Page 21
Twin-carburetors
Make
Type
Diameter
Fuel needle
Float adjustment
Float valve
Damper oil
Quantity of oil in damper
Clearance between fast idle cam and
adjustment screw
Normal idling speed (warm engine
and headlamps on low beam)
CO content:
Up to and incl. model 1976
Zenith
150 CD-2S(E)
As from model 1977
150 CDSEVX
1 1/2"
BlDT
B5EJ (as from 1980 model B5EQ)
0.63-0.67 in. (16-17 mm) between
the highest point of the float and the
mating surface at the carburetor housing
0.08 in. (2.0 mm)
Automatic transmission oil to Ford specification M2C.33F or equivalent
Min. 0.39 in. (10 mm) under the upper
part of the damper cylinder
0.04 in. (1 mm)
850 ± 50 rev/min
Vacuum pipe to distributor, crankcase ventilation hose and, where applicable, the
vacuum pipe to the EG R valve disconnected.
1975 model
max. 3.5 % at 850 r.p.m.
1.5 ± 1 % at 850 r.p.m.
As from 1977 model EUROPE:
As from 1977 model SWEDEN:
1.0 ± 0.25 % at 2000 r.p.m.
Fuel jet setting (adjustable up to and
incl. model 1976)
0.098 ± 0.008 in. (2.5 ± 0.2 mm) between upper surface of fuel jet and jet
bridge surface in carburetter housing
Fuel jet installation setting (fixed as
from model 1977)
Fuel needle fitting in the piston (initial
position when adjusting)
Inserted to a distance of 0.098 in.
(2.5 mm) from jet bridge surface
Lower part of groove for plastic
washer appr. 0.016 in. (0.4 mm)
below bottom of vacuum piston
Initial setting for adjustment of fuel
needle as from model 1977
Temperature compensator opening at
room temperature (+68°F/+20°C)
Return spring for vacuum piston, color
Turn the adjustment screw (in vacuum
piston) clockwise down to the stop
(needle in highest position). Then
turn adjusting screw 1 1/2 turns
anti-clockwise (initial setting for
CO-setting)
0.004-0.012
Blue
in. (0.1-0.3
mm)
Others
Fuel pump (mechanical) type
Static fuel pressure at starter speed
Fuel tank capacity
AC Delco No. 7990045
0.17-0.25 bar (kp/cm 2 , 2.4-3.6
12.1 Imp. gal. (55 liters)
5"-S
J.
psi.)
020-7
Page 22
FUEL SYSTEM, INJECTION ENGINE
Components
Injection valve
Cold start valve
Mixture control unit:
Up to and incl. model 1976
Model 1977
As from model 1978
Air flow sensor:
Up to and incl. model 1976
Model 1977
As from model 1978
Fuel distributor:
Up to and incl. model 1977
As from model 1978
Bosch 0 437 502 004
Bosch 0 280 170 401
Warm up regulator, up to and incl.
model 1976
Warm up regulator, as from model
1977
Auxiliary air valve
Fuel filter, up to and incl. 1978 model
Fuel filter as from 1979 model
Fuel accumulator:
Up to and incl. model 1977
1978 model
As from 1979 model
Fuel pump:
Up to and incl. model 1977 (ca)
As from model 1978 (ca)
Termo time switch:
Up to and incl. model 1977*)
As from model 1977**)
*)
**)
Up to and incl. engine number:
As from engine number:
(As from 1980 model 0 437 502 012)
Bosch 0 438 040 004
Bosch 0 438 040 034
Bosch 0 438 040 049
(Turbo 0 438 040 041)
Bosch 0 438 120 013
Bosch 0 438 120 046
Bosch 0 438 120 071
(Turbo 0 438 120 087)
Bosch 0 438 100 005
Bosch 0 438 100 023
(Turbo 0 438 100 057)
Bosch 0 438 140 013
(Turbo as from 1980 model 0 438 140 070)
Bosch 0 438 140 020
Bosch 0 280 140 107
Bosch 0 450 905 005
Bosch 0 450 905 021
Bosch 0 438 170 001
Bosch 0 438 170 014
Bosch 0 438 170 010
Bosch 0 580 254 994
Bosch 0 580 254 978
Bosch 0 280 130 214
Bosch 0 280 130 217
Bl20 P0l-8201,
Bl20 P0l-8202,
Test values
1. Fuel pump, capacity. (minimum flow
against system pressure, i.e. measured
in the return pipe).
B 120 P02-3301, Bl20 P07-1626
Bl20 P02-3302, Bl20 P07-1627
Up to and including 1977 model 750 cm3/30 sec.
