Page 101
SUPPLEMENTARY
10 000 Ml LES (15 000 KM) SERVICE
INSPECTION
Every 12,000 miles/20,000 km. To be carried out in connection with the regular 6,000 miles/10,000 km inspection.
To be carried out by authorized Saab Dealer.
Engine
1.
1. Change spark plugs.
2. Change breaker points.
3. Change oil in manual transmission, clean magnetic
2.
3.
drain plug (at least once a year).
4. Change oil in final drive of automatic transmission.
5. Check and if necessary adjust camber and caster.
6. Adjust deceleration-valve.
,4.
5.
6.
SUPPLEMENTARY
7.
INSPECTION
8.
Every 24,000 miles/40,000 km. To be carried out in connection with the regular 6 000 miles/10,000 km inspeckm in-
9.
10.
11.
12.
1. Check and if necessary adjust valve clearance.
2. Change air cleaner insert.
3. Change fuel filter (injection engine).
4. Check and if necessary replenish steering gear oil level.
5. Change brake fluid (at least once every second year).
14.
tion and the supplementary 12,000 miles/20,000
spection.
13.
15.
16.
17.
Change oil and oil filter cartridge (at least once a
year).
Clean air cleaner insert.
Clean fuel pump filter. (Carburetor engine).
Check fuelllines in engine compartment for leakage.
Check t~e damper oil level. Top-up if necessary.
(Carburetor· engine).
Check engine idling speed setting and check emission of carbon monoxide as prescribed by the authorities (where applicable).
Check the exhaust system for condition and leaks.
Pressure test the cooling system (check the condition
of the hoses).
Check coolant freezing point.
Check hoses and nipples for the crankcase ventilation.
Adjust deceleration valve.
Check the synchronizing of the carburetors (twincarburetor engine).
Check the choke control.
Check the tightness of the valve cover screws.
Saab 99 Turbo: Check the seal on the charge pressure regulator.
Saab 99 Turbo: Check the charging pressure and adjust as necessary.
Saab 99 Turbo: Check the pressure guard and the
fuel enrichment device.
Electrical System
PERIODIC
SERVICING
AS FROM MODEL
1980
1. Check condition of V-belts and adjust belt tension if
necessary.
2. Check and if necessary adjust headlight alignment.
3. Change the spark plugs.
4. Change the breaker points. Lubricate distributor
breaker cam and lubricating felt. Check and if necessary adjust dwell angle and ignition timing.
5. Check battery electrolyte level and top up if necessary. Tighten and grease cable shoes.
6. Check operation of parking, brake and rear lights, number plate light, direction indicators, horn, reversing
lights, hazard warning flashers, interior lighting, warning and indicator lights, windshield washers and wipers,
brake warning light, instrument lighting, luggage compartment lighting and ventilator fan.
7. Check the vacuum hoses and their connections.
8. Check the condition of the ignition cables.
The maintenance programme lists the most important
things that need to be done to ensure enjoyable and
trouble-free motoring at minimum cost. The 1,200 miles
(2,000 km) coupon in your Service Card entitles you to
guarantee check-ups (except for oils for which a charge
is made). The guarantee is not valid if these check-ups
are not made. Subsequent check-ups at 10 000 miles
(15 000 km) intervals will be charged for. Take the Service Card with you when you turn your car in for servicing.
If less than 10 000 miles ( 15 000 km) are covered in one
year, one engine oil change must be carried out and one
complete service should in any case be carried out in the
year.
5 000 MILES ( 7 500 .KM) SERVICE
Transmission
Change engine oil in Saab 99 Turbo cars and cars driven
under unusually demanding conditions, such as driving
in extremely hot weather, driving at high speeds for a considerable distance, and driving over short distances in extremely cold weather.
1. Check transmission oil level and top up if necessary
(also final drive in automatic transmission).
SA.1'B
110-3
Page 102
Brake system
1. Check level in master cylinder, top up with brake
fluid if necessary.
2. Remove wheels and check thickness of brake pads.
3. Check brake lines and hoses for condition and leaks.
4. Lubricate the front wheel brake units.
Steering, front suspension and tyres
1. Check condition of rubber bellows on. steering gear
and inner and outer universal joints, and of rubber
seals for ball joints and tie-rod ends.
