Page 151
VALVE MECHANISM
4. Remove the adjusting pallets. Be careful not to mix
them up.
5. Remove the camshaft bearing assembly.
6. a. Depress the valve spring using valve spring tool
8392300.
b. Remove the valve locks (clips), loosen the spring
tension and withdraw the tool.
VALVE COVER
Removing
1. Disconnect the crankcase ventilation hose.
2. Detach the ignition cables from the valve cover and
spark plugs.
3. Back off the screws and lift off the cover.
.......
,11111
11111,
11111
,11111
'""
:""'
♦:♦:♦:♦:•
Replacing
11111
:,:,:❖:•
If the screws have been tightened too hard so that the
contact surface around the screw holes has been depressed,
the surface should be restored before the cover is fitted.
If this is neglected, the contact pressure between the holes
will be reduced.
1. Fit the gasket. The original gasket may be reused if
undamaged.
2. Fit the cover.
3. Connect the ignition cables.
4. Connect the crankcase ventilation hose.
11111
IHII
S3827
NOTE
Do not tighten the screws so hard that the cover is
deformed - see tightening torques, Group 0.
VALVES
REMOVING THE VALVES
Tool8392300
7. Remove the top valve retainer, valve spring and guide
sleeve.
8. Withdraw the valve.
Disassembling
(Cylinder head removed from cylinder block)
1. Remove the camshaft bearing caps.
2. Lift out the camshaft.
3. Withdraw the valve depressors, using the magnetic
tool, and lay them aside in the correct order.
VALVE MECHANISM
1. Valve
2. Valve spring seat
3. Valve spring
4. Retainer
5. Lock
6. Adjusting pallet
7. Valve depressor
8. Camshaft
REMOVING THE VALVE DEPRESSORS
Tool8391401
SAAB
214-1
Page 152
Assembling
VALVE GUIDE
1. Insert and oil the valve spindles.
2. Insert the guide sleeve before the spring.
3. Insert the springs and top retainers.
4. Depress the spring, using a valve spring tool, and fit
the valve locks (clips). Then release the pressure on
the spring and check that the clips are correctly positioned on the spindle. Remove the tool.
5. Mount the camshaft bearing assembly.
6. Insert adjusting pallets, replacing them in their original
positions.
7. Insert the valve depressors, lubricating the bearing surfaces with engine oil.
8. Install the camshaft.
9. Install the bearing caps. (NOTE the markings!)
Checking the wear
Pull out the valve about 0.12" (3 mm) from its seat and
check the radial play of the valve, by rocking the valve
disc. If the play at the disc exceeds 0.02" (0.5 mm). the
valve guide is to be exchanged.
CAUTION
Do not turn or tip the cylinder head after inserting
the valve depressors, as these will then slide out and
the adjusting pallets will fall out of position and be
randomized.
Scrapping of sodium-filled exhaust valves
CHECKING THE VALVE
CAUTION
Never allow discarded sodium-filled valves to become mixed with normal scrap before they have
been properly treated. Failure to observe this will
result in a serious risk of explosion when the scrap
is melted.
GUIDE WEAR
Removal
Before removing a valve guide, flush the cylinder head
with warm water. The guide should be pressed out using
a press and the drift belonging to valve guide tool 83 92
631. (Valve guide tool 83 90 437 can be used as an alternative).
Sodium-filled exhaust valves (introduced during model
1977) are fitted in injection engines as from engine Nos.:
f
Wl!!JIJi1""
Bl 20 P01006201, Bl 20 P02002615, Bl 20 P04003376,
Bl 20 P05001556, Bl 20 P07001001 (and
Bl 20 P07000604-625)
Valves to be scrapped should be treated as follows:
1. Drill a hole through the centre of the valve head down
to the sodium compound.
2. Drill an additional hole in the stem or cut off the stem
about 25 mm from the bottom.
CAUTION
Keep the valve and sodium compound well away
from water when drilling or cutting the valves or
exposing the sodium compound in any other way,
as contact with water is likely to cause an explosion.
PRESSING OUT THE VALVE
Drift for tool 8392631
3. Throw the valve into a bucket of water. This will
cause an explosive chemical reaction. The manufacturer recommends that you should withdraw to a distance of at least 3 metres from the bucket. After a
period of one or two minutes, the reaction will die
down and the valve may be scrapped in the normal
way.
214-2
SA.Ml
GUIDE
e
Page 153
Installation
MILLING VALVE SEATS
First flush the cylinder head with hot water. Insert the
guide from the camshaft by using a press and valve guide
tool 83 92 631 (valve guide tool 83 90 437 can be used
as an alternative).
