Page 131
14.
15.
16.
17.
18.
Detach the speedometer cable from the transmission.
Undo the engine brackets.
Undo the larger clips round the rubber bellows on
the inner universal joints.
Fit the lifting yoke to the two engine lifting lugs.
Undo the lower end piece from the control arm on
the right-hand side and turn the steering wheel to
the left. Raise the power plant from the rear engine
cushions (the front bracket may rest on the cushion)
and withdraw the left universal joint, by moving the
power plant to the right. Move the power plant to
the left and withdraw the right universal joint.
GEAR SHIFT ROD JOINT TAPER PIN
13.
Automatic transmission:
Remove the gear selector cable retaining screw
from the gear box and position the gear selection
lever in "P".
UNDOING LOWER END PIECE FROM CONTROL ARM
REMOVING THE GEAR SELECTOR WIRE
Tool8790388
Earlier design: detatch the spring which holds the
cable to the gear selector lever using tool 87 90 388.
(Insert the tool in the end of the spring, rotate it
slightly and pull out the cable).
SEPARATING THE INNER UNIVERSAL JOINT
REMOVING THE GEAR SELECTOR WIRE
Later design: push back the spring loaded-sleeve on
the gear selector lever and release the end of the
cable.
19.
20.
..
Lift the power plant to a convenient height for ac•
cess to the cable connections on the starter. Disconnect the cables.
Hoist out the power plant. Fit protective caps over
the inner drivers and rubber bellows.
201-3
Page 132
LIFTING OUT THE POWER PLANT
INSTALLING THE POWER PLANT
1.
ASSEMBLING THE RIGHT INNER UNIVERSAL JOINT
5.
Cars with servo-assisted steering are equipped with
special rear engine cushions. The cushions are designed to prevent the power plant from hitting the
steering gear and damaging it in the event of a collision. A wire runs between the rear edge of the upper retaining plate and the front edge of the lower
retaining plate in the cushions. The position of the
cushions is determined by guides in the engine
bracket and the cushion.
a. Check that the inner universal joints are packed
with grease.
b. Check the front engine cushion. Make sure that
the washer is property tightened.
6.
7.
8.
FRONT ENGINE CUSHION
2.
3.
4.
Raise the power plant with the lifting yoke (tool
8292177) balancing the engine in such a way that
the engine mounting at the flywheel end comes into position before the other two mountings. Position the power plant in the engine compartment.
Lower the power plant to a convenient height for
f"rtting the starter. Connect the cables.
Assemble the inner universal joints as follows:
Hang the clips on the inner drivers. Lower the power plant until it is about 2-2 1/2" (50-60 mm)
from the engine cushions. Assemble the right-hand
universal joint, then lower the power plant until it
is about 1" (20-30 mm) above the engine cushions
while guiding the left-hand universal joint into place.
Connect the end piece to the lower control arm.
8.
9.
10.
11.
12.
13.
14.
15.
116.
17.
201-4
a. Align the engine brackets.
b. Bolt the power plant to the engine cushions.
Remove the lifting yoke.
a. Push the rubber bellows over the inner universal
joint drivers and fit the clamps.
b. Wipe any surplus grease off the rubber bellows
and check that the bellows are not deformed.
Manual transmission:
a. Connect the gear shift rod joint to the gear selec•
tor rod and insert the taper pin.
b. Model 1975: Fit the slave cylinder and adjust
the clutch. As from model 1976: Connect the
hose to the slave cylinder and bleed the clutch
system.
Automatic transmission:
Connect the gear selector wire to the transmission.
Connect the speedometer cable to the transmission.
Bolt the exhaust pipe to the exhaust manifold.
Lower the front e_nd of the car.
a. Connect the ground cable.
b. Fit the alternator.
Mount the front sheet complete with radiator and
connect the.hood lock operating cable to the attachment at the dash panel.
Fit the grille.
Reconnect the cables to the radiator fan, thermostat contact, headlights, headlight wiper motor and
clip the bundle of wiring to the front sheet.
Connect the coolant hoses to the radiator. thermostat housing, water pump and inlet manifold.
Connect the vacuum hose and fuel hose and connect cables to the temperature transmitter, ignition coil and oil pressure transmitter.
Page 133
18.