2. Check depth of tyre tread patterns.
3. Check the tyre pressure in the spare wheel.
4. Check the fluid level in the power steering fluid
container.
5. Check the wear in inner and outer steering joints.
Body
1. Lubricate door stops, door hinges and bonnet lock
mechanism.
2. Check condition of washer jets and rubber wiper
blades.
Test Driving
1. Test drive car on road and check operation of all systems, especially brakes and clutch.
20 000 MILES (30 000 KM) SERVICE
To be carried out in connection with the 10 000 miles
(15 000 km) Service.
1. Saab 99 Turbo: Check and if necessary adjust valve
clearance.
2. Saab 99 Turbo: Change air cleaner insert.
3. Change oil in automatic transmission, clean filter and
magnet. Adjust gear selector cable, rear brake lining
and throttle cable. Only first 20 000 miles (30 000 km).
30 000 MILES (45 000 KM) SERVICE
To be carried out in connection with the 10 000 miles
(15 000 km) and 20 000 (30 000 km) Service.
1. Check and if necessary adjust valve clearance.
2. Change air cleaner insert.
3. Change fuel filter (injection engine)
4. Change oil in final drive of automatic transmission.
5. Change brake fluid (at least once every two years).
6. Check and if necessary adjust toe-in, camber and
caster.
7. Saab 99 Turbo: Clean the charge pressure regulator.
110-4
Page 103
LUBRICATION
LUBRICATION CHART
Ref.
Lubrication point
Oty.
Lubricant
Brake fluid, grade DOT3 or
DOT4, earlier SAE J 1703
Brake fluid grade as above
Follow recommendations
on page 120-2
Follow recommendations
on page 120-2
1
Brake system
1
2
3
Hydraulic dlutch
Engine
1
1
4
Manual transmission
Automatic transmission
Final drive, automatic transmission
Follow recommendations
on page 120-2,
5
Carburetor (oil damper)
1
6
Distributor, breaker cam
Distributor, lubr. felt under
breaker plate
Throttle control, wire bearing
Hood lock mechanism
Door hinges and door stops
1
1
7
1
1
4-+4
(8-+8)
Oil for autom.transmission
Ford M2C.33F or M2C.33G
type A, Suffix A or Dexron
Bosch Ft 1 v 4
SAE 40 oil
SAE 40 oil
SAE 40oil
SAE 40 oil
Direction
Brake fluid should be changed every 25,000 miles (40,000
km, up to and including 1978 model)
Change oil and oil filter cartridge
NOTE! Use only Saab original filter cartridge
. Up to and including 11378model check level every 5,000
miles (10,000 km), change every 20,000 miles (30,000 kml.
As from 1979 model check level every 10,000 miles
(15,000 km), change every 30,000 miles (45,000 km).
Up to and including 1978 model check level every 5,000
miles (10,000 km).
Change every 20,000 miles (30,000 km) (in conjunction
with servicinb).
As from 1979 check level every 10,000 miles (15,000 km).
Up to and including 1978 model check level every 5,000
miles (10,000 km), change every 20,000 miles (30,000 km).
As from 1979 model check level every 10,000 miles
(15,000 km), change every 30,000 miles (45,000 km).
Check every 6,000 miles (10,000 km) at time of service,
inspection
Grease cam
Oil can, sparingly plate (the accelerator cable should not be
lubricated).
Oil can
Oil can
Oil can
4
6
4
4
7
NOTE
Saab Special chassis grease must be used with care,
as it is apt to discolor the paintwork Cifthe car.
3
5
2
S 3694
WEI
120-1
Page 104
1. Brake system
The brake fluid container must always be kept well
filled. The level in the container should be checked
every three months, when the filler cap should also
be inspected to make sure that the holes are not
blocked. Follow the brake fluid recommendations
given in the lubrication chart.
2. Hydraulic dutch operation
Check that the container is full.
3. Engine
Oil volume 6 Imp. pints (3.5 liters).
Oil recommendations, see group 0.
The engine oil level should be checked regularly.