As from 1978 model 900 cm3/30 sec.
2. Control pressure, cold engine
kp/cm2
barr---.---.-----.-----,--~
kp/cm2
L&.
2,5 t---+--+--+-t--+--+-71!f!l;,.;,.;t-t---i
2,5
,'</!:...·.:.::
:
/
2,0
V I/
VV
1,5
V V
V
1,0
/
I/
./
,V
1,0 r--+--+--+---+--~
V
I/
0,5 _...___.___._,.._._....___.___._~
30
40
0
10
20
0,5
Q5L--......L.. _
0
10
20
30
40
10
__j
__
20
0 438 140 013
020-8
0 438 140 020
30
_
40
__J
oc
S 7197
S6648
S 5200
_J__........I
0 438 140 070
Page 23
Wt't',1
1111111
111111
1111111
111111
1111111
111111
1111111
1
3. Control pressure, warm engine
4. Control pressure, fully-laden Turbo
1978-1979 models:
- throttle valve switch activated
(62° throttle opening)
- Speed function (80 m.p.h.
(130 km/h)
1980 model:
- Throttle valve switch activated
(62° throttle opening)
- Simulated charging pressure over
0.33-0.40 bar
5. Line pressure:
Test value
Setting value
6. Leakage check:
Minimum pressure after 20 minutes
As from 1978 model
7. Injection valve:
Opening pressure up to and including
date code 828 ( 1978)
Opening pressure as from date code
829 (~ 1979 model)
Opening pressure ~ 1980
model
Maximum variation between injection valves in same engine
8. Leakage check, injection valve
9. Idling speed setting (warm engine and
dipped headlights):
RPM
CO content:
- Up to and including 1976 model
- EUROPE as from 1976 model
- SWEDEN as from 1976 model
Tightening torques
Air flow sensor:
Stop bracket retaining screws
Counterweight retaining screw
Air flow sensor plate retaining screw
Fuel distributor retaining screws
Line pressure regulator screw plug
M 8 bolt
M 10 bolt
M 12 bolt
M 14bolt
M12capnut
M 14 cap nut
3.4-3.8
bar (~ kp/cm2, 48.5-54.0
1 .'.♦.'.♦.'1
psi.)
,'t'.♦.'.'.'1
111111
1111111
.1.11.1.1.1
2.5-2.9 bar (~ kp/cm 2 , 35.6-41.2
psi.)
2.5-2.9 bar (~ kp/cm 2 , 35.6-41.2
psi.)
2.5-2.9 bar (~ kp/cm2, 35.6-41.2
psi.)
2.5-2.9 bar (~ kp/cm2, 35.6-41.2
psi.)
4.5-5.1 bar(~ kp/cm2, 64.0-72.5 psi.)
(Turbo 5.2-5.8 bar (~ kp/cm2, 74-82.5 psi.)
4. 7-4.9 bar (~ kp/cm2, 66.9-69. 7 psi.)
(Turbo 5.4-5.6 bar (~ kp/cm2, 76.8-79. 7 psi.)
1.0 bar(~ kp/cm2, 14.2 psi.)
1.5 bar (~ kp/cm 2 , 21.3 psi.)
2.5-3.6 bar (~ kp/cm2, 35.6-49.8
psi.)
2.7-3.8 bar(~ kp/cm2, 38.4-54 psi.)
3.0-4.1 bar (~ kp/cm2, 42.6-58.3
psi.)
0.6 bar (~ kp/cm2, 8.5 psi.)
The system should maintain a pressure of
2.4 bar (~ kp/cm2, 34.1 psi.) for 15 sec.
875 ±50
Max. 3.5 %
1.5 ± 1 %
1.5 ± 0.5 %
4.7-5.3 Nm (3.4-3.8 ft.lb., 47-53 kpcm)
4.7-5.3 Nm (3.4-3.8 ft.lb., 47-53 kpcm)
5.0-5.5 Nm (3.6-4.0 ft.lb., 50-55 kpcm)
3.2-3.8 Nm (2.3-2.7 ft.lb., 32-38 kpcm)
13-15 Nm (9.4-10.8 ft.lb., 130-150 kpcm)
10-12 Nm (7.2-8.7 ft.lb., 100-120 kpcm)
13-15 Nm (9.4-10.8 ft.lb., 130-150 kpcm)
20-24 Nm (14.4-17.4 ft.lb., 200-240 kpcm)
15-20 Nm (10.8-14.4 ft.lb., 150-200 kpcm)
15-20 Nm (10.8-14.4 ft.lb., 150-200 kpcm)
25-30 Nm (18.1-21.8 ft.lb., 250-300 kpcm)
Turbo system
Turbo compressor make
Maximum charging pressure (see
Measuring the charging pressure)
Approximate length of spring in
charge pressure regulator (basic
setting
Pressure switch actuating pressure
Play, turbo shaft bearings:
Axial play
Radial play
Garrett Ai Research
0.70±0.05 bar (kp/cm2, 12.8±1.4 psi.)
