04 1.50 10.02 3810.5 3.33 10.06 84.5 11.5 8.27 10.04 3.90 10.02 1 0.5 9.82 10.06 249.5 11.5 3.94 10.02 10.5 19.09 1 0.06 11.5 90.31 10.12 2294 30.87...
Page 551 nil—\—...
Page 552 Body measurements, Saab 96 Underside of sill 1’ 0.08 84.17 213812 13.66 1 0.04 1.50 1 0.02 3810.5 3.33 1 0.06 84.51 1.5 8.27 1 0.04 3.90 1 0.02 10.5 9.82 1 0.06 249.5 11.5 3.94 1 0.02 10.5 19.09 1 0.06...
Page 553 PHIL] rtNDERS HOOD HOOD WITH ATTACHMENT COMPONENTS Removal Open hood with control mechanism under instrument panel. The hood then opens half-way. To open the hood wide, move the latch its rear edge forwards and lift the hood forwards. ’1 _—r-“1_— HOOD REMOVAL j,II‘J'l—_...
Page 554 Hood lock Disconnect the hood control and the cable connections for the headlights and direction indicators/and parking lights. car, proceed follows. Pass a screwdriver through the g rille immediately under lock press control right. hood opened. As from model 1976, stay intro duced, by which the...
Page 555 FRONIFLH'L' IVIVIJLL IUUU_ IHIU Decor frames, headlights Two pins in the lateral part of the decor frame are presSed into the rubber bushings outer ends of the front plate: and a selftapping screw is inserted through the 0p. posite side of the decor frame. At removal, loosen self tapping...
Page 556 FRONT PLATE WITH HEADLIGHT WIPERS, AS FROM MODEL 1971 FRONT PLATE WITH GRILL Decor frame, incl. model 1973 Fixing screw, fender Rubber bushings Fixing screw, wheel housing stay Self tapping screw, decor frame Self tapping screws grille plate Fixing screw front plate Grille,...
Page 557 FENDERS Installation After considerable mileage, especially on gravel roads, After having treated the fender with underbodv coating the underbOdV coating be worn away at exposed refitted moldings, lights possible rubber points: and should therefore be examined at regular in- grommet (left rear fender), reinstall as follows: tervals and touched up as required.
Page 558 Only the new type of rear fender is available for replacements. A new filler tube has therefore been pro- lation). duced for Saab 95 up to and incl. chassis No.95.010.115, while for other cars up to and incl. model...
Page 559 UUUH" r‘l" I-IIJU NOTE DOORS Be CGII'Gful "Gt to damage the front fender when °pen|n9 the door without the door stop being RemOVal fitted. Remove the interior door trim. Adjust the door in the ‘ Relisegtehe door stop drivmg out the at the up- by advancing or backing off the nuts a...
Page 560 Incl. model 1971: check that the moving parts of the lock, and the lock Depress the push button (7) and drive out the pin (2) springs, are well lubricated with Saab Special Chassis with a driver (max. 0.12 in/3 mm).
Page 561 Disassembly, as from chassis Nos. 95773000542 and 96773000961 Remove lock washer securing push button the handle Now remove the push buttOn with the lock cylinder push button and lock cylinder form an integral unit must be taken apart. HANDLE, UP TO AND INCL. MODEL 1971 OUTER Sleeve ;...
Page 562 NOTE! Never lubricate the indented side of the key. After lubricating in this way, turn the key back and forth a few times. REAR DOOR, SAAB 95 Removal and installation ADJUSTMENT REAR DOOR BALANCE SPRING TENSION Open the door.
Page 563 door locks rods loosely together Refilove the two retaining screws and hook the with the adjusting nuts. 59”"9 Off the clamp, whereupon the latch can be Adjust length rods that door removed. |ockS are in the outmost position when the control Put the new latch in place with the serrated handle is standing horizontally.
Page 564 Install a new mechanism. Adjust the flush fit of the trunk moving the yoke up or down. LOCK, REAR DOOR,SAAB 95 Locking Lock cylinder Tubular pin Handle Fitting is carried out in the reverse order. Position the...