This should be done when the engine has been at a
standstill for about one minute. The oil level must
not be allowed to fall below the lower mark on the
dipstick, nor must it be topped up beyond the upper
mark, as this may result in abnormal o_ilconsumption.
The distance between the upper and lower marks corresponds to a volume of one liter (ro1..,ghly1 3/4 Imp.
pints). Top up as needed with oil of the recommended
grade. Engine oil should be changed for the first time after
1,200 miles (2,000 km). Subsequent oil changes every
5,000 miles (10,000 km) (up to and including 1978
model) and every 10,000 miles (15,000 km) (as from
1979 model) respectively or at least once a year.
DRAIN PLUGS
1. Engine
2. Transmission
The oil filter cartridge should be replaced when chang,ing the oil.
The engine drain plug has a hexagonal head.
Tightening torques
Drain plug
engine
Drain plug
gear box
Level plug
120-2
30-45 ft.-lb., 40-60 Nm (4-6 kpm)
30-45 ft.-lb., 40-60 Nm (4-6 kpm)
22-30 ft.-lb., 30-40 Nm (3-4 kpm)
5'lMI
4. Manual transmission
Check the oil level in conjunction with servicing (up
to and including 1978 model every 5,000 miles
(10,000 km) and as from 1979 model every 10,000
miles (15,000 km). Up to and incl. model 1977, check
,the .level by removing the level plug. As from model
1978, check the level on the dipstick.
When changing oil, drive the car for 15-20 minutes
before draining off the old oil. Clean the magnetic
drain plug, then add fresh oil through the transmission
filler plug opening until it runs out of the level plug
opening. Remember that it takes some time for the
oil to run from the primary gear housing into the
transmission case.
Transmissions with gear-train primary gear hold 3.0
litres of oil, and transmissions with chain-drive primary gear, 2.5 litres. Oil should be changed for the first
time after 1,200 miles (2,000 km) and thereafter:
- up to and including 1978 model every 20,000
miles (30,000 km)
- as from 1979 model every 30,000 miles (45,000
km)
the oil prescribed in API service SE.
Automatic transmission
Check the oil level in the automatic transmission in
conjunction with servicing (up to and including 1978
model every 5,000 miles (10,000 km) and as from
1979 model every 10,000 miles (15,000 km). Concerning oil change, see "Inspection of automatic transmission every 18,000 miles (30,000 km)". The filter
tube with graduated dipstick is located immediately
behind the radiator. The dipstick has different level
graduatior:is for hot and cold oil.
When the oil level is measured the car should be standing
on a level surface with the selector at P and the engine
idling. The oil level should then be somewhere between
the top and bottom of the appropriate cutout on the dipstick (see illustration).
Use a nylon rag, lint-free paper or chamois leather to
wipe off the dipstick - do not use rags that may leave
fluff on the dipstick.
If the transmission needs topping up, use only special
automatic transmission oil according to the following
recommendations:
Automatic transmission oil according to Ford specification M2C.33F or M2C.33G.
AL:tomatic transmission oil Type A, Suffix A and
Dexron may also be used for topping up.
The most scrupulous cleanliness must be observed
during filling.
The oil in the final drive unit must be checked:
- up to and including 1978 model every 5,000 mile~
(10,000 km)
- as from 1979 model every 10,000 miles (15,000
km) and changed:
- up to and including 1978 every 20,000 miles
(30,000 km)
- as from 1979 model every 30,000 miles (45,000
km)
Page 105
INSPECTION OF AUTOMATIC TRANSMISSION EVERY
18,000 MILES (30,000 KM) (MAINTENANCE PROGRAM
U3b)
DIPSTICK, AUTOMATIC
TRANSMISSION
DRAIN PLUGS, AUTOMATIC
TRANSMISSION
1. Engine
2. Final drive
To ensure the correct functioning and a long service life
of automatic transmissions, the following additional actions are recommended in conjunction with the ordinary
18,000 miles (30,000 km) inspection service.
1. Drain the oil.
2. Remove the cover plate and front oil pan.
3. Clean the strainer and the magnet.
4. Check the adjustment of the gear selector. Adjust as
required (adjusting nuts by transmission).
a. Find the central position of the D position in the
manual valve with the pawl button depressed.
b. Release the pawl button. Move the lever backwards
against the stop in the selector housing and note
the play.
c. Find the central position of the N position in the
manual valve with the pawl button depressed.
d. Release the pawl button. Move the lever forward
against the stop in the selector housing and note
the play.