Clean all parts and remove all traces of soot and dirt from
the valve and cylinder head duct.
Insert the centering guide for the set of cutters into the
valve guide from the valve seat end and tighten the clamping screw until the centering guide is securely clamped in
the valve guide. The valve seats in the cylinder head are
to be milled clean with a 45° cutter. It may be necessary
S367:
MILLING
VALVE SEATS
Tool 8392193
92 631
INSTALLING
to break up the hard surface of the exhaust valve seat first
with an emery cloth. After being ground clean, the valve
seat will usually be found to be too wide and must therefore be reduced. Reduce from inside with a 75o correcting cutter and from outside with an 11-12° correcting
cutter. Adjust the reduction so that the contact surface
of the valve seat touches the valve plate as close as possible to the center of the seat. This can conveniently be
checked by the use of a marking dye. After adjustment,
the seat width of both inlet and exhaust valves should be
0.040-0.080"
(1-2 mm).
avgasventilerna.
THE VALVE GUIDE
Tool 8392631 and press
S4586
VALVE SEAT ANGLES
The condition of the valve will decide whether it can be
machine ground or must be exchanged. The valve plate
angle must be 44.5°.
214-3
Page 154
GRINDING VALVES
Smear a thin coat of grinding paste on the valve seat and
insert the valve in the cylinder head. Make a few grinding
movements with the grinding tool, clean all traces of paste
off the seat, and check the fit with marking dye. Grind
once more if required and finish by milling if necessary.
gauge. The minimum feeler should slip in, but the maximum feeler should not. If this result is not obtained,
the clearance must be measured for adjustment.
4. Refit the valve cover.
Measuringand adjusting
VALVE CLEARANCE
General
The valve clearance is stable and adjustment is only
needed after long periods or when the valves are being
reconditioned. However the valve clearance should be
checked as follows:
1978 model every 25,000 miles (40,000 km)
1979 model every 30,000 miles (45,000 km)
Turbo
every 20,000 miles (30,000 km)
Checking
Check the valve clearance with a feeler gauge, comparing
with the maximum and minimum tolerances. The tolerance limits for pu~posesof valve clearance checking are
0.006" - 0.012" (0.15-0.30 mm) for inlet valves and
0.014" - 0.020" (0.35-0.50 mm) for exhaust valves.
The procedure is as follows:
1. Remove the valve cover.
2. Cars with manual transmission:
Engage 3rd gear. Push the car forward or backward to
bring the camshaft cams into the correct measuring po·
sitions, i.e. with the cam of the valve to be measured
pointing 180° away from the valve stem. Two cams
will be in the ·measuring position at the same time.
2. Cars with automatic·transmission:
Rotate the crankshaft using special wrench 8392185
to bring the camshaft into position for measurement.
This special wrench fits the center screw of the crank·
shaft belt pulley at the dash panel.
3. Try the maximum and minimum clearances with feeler
If the clearance of any valve is found on checking to be
,outside the permissible limits, the clearance of all valves
must be measured.
Adjustment of valve clearance is to be based on actual
measurement. Measurements are made with tool 8391450
and a dial indicator.
Adjust the deviation of the valve clearance from the cor•
rect value by changing the adjusting pallet.
The procedure for measurement and adjustment is as follows:
1. Turn the cam to the measuring position ( 180° from
the valve stem).
2. Mount tool 8391450 and screw it on so that its triple
claw grips the valve depressor.
MEASURING THE VALVE CLEARANCE
Tool 8391450 and dial indicator
3. Mount the indicator dial in the tool so that the measuring point rests on the tip of the cam; zero the dial.
4. Lift the valve depressor with the measuring tool and
read off the deflection of the instrument pointer,
which indicates the valve clearance. Note the reading.
5. Measure and note down the clearances of all valves in
the same manner. Proceed to adjust the clearance of
any valves in which it does not lie within the following
limits:
Inlet valves
0.008"-0.010"
(0.20-0.25 mm)
Exhaust valves 0.016" -0.018" (0.40-0.45 mm)
(Turbo0.018" -0.020" (0.45-0.50mm)
6. Remove the camshaft and the valve depressors and adjusting pallets of any valves needing adjustment.
CHECKING VALVE CLEARANCE
214-4
Page 155
7. Measure and make a note of the thickness of the pallet.
(Special tool 8391633.) This thickness plus the valve
clearance adds up to the total distance between the
valve and the cam.