Page 565 k lid lock Isassembly, as from chassis 96773000961 nscrew locking mechanism lugtilage compart- ment lock from lid. four retaining screws and remove the lock 1hunscfew Remove the crrclip (1) and carefully withdraw the mechanism. knob and lock cylinder assembly WWW care mt Back off the two cross recess head screws holding the Thto lose the two balls lock mechanism installation washer.
Page 566 GLA5° cENERAL The Windshield made of laminated glass and all other windows of toughened glass. When fitting new windows use only Saab original parts ensure approved glass quality and a perfect fit. WINDSHIELD Replacement INSTALLATION WINDSHIE LB 1‘ Remove windshield wiper arms.
Page 567 WINDOWS Replacement The windows are replaced in the same manner as the Windshield. When replacing the rear window in a Saab 96, first remove the shelf over the luggage compartment Opening side windows Opening side windows are fitted on some models. The...
Page 568 Installation Fit the rubber inserts in the glass retainer channel press the glass firmly into the channel. Make sure tahnd the retainer holds the glass firmly. Lower the glass at an angle from inside the door and with the hinge at the bottom. At the same time u‘d the window regulator pin into the slot.
Page 569 PILLAR TRIM HEADLINING. SAAB 95 The door pillars in the Saab 96 are fitted with trim. The Headlining Retainer trim is fastened with tape carrying adhesive on both sides. 3. Wire spiral with...
Page 570 HEADLINING, SAAB 96 IMPORTANT stretch from headlining’s border. The headlining is stretched on piano wire bows and re- tamed the following way. The cloth is wrapped round upper edges of the frames for the windshield-, side- Fit the headlining to the...
Page 571 MATS The rubber mats at the front sides are glued to the wheel houses, while the front and rear mats are loose. AS from model 1968, the mats are of nylon fiber on jute backing- They are secured by snap buttons and velcro gripS- Insulating sheets of wallboard are fitted under the floor mats.
Page 572 SEATS Front seats, Saab 95 up to and incl. model 1977 and Saab 96 up to and incl. model 1976 The front seats are made of resilient steel tubing with foam rubber cushions and covers fitted on transverse coil springs. The front seats are adjustable for legroom, and...
Page 573 Separalc LIIC apllllbu jun”. VVILII SCI'erI’IVer. Separatin backrest—seat cushion NOTE emove Philips head screws, according fig. Make sure that the eccentric does not slip out of the hole in the locking arm. If this happens, the eccen- triC shaft tension spring will lose its grip.
Page 574 Changing the backrest upholstery Remove seat from car. Undo the lower edge and unhook hooks bottom each side. Roll up the upholstery as far as the band middle of the backrest. Undo the clip at the rear of the back- rest pull band...
Page 575 j—olU Odom tune gluuvcb ll‘lSlue hole Elect "c heatinQ driver's seat from model 1972 As fr0m mOdEI 1972, the driver's seat is electrically heated. Heatin flector? felleelirjn EMS ConSIsting Of reSiStance WI’ i"Q and re- rest cushicms DIEM“: mounted seat back- tion lock,...
Page 576 Possible wiring fracture heating pads, check with buzzer (Disassembled, heated seat) Backrest heating pad: Connect one of the leads of the buzzer to the pad leads (the splicing sleeve is pushed into the PVC tube). there fault the wiring, buzzer will sound when...
Page 577 Rear seat and auxiliary jump seat, Saab 95 seat, Saab 96, up to and incl. model 1969 In the Saab rear seats made foam rubber :1st the rear seat cushion and back consist of base which serves luggage deck when seats folded down.
Page 578 Rear seat, Saab 96, as from model 1970 Cleaning upholstery Conversion freight space When attempting to remove stains from fabrics back seat collapsed provide extra freight space commended that the area adjacent to the stain first be station wagon principly...
Page 579: Instrument Panel
INSTRUMENT PANEL Removal and Installation RemOve the instrument panel take off the instru- Release from point attachment body merits and glove compartment. brace located I“ center instrument pane| Release the m°|ding pushing clips from Back remove the two screws either rear.