The play should be the same. For adjustment, follow
the directions contained in Section 4 of the service
manual.
5. Check and if necessary adjust the rear band.
6. Check the tension and adjustment of the throttle
cable. The clearance between the clip on the cable and
the threaded part of the sheath should be between 1
and 2 mm. Adjust as necessary.
7. Install the front oil pan and cover plate. Fill with new
oil. Capacity: 3-3.5 litres.
STEERING GEAR, OIL LEVEL CHECKS
Check every 15,000 miles (20,000 km).
5. Carburetor damper.
Oil for automatic transmission type M2C.33F or equal
oil. The level should be min. 0.40 in (10 mm) under
the damper cylinder lower end.
6. Distributor breaker cam
Apply a small quantity grease at the rivet holding the
notch to the breaker contact.
Distributor lubricating felt under breaker plate:
Impregnate the felt with a moderate quantity of grease.
Throttle control: Wire bearing should be oiled. (the
accelerator cable should not be lubricated).
Hood lock mechanism: Door hinges and door stops.
Oil the hinges by dropping oil into the groove in the
head of the hinge pin. The hinges are accessible from
the front when the hood is open.
1. Lift the car in the left front jack support until the
wheel is just free from the floor and remove the
wheel.
2. Loosen the rubber bellows on the left tie rod and
turn the steering wheel to full right lock.
3. Check that the oil level reaches the middle of the tie
rod by inserting a screwdriver between tie rod and
bellows.
If necessary fill oil with the aid of an oil can.
4. Refit the clamp which is easier done if the steering
wheel is turned a little towards the middle position.
5. Refit the wheel and lover the car.
Lubricant oil: ,
Manual steering gear: According to API-Service G L4
SAE 80-90.
Servo steering gear: According to API-Service GL5
SAE 75.
r
120-3
f
Page 106
I
IN CONJUNCTION WITH RECONDITIONING
STEERING GEAR
In conjunction with reconditioning, the following lubrication points should be repacked with chassis grease.
Tie-rod end assemblies plus upper and lower ball joints:
Pack the bellows 3/4 full.
Lubricant: Saab special chassis grease.
Rear wheel bearings: Repack.
Lubricant: Saab special chassis grease.
Inner universal joint: Fill with grease. The quantity will
be correct if the driver is completely filled. Wipe off excessive grease after the drive shaft has been installed.
Lubricant: Soft EP grease with a lithium-lead base, and
which is capable of withstanding considerable variations
in temperature and load. Consistency according to
NGLI 1, ESSO Beacon EP 1, SHELL Alvania EP grease 1
type or equivalent.
Outer universal joint: The correct quantity of grease will
be obtained if the cup with the balls inside is completely
filled with grease.
Lubricant: Saab special chassis grease.
Clutch control: Coat the joint with grease.
Lubricant: Saab special chassis grease.
Release bearing: Fill the groove 3/4 full.
Lubricant: Saab special chassis grease.
Manual steering gear
In conjunction with steering gear overhaul, fill 8.1 fl.oz.
(0.23 dm3, 2.3 di) oil type EP 90.
Servo steering gear
Lubricant oil
When the steering gear is overhauled, add 6.5 fl.oz. (0.19
dm3, 1.9 di) of oil at one of the rubber bellows.
Oil grade: According to API-Service GL5 SAE 75.
Hydraulic oil
When making repairs on the hydraulic system, hydraulic
oil is added as follows:
1. Add oil to a level 0.4 in. (1 cm) above the lower part
of the strainer in the oil resen)oir.
2. Start the engine and re-fill to the above-mentioned
level.
Oil grade: Automatic transmission oil with the same specifications as that used for the automatic transmission.
The whole servo hydraulic system contains 2.0 pints
(1.2 dm3; liters).
FUEL
Recommended grade of fuel:
Carbureted engines minimum 97 octane gasoline
Injection engines
minimum 97 octane gasoline.