Example:
Measured valve clearance
0.005" (0.13 mm)
0.100" (2.54 mm)
Measured pallet thickness
Total distance
0.105" (2.67 mm)
MEASURING AND ADJUST! NG VAL VE CLEARANCE
AFTER VALVE RECONDITIONING
1. Install adjusting pallets with a minimum thickness of
0.070" (1.77 mm).
2. Insert depressors and install the camshaft.
3. Measure the valve clearances, note the reading for each
valve and calculate the total distance.
sn10
MEASURING ADJUSTING PALLETS
TURNING THE CAMSHAFT ON A REMOVED CYLINDER
HEAD
Tool8391633
4. Select nelllipallets to give the correct clearances.
5. Remove the depressors and the camshaft, take out the
0.070" ( 1.77 mm) pallets and insert new pallets to
give the correct clearances.
6. · Replace the depressors and reinstall the camshaft.
7. Check clearance measurements once more with the
dial indicator. To make your choice of adjusting pallets easier, use the table on the next page.
The choice of adjusting pallet is determined by the
measured total distance between the valve depressor
and the cam less the specified valve clearance for an
intake or exhaust valve as the case may be.
Example:
0.105" (2.67 mm)
Total distance
Less specified inlet valve 0.008" -0.01 0"
(0.20-0.25 mm)
clearance
Required pallet thickness 0.097". (2.44 mm)
Choose a pallet with thickness 0.096" (2.43 mm).
8. Insert the new adjusting pallet and the valve depressor
and install the camshaft.
9. Repeat the measurement procedure to check that the
clearances are now correct.
S.MI
.L
214-5
Page 156
REPLACEMENT OF VALVE SPRINGS WITHOUT REMOVING CYLINDER HEAD
1. Remove the valve cover.
2. Rotate the crankshaft until the No. 1 cylinder is in
the ignition position.
3. Fit a nut (screw) to the camshaft sprocket center and
tighten the camshaft sprocket against the retaining
plate.
WARNING
..
Tighten the nut (screw) fully, so that the center
stud is held securely immobilized. Otherwise the
chain tensioner will tighten the chain and lock in
a new position so that the sprocket cannot be refitted.
4. Remove the screws holding the camshaft sprocket to
the camshaft.
5. Unscrew the camshaft caps and remove the camshaft.
6. Remove the valve depressors and adjusting pallets.
7. Remove the camshaft bridge.
8. Take out the spark plug for the cylinder requiring a
new valve spring and fit an air hose connector (tool
8392326) in the spark plug hole. Connect the cylinder to a compressed air supply to prevent the valve
dropping into the cylinder.
9. Apply the valve spring tool (tool 8392300) as shown
REMOVING VALVE SPRINGS
Tools 8392300 and 8392326
in the illustration. Compress the valve spring and pick
up the valve spring retainers using a magnetic tool. Remove the valve spring and the valve spring seat.
Reassemble in the reverse order.
NOTE
When the camshaft is fitted the installation marks
for the camshaft and the crankshaft must be in
the firing position for no. 1 cylinder.
A fully-opened exhaust valve can strike the piston at top dead centre.
214-6
SAAB
Page 157
..
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..0B
'6
.!:
iii
..
..
..
.,,
.,
~
..
I
u
..
,5
~
'i
'ti
I
0,00
0,02
0,05
0,07
0,10
2,64
2,69
2,69
2,74
2,74
012
0,15
0,17
0,20
2,79 2 74 269
2,79 2,74 2,69
2,84 2,79 2,74
2,84 2,79 2,74
0,22
0,25
0,27
0,30
0,32
0,35
0,37
0,40
0,42
0,45
0,47
:,
0,50
0,52
0,55
u
0,57
0,60
0,62
0,65
0,68
0,70
C
!!