19.
19.
a. Connect the throttle control wire to.driver an(}
bracket.
b. Carbureted engine:
Connect the choke control wire to the carburetor.
Carbureted engines:
a. Mount the air cleaner and preheater complete
with hoses.
b. Connect the ventilation hose.
c. Connect the cables between the distributor and
ignition coil.
d. Connect the fuel pipe.
Injection engines:
a. Mount the air cleaner and mixture control unit
and COfVleCt the rubber bellows to the throttle
valve housing and the air flow sensor.
b. Fit the fuel lines.
c. Fit the cables to the warm-up regulator, auxiliary air valve, cold start valve, thermo-time switch
20.
21.
22.
23.
24.
and air flow sensor.
Install the battery and connect the cables.
Close the radiator and engine block drain cocks,
fill with coolant and oil.
Start the engine, checking oil pressure and coolant
temperature. Check the operation of the transmission. Check the operation of the radiator fan by
groundingthe thermostat contact cable to the radiator.
a. Mount the hood and connect the windshield
washer hose.
b. Check the fit of the hood. Close the hood, open
the doors, and check that the door jambs clear
the rear edge of the hood.
c. Check the headlight alignment.
Take the car out for a test run. Check the coolant
level after driving.
--L
20t-5
Page 134
SEPARATING ENGINE FROM MANUAL TRANSMISSION
1. Clean the power plant.
2. Drain the engine oil.
3. Take off the clutch cover.
4. Remove the starter.
5. Withdraw the clutch shaft (see instructions for disassembling the clutch).
6. Model 1975: Undo the three screws of the release
bearing guide sleeve.
As from model 1976: Remove the three retaining bolts
for the slave cylinder.
7. Back off the adjusting screw and disconnect the clutch
lever (model 1975).
8. Undo aH screws in the mating flanges of engine and
transmission.
9. Lift the engine carefully off the transmission (see
illustration). At the same time remove the release
bearing guide sleeve.
Reassemble in the reverse order.
CAUTION
If the engine and transmission fail to separate, ~o
not attempt to force them apart without first checking that all the screws have been taken out.
LOCKING THE ENGINE STAY SCREW
SEPARATING ENGINE FROM AUTOMATIC TRANSMISSION
SEPARATING ENGINE FROM TRANSMISSION
1. Clean the outside of the power plant.
2. Drain the engine oil.
3. Remove the cover over the flywheel ring gear.
4. Remove the starter.
5. Disconnect the throttle wire from the throttle valve
housing (carburetor).
6. Remove all screws in the mating flanges of enginf: and
transmission.
7. Remove the four screws securing the flywheel ring
gear to the torque converter. The screws can be reached from above the oil pump mounting.
Reassemble in the reverse order.
The threads of the following bolts through the mating
flanges of the engine/transmission should be coated with
a sealing compound (e.g. Permatex): 1, 2, 3, 6, 8 and 9
(refer to automatic transmission section for illustration).
Lock the bolt securing the engine stay to the cylinder
head by means of Loctite or equivalent.
201-6
SAAB
Page 135
Lock the bolt securing the engine stay to the cylinder
head by means of Loctite or equivalent.
SCREW HOLES FOR FLYWHEEL RING GEAR - TORQUE
CONVERTER
8. Turn the driver disc, so that the plate angles will be
horizontal. Lift the engine carefully off the transmission.
9. Fit the torque converter support (special tool 8790255).
LOCKING THE ENGINE STAY SCREW
Reassemble in the reverse order.
Reassemble in the reverse order.
When fitting together the engine and transmission:
Ensure that the mating flanges between the engine and
frahsmission are absolutely clean.
Check that the two dowels are fitted in the transmission casing.
Fit a new gasket on the transmission housing. Apply
sealing compound to both 3ides of the gasket as shown
in the illustration above.
Apply thread locking compound to the six bolts in the
h'ol-esas indicated in the lower illustration.
S.AEI
201-7
Page 137
ENGINEBODY
DISASSEMBLINGTHE ENGINE
1.
Mount the engine in a work stand.
REMOVING THE DISTRIBUTOR
7.
a. Remove the inlet manifold together with the
front lifting lug.
b. Remove the alternator bracket.
ENGINE MOUNTED IN WORK STAND
2.