120-4
5"1'11
.L
Page 107
UNDERBODY AND
RUSTPREVENTING TREATMENT
PRELIMINARY WORK
TOUCHING-UP OF UNDERBODY COATING
partment, panel welds in the front floor, wheel housings and front fenders.
2. Remove the scuff plates, turn up the floor mats at the
sills and seal the four drain holes in the sills (two in
each sill), see fig.
Work site: Grease pit or 1.ift.
To retain the advantages afforded by underbody composition, the underbody, too. should be.regularly
inspected
0
and the coating touched up as necessary. Apart from protecting against corrosion, the coating improves sound insulation. This protection is particularly important with
regard to the fenders, which are continuously exposed to
wear from a constant barrage of flying stones and gravel.
Before covering worn or bare parts with fresh underbody
composition, clean the metal thoroughly with a scraper
and a steel-wire brush and then wash with gasoline or
suchlike. Before applying fresh composition, coat the
metal with a reputable make of rust inhibitive, and then
apply about 0.06 in ( 1.5 mm) thick coating of composition before the rust inhibitive has dried. Excessive application will result in the composition running and it may
even pull right away from the metal which it is intended
to protect.
Naturally, new metal panels, such as fenders, must always
be treated in a similar manner after fitting. If underbody
coating is applied prior to spraying it is essential that all
composition be washed off the surfaces which are to be
enameled.
.,
I
f
'\.;1
RUST-PREVENTING TREATMENT
The cars are treated with a rust preventive agent before
leaving the factory. Spraying with rust-preventive oil has
been greatly increased. The underside of the floor is
sprayed after the underbody compound is applied. The
rust preventing treatment which the car receive at the factory should be repeated within 12 months after delivery.
The reason for this is that some settlement of the electrophoretic paint may occur in the welded body joints after
the car has been driven for some time. Provided that this
treatment is performed in accordance with the instructions issued by Saab-Scania, further spraying with rustpreventive oil will only be necessary every second or
third year.
HOLES AND RUBBER PLUGS IN THE BODY
1. Clean the underbody, wheel housings and engine com-
DRAIN HOLES IN THE SILLS
3. Remove the wheels.
4. Mask the brake discs.
5. The reel belts on 2-door models should be completely
pulled out and remain out until the treatment is finished.
OIL, PRESSURE AND TEMPERATURE
About 3 1/2 pints (3 dm3; liters) of oil are used in the
treatment. Information on pressure for spraying should
be obtained from the oil manufacturer. Use heavy oil for
the underbody and wheel housings and light oil for the
members, cavities and welds. Heavy oil should be used
for application with a brush or oil can. In order to assure
sufficient penetration, the temperature of the car should
not be less than 50°F (+10°C).
The parts of the body which must be sprayed with rustpreventive oil are listed under the heading Points of
Treatment. In the body, holes equipped with slitted rubber plugs are provided. Through these holes spraying of
enclosed spaces is made.
141-1
Page 108
EQUIPMENT
2 high-pressure compressors for airless spraying with a
40: 1 pressure increase for heavy oil and 48: 1 for light
oil.
2 spray guns.
11.'11 Nozzles-which permit-t1c~~~s,to cavities, members, doors
1
1
•II I
.
,
\
H ,,
and through slitted 'rul:Hl'erplugs.
Oil can and brush for treatment of welds between wheel
housings and fenders.
compartment and the weld between the wheel housing
and the outer side panel in the luggage compartment.
The oil is applied liberally to the uppermost point of
the weld so it runs down along the weld.
POINTS OF TREATMENT -
NOTE
Points of treatment with slitted plugs can be treated
through the plug if the right nozzle is used.
Group 1 (from below)
The cavity formed by the front engine member up
against the front floor panel.
A hole 1.4 in. (35 mm) in di~. is provided in the
front floor panel.
The front floor, the wheel housings and the entire
underbody are sprayed with oil. Special care must
be taken in treating Z-beams, the cross member in
the engine compartment, jack attachment points
(including the rear attachment point) and the linkage arm attachment point in the middle of the floor.
Cross bar member.
The cavity in the cross bar member is treated
through the 0.4 in. ( 11 mm) dia. hole in the middle
of the member.