>
ii
>
2,59 2,54
2,64 2,59
2,64 2,59
2,69 2,64
2,69 2,64
2,48
2,54
2,54
2,59
2,59
2,43
2.48
2,48
2,54
2,54
2,64 2 59
2,64 2,59
2,69 2,64
2,69 2,64
2,89 2,84 2,79 2,74 2,69
2,89 2,84 2,79
2,89 2,84
2,89 2,84
2,89
2,89
2,74
2,79
2,79
2,84
2,84
2,89
2,89
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,89
2,89
0,72
Measured pallet
thickness, inlet (mm)
Measured pallet
thickness, exhaust (mm)
2,89 2.84 2, 79 2,74 2,69
2,38
2,43
2,43
2,48
2,48
2,33 2,28 2,23
2,38 2,33 2,28
2,38 2,33 2,28
?,43 2,38 2,33
2,43 2,38 2,33
2 54 2 48 2 43 2,38
2,54 2,48 2,43 2,38
2,59 2,54 2,48 2,43
2,59 2,54 2,48 2,43
2,64 2,59 2,54 2,48
2,18
2,23
2,23
2,28
2,28
.I
2,13
2,18
2,18
2,23
2,23
2,08
2,13
2,13
2,18
2,18
2,03
2,08
2,08
2,13
2,13
1,98 1,93 1,88 1,82 1,77
2,03 1,98 1,93 1,88 1,82 1,77
2,03 1,98 1,93 1,88 1,82 1,77
2.08 2,03 1,98 1,93 1,88 1,82 1,77
2.08 2,03 1,98 1,93 1,88 1,82 1,77
2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93 1,88 1,82 1,77
2,33 2,28 2,23 2, 18 2, i3 2,08 2,03 1,98 1,93 1,88 1,82 1,77
2,38 2,33 2,28 2,23 2, 18 2,13 2,08 2,03 1,98 1,93 1,88! 1,82 1,77
2,38 2,33 2,28 2,23 2.18 2,13 2,08 2,03 1,98 1,93 1,88i1,82 1,77
2,43 2,38 2,33 2,28 2,23 2,18 2, 13 2,08 2,03 1,98 1,93 1,88 1,82 1,77
2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2.18 2,13 2,08 2,03 1,98 1,93 1,88
1,82 1,77
2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03
1,98 1,93 1,88 1,82 1,77
2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93
1,88 1,82 1,77
2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93
1,88 1,82 1,77
2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93 1,88 1,82 1,77
2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93 1,88 1,82
1,77
2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93 1,88 1,82
1,77
2,84 2,79 2,74 2,69 2,64 2,59 2,54 12,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93 1,88 1,82
1,77
2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93 1,88
1,82 1,77
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18
2, 13 2,08 2,03 1,98 1,93 1,88 1,82
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13
2,08 2,03 1,98 1,93 1,88 1,82
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2.48 2,43 2,38 2,33
2,28 2,23 2,18 2, 13 2,08 2,03 1,98 1,93 1,88
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23
2,18 2,13 2,08 2,03 1,98 1,93 1,88
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08
2,03 1,98 1,93
2,8912,84 2,79 2,74 2,69 2,64 2.59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03 1,98 1,93
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2.54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08
2,03 1,98
2.39 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2.18 2,13
2,08 2,03 1,98
2,89 2,84 2,79(74
2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08 2,03
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2.28 2,23 2,18 2,13
2,08 2,03
2,89 2,84 2,79 2,74 2,69 2,64 2,59 2,54 2,48 2,43 2,38 2,33 2,28 2,23 2,18 2,13 2,08
2,64 2,59 ~ 2,48 2,43 2,38 2,33 2,28 2.23 2,18 2,13 2,08 2,03 1,98 1,93 1,88 1,82 1,77
2.89 2,84 2.19 2. 14 2.69 2,64 2.59 2,54 2.48 2.43 2.38 2,33 2,28 2.23 2. 18 2. 13 2.oe 2.03 1,98 1,93 1,88 1,82 1,77
HOW TO USE THE VALVE ADJUSTMENT TABLE
The following example illustrates how the table is used:
The inlet valve clearance is 0.13 mm and therefore needs
adjustment. The measured thickness of the adjusting pallet for this valve is 2.54 mm.
Starting from 0.12 mm, which is the closest figure in the
table to the measured clearance, go horizontally across
the table to the column above the inlet pallet thickness
of 2.54 mm. The correct pallet thickness, 2.43 mm, can
be read from the table at the intersection of the horizontal line from 0.12 mm and the vertical column from inlet
2.54 mm.
Page 159
TRANSMISSION
Instructions for transmission chain, camshaft and idler
shaft settings will be found in section 210.
CHECKING THE CHAIN TENSIONER
In order to prevent transmission damage caused by the
chain tensioner running out to far, the position of the
chain tensioner can be checked with the engine mounted
in the car.
1. Remove the valve cover.
2. Insert a steel rule down against the rubber neck on
the chain tensioner and measure the distance to the
level of the cylinder head cover.
3. The distance should be more than 11.8" (300 mm). If
the distance is less than 11.8" (300 mm), the engine
should be removed as soon as possible for correction.
For completely tight chain tensioners (newly adjusted
transmissions) the distance should be about 12.3" (313
mm).
SA.Ml
CHECKING THE CHAIN TENSIONER
215-1