Approx. 18 mm (0.708 in.)
0.9±0.1 bar (kp/cm2, 12.8± 1.4 psi.)
0.025-0.10 mm
0.075-0. 18 mm
SA_AUI
020-9
Page 24
Fuel boosting device, 1979 model:
Type
Throttle valve switch (throttle
opening when switch closes)
Speed transmitter (closing speed)
Pressure regulator (reduced control
pressure)
CO value with throttle valve switch
depressed (CO value at idling speed
set at 1.0-2.0 %)
Fuel boosting device as from 1980
model:
Type
Warm-up regulator
Simulated charging pressure when
the control pressure is reduced
Reduced control pressure (with
charging pressure over 0.4 bar
(5.7 psi.)
Throttle valve switch (throttle
opening when the contact closes
Increased CO value at idling speed
with simulated charging pressure
over 0.4 bar (5. 7 psi.)
Control of line pressure (Cl system) using throttle
valve switch and speed transmittor
62° approx.
80±3 m.p.h. (130±5 km/h)
2.5-2.9
bar ( kp/cm2, 35-41.2
psi.)
4-6 % CO approx.
Charging pressure activated fulload
boosting. (Warm-up regulator
and special control system)
0.33-0.40
2.5-2.9
bar (kp/cm2, 4.7-5.7 psi.)
bar (kp/cm2, 35-41.2
psi.)
62° approx.
4-6 % CO approx.
EXHAUST EMISSION CONTROL SYSTEM
On-off
Around 1 900 rev/min
2.36 ± 0.20 in (60 ± 5 mm) Hg
Approx. 100°F (38°C)
Two port(lnjection engine with
automatic transmission, as from
model 1978)
2 600 ± 300 rev/min
2.36 ± 0.2 in (60 ± 5 mm) Hg
Approx. 1oo°F (38°c)
0.16 in (4 mm)
No restriction
EGR system
EGR cut-in speed (fast idling)
Vacuum necessary to open EGR valve
Opening temperature of PVS valve
Restriction diameter at EGR outlet
in exhaust manifold
Deceleration valve, carbureted engines (up to
and incl. model 1977)
Setting:
1. Turn the valve screw clockwise until engine speed
ceases to increase.
2. Turn the valve screw counter-clockwise until the engine has returned to idling speed and then turn the
screw a further 1/2-3/4 turn clockwise from this position.
Checking:
Rev the engine and release the throttle. Check that the
engine speed - after slight delay - returns smoothly and
surely to idling speed.
020-10
SAftll
Page 25
Electrically controlled deceleration device
(Carbureted engines as from model 1978)
Speed transmitter
Deceleration solenoid, adjusting
Provides voltage to the solenoid when
the speed of the car exceeds 19-22
mph/30-35 km/h. (The speed transmitter should be checked with a test
lamp of 0.1 W max.)
Increasesthe idling speed to 1 550
rev/min. (Turbo USA 1978-1979
model: 1400±50 r.p.m.), when the
throttle is closed and the colenoid
throttle is closed and the solenoid
connected to battery voltage (at
speedsabove 19-22 mph/30-35
km/h)
N.B.
The solenoid cannot open the
throttle valve but merely functions as a stop to prevent the
throttle closing completely
during engine overrun at speeds
exceeding 19-22 mph/30-35
km/h.
Deceleration valve, injection engines
Time for engine speed to drop from
3000 rev/min to idling speed
Up to and incl. model 1976
As from model 1977
4-5 s
3-6 s
Delay valve
Delay of vacuum signal to vacuum
regulator in distributor
Dashpot, fuel injection engines
Check. Deceleration time from 3000
r.p.m. to idling speed
Setting. R.p.m. when the dashpot rod
hits the stop on the throttle spindle.
(Vacuum pipe disconnected from the
distributor, engine warm)
6±2 sec. (Turbo Sweden as from
1979 model: 20±4 sec.)
3-6 sec.