Page 580 BUMPEHE Up tgvxg 9m and “"0 brackets with braces. Up to and incl. model 1975 m°di9| 1968 there are splash guards 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...
Page 581 1:19:13; W bars to which the bumper brackets are mounted. There rear bumper of the Saab 95 Is equrpped Wit shock absorbant cellular blocks polyethylene parate outer parts consisting of steel covered wrtl:i rug-he bars. Outside the...
Page 582 REMOVAL AND IND HLLAI IUN Front bumper and rear bumper, Saab 96 Remove the filler plates and loosen the two bumper brack- ets. |nstallation is made in the reverse order. Rear bumper, Saab 95 Remove the filler plates, loosen the cable...
Page 583 from model 1971 0 3.. +05833. 2 n ew ._oEmco 35.3 gone . x o x u a n .8 N Z O N 5 . E E 3 6 2 . 2 5 4 0 oz: . 5 5 . wen E .lo 8 c o u c h e d —...
Page 584 Manufacturer AB Wilhelm Beckers Kurt Herberts Skin thickness after stoving appr. 25pm Intermediate coat Spraying viscosity 35—45 sec. (Saab standard 860 at 68°F/20°C) Mode of application Hot spraying. Paint temperature approx. 122°F (50°C) Curing min. at 320—3380F (ISO—170°C) Supplier AB Wilhelms Beckers Skin thickness appr.
Page 585 Measure the viscosity with a beaker according to the of the old paintwork by one or the other of these methods, method described in the Saab standard 860 at a tempe- degrease the metal with spirit, thimmer or some other suit- rature of approx. 68°F (20°C).
Page 586 Measure the viscosity with a beaker according to the must removed prevent them from being damaged method described in the Saab standard 860 at a tempera- by the heat. ture approx. 68°F (20°C). The air inlets and air outlets from the passenger compart-...
Page 587 CONTENTS GENERAL INSTRUMENTS ACCESSORIES, MECHANICAL ACCESSORIES, ELECTRICAL HEATING VENTILATION SYSTEM TOWHOOK ASSEMBLY...
Page 588 Glam-""- *1an button Model 1967 Ashtray. Also provided in r passenger compart- ment. Gear lever. coNTROLS Lockable glove compartment. The door is provided war] a detachable plate for the installation of a radio if desired, Direction indicator 5 witch and except USA versions headlight flasher.
Page 589 Model 1968 CONTROLS SIGNAL HORN WINDSHIELD WIPE RSI SWITCH WASHE R (Pas. 0—3) Windshield wipers —— neutral position Windshield wipers — speed Windshield wipers — high Speed Windshield wipers — high speed washer Gear lever. Lockable glove compartment. provided with a detachable plate for the installation...
Page 590 Rear brakes need adjustment. Direction indicator switch. Also functioning as dim- If the warning light glows an authorized Saab Service switch switch high beam headlight sig- garage should be consulted for investigation and neces- when the lever is moved towards the steering sari! remedy.
Page 591 The odometer shows the distance covered in miles Gear lever. Indicator light, pressure. The back-up light on the Saab V4 station wagon lamp glows when the oil pressure of the engine is automatically lighted when the reverse gear low.
Page 592 364. catch to prevent unintentional switching off. Gear lever. Hazard warning signal switch. All direction indica— The back-up light on the Saab V4 station wagon is lights flash together when button pulled automatically lighted when the reverse gear is en- out.
Page 593 The front can now authorized Saab service shop. spring up, and you can open the hood by lifting Direction indicator repeater light. Flashes...
Page 594 CONTROLS, AS FROM MODEL 1976 Warning light for safety belt. Ventilator fan switch. N — h Windshield wiper and washer control. Combined direction indicator, headlight dimmer Horn control. and flasher switch. Heater and ventilation controls. Headlight and parking light switch. Choke (up to and incl.
Page 595 Saab When starting, never move until this light dealer as soon as possible. gone out.