3.
J.
Remove the distributor cap and disconnect the ignition cables.
Carbureted engine:
Remove the carburetor.
Injection engine:
Remove the throttle valve housing.
REMOVING THE INLET MANIFOLD
8.
9.
CAUTION
The water pump is available in two versions and the
procedure for removal and assembly of each is different. Under no cira.imstances must tappi~
hammers or the like be used during the removal or
assembly of pumps of versions II and Ill.
REMOVING THE CARBURETOR
4.
5.
6.
a. Remove the oil filter.
b. Remove the oil pump.
c. Remove the oil pump spacing piece.
d. Remove the suction line to the pump.
Remove the water pump {see section 262).
Undo the hose connections from the water pump,
by-pass system and aankcase ventilation circuit.
Remove the valve cover.
Remove the distributor.
SFllB
210-1
(
Page 138
10.
Remove the thermostat housing.
NUT (SCREW) MOUNTED ON THE CENTER STUD
REMOVING THE THERMOSTAT
11.
HOUSING
Remove the exhaust manifold with radiation shield.
(As from model 1976, the exhaust manifold is of a
2-branch type.)
CAUTION
Tighten the nut (screw) securely to immobilize the
center stud. Otherwise the chain tensioner will
tighten the chain and lock 1n a new position so that
the sprocket cannot be replaced in position.
13.
14.
c. Undo the retaining screws from the camshaft
sprocket. Separate the wheel from the camshaft
plate until it hangs free on the center stud in
the mounting plate.
Remove the camshaft bearing caps and lift out the
camshaft.
Remove the valve depressors and adjusting pallets.
REMOVING THE EXHAUST MANIFOLD
12.
Remove the camshaft sprocket as follows:
a. Turn the crankshaft to ignition position for No.
1 cylinder.
b. Model 1975: Screw a M8 nut on to the threaded
center stud of the camshaft sprocket and tighten
the center stud against the mounting plate provided
for the purpose.
b. As from model 1976: Bolt the mounting plate to
the center of the camshaft sprocket using one of
the camshaft sprocket retaining screws.
REMOVING THE VALVE DEPRESSORS
Tool8391401
15.
16.
17.
210-2
Remove the camshaft bearing assembly.
Unscrew all cylinder head screws.
Lift off the cylinder head and remove the gasket.
I
Page 139
REMOVING THE CYLINDER
HEAD
REMOVING THE CHAIN TRANSMISSION
18.
Remove the belt pulley screw and the pulley, using
when necessary puller 8392151.
REMOVING THE BELT PULLEY SCREW
20.
21.
COVER
Remove the chain tensioner.
Undo the chain guides, the mounting plate with
the camshaft sprocket and'transmission chain.
REMOVING THE TRANSMISSION
22.
I
PLANT
Remove the crankshaft sprocket. Universal puller
and tool 8391849 may be used, if necessary.
REMOVING THE BELT PULLEY
Tools 8390270 and 8392151
REMOVING THE CRANKSHAFT
Universal puller and tool 8391849
19.
Remove the chain transmission cover.
23.
SAMI
SPROCKET
Remove the idler shaft sprocket.
210-3
Page 140
REMOVING THE BEARING CAPS
REMOVING THE IDLER SHAFT SPROC;<ET
24.
Unscrew the idler shaft keeper plate and carefully
withdraw the idler shaft.
REMOVING PISTON AND CONNECTING ROD
27.
REMOVING THE KEEPER PLATE
28.
28.
25.
26.
Carefully remove any crusts and deposits of soot
from the top ends of the cylinders.
Note the markings on the connecting rods and bigend bearing caps so that they can be reassembled
later in their original positions. Remove the nuts
and bearing caps and push the pistons complete
with connecting rods out of the cylinders (see illustration). Protect the stud threads with pieces of
plastic hose when dismantling pistons and connecting rods.
For instuctions with regard to exchanging pistons
see page 210-10.
29.
Replace the big-end bearings and caps loosely on
the connecting rods from which they came.
Manual transmission:
Dismantle the clutch and flywheel.
Automatic transmission:
Remove the driver disc.
Remove the gable plate and shaft seal.
REMOVING THE GABLE PLATE
210-4
&AMI