1.1.
1.2.
1.3.
EQUIPMENT FOR RUST-PREVENTIVE
TREATMENT
1. Nozzle for spraying doors
2. Nozzle for spraying members and cavities
3. Nozzle with reduced pressure for treatment of welds between
wheel housings and fenders. Can be substituted by brush or
oil can.
Group 2 '(from the sides)
2.1.
OIL SPRAYING
The treatment is divided up into four groups. In group 1,
the treatment i, done from below, in group 2 from the
sides and in groups 3 and 4 (horizontal reference line)
from inside the engine compartment. The underbody and
wheel housings are sprayed externally.
Cavities and members are sprayed internally. The welds
between the front floor and the wheel housings are
sprayed in the engine compartment,
Treated areas shall have a coat at least 30 µm thick. The
points of attachment between Z-beams.and the floor
shall be oiled liberally. All doors are oiled through holes
in the end, about 4 in. (100 mm) from the bottom edge.
A thin coat of oil shall be applied to the inside of the
doors.
TREATMENT WITH BRUSH OR OIL CAN
A brush or an oil can is used to treat the weld between
the wheel housing and the front fender in the engine
141-2
2.2.
The inside of the scuff plates is treated through the
0.8 in. (20 mm) holes in both ends on 2-door models.
The cavity formed by the outer side panel against
the outer scuff plate is treated through the 0.8 in.
(20 mm) dia. hole in the front edge.
Insert the nozzle through the hole in the end of the
side panel. Hold the gun as in fig. 1 and spray, then
twist the gun a half turn and spray again (fig. 2).
The oil stream should hit the outlined areas. Any
other spray direction will cause oiling of the seat
belts, side boards and adjoining trim. Only airless
spraying may be practised.
CAUTION
Point 2.2, 2-door models: Because of the location
of the reel belt next to the side panel, only the lower part of the side panel may be sprayed.
Page 109
S 4141
TREATMENT
2.3.
2.4.
2.5.
2.6.
Rear wheel housing bracket.
Two 0.8 in. (20 mm) holes are provided.
Doors.
2- and 4-door models are treated through the 0.8
in. (20 mm) holes in the rear ends.
4-door models only: The cavity in the lower rear
pillar is treated through the 0.4 in. ( 11 mm) hole.
4-door models only: The cavity up near the door
frame between the side panel, outer wheel housing
and end panel is treated through the 0.8 in. (20 mm)
dia. hole in the end panel.
OF SIDE PANEL
Groups 3 and 4 (horizontal reference line)
3.1.
3.2.
3.3.
4.1.
4.2.
SA.Ml
Hood.
The front part of the front hood frame is treated
through the holes provided.
Treat the joint between the outer wheel housing
and the front fender and between the front fender
and the fender end and the reinforcing piece in the
wheel housing panel beneath the bracket for the
lower door hinge.
Treat the joint between the front floor and the inner wheel housing back towards the bearing bracket.
Treat the cross member connected to the bearing
brackets through the excisting holes.
Treat the joint between the outer wheel housing
and the outer side panel from the trunk.
Trunk lid.
T_reatthe lower rib, as well as the other corners,
through the holes provided.
141-3
Page 110
---
-:::.-
3:3 Joint between front floor and
wheel housin.9
1 :1 Front engine member
1 :2 Z-Beams
1 :2 Jack atta~hment points
e::.=:."·:::;'.;:J
c=:' ::,_.:,_".)
3:3 Joint between front cross member
through holes provided
1 :2 Entire underbody + wheel housing
is sprayed with oil
4:2 Trunk lid
Lower rib, upper corner
4: 1 Joint between outer
wheel housing and
outer side panel
housing
~-----
2:2 Cavity between outer side panel
_an_d_scuff
plate
3: 1 Front part of hood .frame
1 :2 Front wheel housing
flange
2:4 Doors, 4 in (100 mm)
from bottom edge
2:5 Cavity in door
pillar
2: 1 Scuff plates, internal
~-,---~_2_:_3_R_e_a_r_w~heel housing bracket
/ 1 :3 Outer hole in lateral
load member
L
2: 1 Scuff plates,
internal
)
S4140