Page 596 Back off the knurled center nut retaining the Rapairs adjustments of any of theee instru- yoke. Saab 95: Back off the two knurled nuts retaining Rents Sh°u'd 3'W3YS be entrusted to a specialist the yoke. Remove the instrument from the panel.
Page 597 REVOLUTION COUNTER CAUTION The Saab Monte Carlo is equipped with an electric re- not confuse plus and minus leads, or the instru- volution counter, connected to the ignition primary circuit. ment ruined. See the wiring diagram in Section 3. When...
Page 598 ACcESSUl1lco, IVIcunHwal-u. Seat belts, front seats General All cars are equipped with seat belts of the so called three points type and as from model 1968 on, the be|ts are of “yoke type. —When not used, the strap of the 3-point type is hung on a hook at the door pillar.
Page 599 On Saab 96 the band runs through an tion when the lower strap is worn low across the hips and inlet in the parcel shelf. On the Saab 95 the reel is placed Inside the rear side lining. The band runs through an open—...
Page 600 Abuhvv' GENERAL The radio and any other electrical accessories, such extra lights, etc, must be properly fused off and should therefore be Connected to the Ignition switch or to the fuse block on the dash panel, which provided with spare fuse for this purpose. The wiring for electrical accessories should be so dimen-...
Page 601: Model 1972
HEAIII‘U ‘ VIOIEIVI led to the floor or thro the defroster jets, or both ways at the same time. As from model 1971 the car equipped with chan- nels to the floor space in th rear seat. When the road speed excee The heating system is separate and connected to the ds 30 m.p.h.
Page 602: Saab
MOTOR Disconnect three cables from the fan motor, noting their respective locations Removal installation Back off and remove the six screws retaining the front cover housing. Lift motor. Disconnect three cables from fan motor, noting their respective locations. Back remove the screws retaining the front cover...
Page 603 Back screws norumg together the fan housing “yr-’95. Eight screws are accessible from the engine THERMOSTAT VALVE compartment and two nuts from inside the car. To provide access to these two nuts, fold back the umber Rem aid installation mat'unscrew the freewheel control handle and loosen the two trim clips, whereupon...
Page 604 S 3601 TOWH 00K ASSEMBLY, SAAB 95 mount the angle iron the same way. Relay The tOWhook assembly for the Saab 95 is designed for a rubber matting. maximum trailer weight (2000 lb). After the towhook assembly has been approved...
Page 605 WIRING DIAGRAM 5‘ 5‘ 0‘0 Rwdnmeli ‘9 92noo,75 >2< GR2,5 § 12114 GR” I_-I ROM 1.0 54:: 0,75 VT1.0 31.1.0 2Sah BL/VT1,0 RDl,0 538h 7 - p o l e s o c k e t 0,75 GN 0.75 License plate lights l i g h t l i g h t...
Page 606 WIRING INSTRUCTIONS Remove tape from protective tubes to lamps. Pull wiring from the towhook assembly through the tube to Permanent wiring lamps and then mount five cable shoes 85 03 286 on the ends. Retape the opening to keep water out. Same proce- Towhook wiring system dure for both...
Page 607 Saab 96 GENERAL S 3604 TOWHOOK ASSEMBLY, SAAB 96 The towhook assembly for the Saab 96 is designed for a After the towhook assembly has been approved maximum trailer weight of (2000 lb). appropriate inspecting authority, coat any expo- To fit the towhook, proceed as f°”°W$5...
Page 608 w|RING DIAGRAM ligh Stop Tail light Trunklight GRO,75 2813 BL 0,75 0,75 25:! 253?! BL/VT 7-pole socket SV 2,5 0,75 SV 0,75 5‘4 License plate lights S 3605 ‘O 7‘5 WIRING DIAGRAM NOTE COLOR CODE The cable 121H G R 2,5 is, according to the wiring WHITE Instructions, intended to be connected to 92 RD 0.75.
Page 609 WIRING INSTRUCTIONS Permanent wiring Towhook wiring system Clips 71 75 706 1 / 2 " ) 140 mm Mount cable shoes 85 O3 286 after pulling the wiring through the tubes to the lamps and after running the wire trunk light.

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