1979 model: 2600±100
As from 1980 model: 2000±100
EXHAUST SYSTEM
Exhaust pipe inner diameter
1.73" (44 mm)
COOLING SYSTEM
Type
Liquid capacity of cooling system incl.
heating system
Thermostat opens at
Radiator pressure cap opens at
Pressurized
7 Imp. quarts (8 liters)
89°±2°
0.9-1.2 bar (kp/cm 2 , 12.8-17.0 psi)
SAMI
.L
020-11
Page 26
WATER PUMP
Clearance between pump shaft and
pump cover
No adjustment needed. Original
gasket gives correct clearance.
Hammers must never be used when
removing or installing the later version water pumps (impeller retained
by nut). As from model 1977, the
thread on the water pump shaft is
only used during removal of the
pump.
See Group 2.
TIGHTENING TORQUES
Main bearings
Crank bearing screws
Camshaft bearing caps
Valve cover
Crankshaft belt pulley
Sealing end (flywheel side)
Cylinder head screw
Flywheel
Water pump impeller (earlier version,
screw)
Water pump impeller (later version, nut)
Oil pump
Spark plugs
Jackshaft keeper plate
Chainwheel, jackshaft
Chainwheel, camshaft
Inlet manifold
Thermostat housing
Throttle valve housing
Exhaust manifold( model 1975)
Exhaust manifold (as from model 1976)
Dimension
M 12
M 10
MS
M6 (M 8)
M 16
MS
M 12
M 10
M 8 (left-hand
thread)
M 12 ( left-hand
thread)
MS
M 14x 1.25
MS
M 10
MS
MS
MS
MS
M 10
MS
'
For other bolts, use general tightening torques:
Dimension
M5
M6
MS
M10
020-12
Nm
4.9
9.8
19.6
39.2
Tightening torque
kpm
ft.lb.
0.5
1.0
2.0
4.0
3.6
7.2
14.4
28.9
Nm
108
54
18
2.0
190
20
93
59
25
Torque
kpm
11
5.5
1.8
0.2
19
2.0
9.5
6.0
2.5
15
1.5
11
18
28
20
25
20
18
1.8
2.8
2.0
2.5
2.0
1.8
1.8
1.8
2.5
2.0
13
20
14
18
14
13
13
13
18
14
18
18
25
20
ft.lb.
-79
40
13
1.4
137
14
69
43
18
Page 27
Electrical system
BATTERY
Voltage
Capacity
12 V
60Ah
ALTERNATOR
Bosch55 A
Type designation
Rated voltage
Rated speed
Max. permissable continuous load
Power rating
Stator connection
Bosch K1 ____,. 14 V 55 A 20
14 V
2,000 r.p.m.
55 A/14 V
790W
Star connection
J..
SEV and Marchal 55 A
Up to and including 1978 model
As from 1979 model
Voltage/current at 5000 r.p.m.
Stator connection
with separate charging regulator
with intergrated charging regulator
14 V/55 A
Delta connection
4
Bosch65 A
Type designation
Rated voltage
Rated speed
Max. permissable continuous load
Power rating
Stator connection
Bosch K1--.
14 V
2,100 r.p.m.
65 A/14 V
840W
Star connection
14 V 65 A 21
,A.
Motorola 70 A
Rated voltage
R.p.m./current produced at:
1,800 r.p.m.
3,300 r.p.m.
5,000 r.p.m.
6,000 r.p.m.
8,000 r.p.m.
Power rating
Stator connection
Direction of rotation
Pully ratio, engine/alternator
14 V
36.5 A
62 A
69A
71 A
73 A
950W
Delta connection
Clockwise
1 :2.3
A
·'
STARTER
Type designation
No. of cogs on pinion
No. of cogs on ring gear
Gear ratio
Output rating
Bosch GF (R) 12 V O 001 311 108
9
142
15.8:1
0.8 kW (1.1 hp)
SAAB
020-13
Page 28
Test results
Mechanical:
Brush spring pressure
Backlash
Distance from pinion to ring gear
Contact reserve
Axial play of rotor
Rotor brake friction torque
Pinion free wheel torque
Electrical:
No load, 11.5 V and 35-55 A
Loaded, 9 V and 205-235 A
Locked starter
Lowest engagement voltage for solenoid
DISTRIBUTOR
11.3-12.8 N (41-46 oz., 1150-1300 p)
0.014-0.024"
(0.35-0.60 mm)
0.098-0.118"
(2.5-3.0 mm)
0.039" ( 1 mm)
0.002-0.012"
(0.05-0.30 mm)
0.25-0.40 Nm (2.2-3.5 in.lb., 2.5-4.0 kpcm)
0.13-0.18 Nm (1.1-1.6 in.lb., 1.3-1.8 kpcm)
6,500-8,500 rev/min
1,000-1.300 rev/min
6 V 325-375 A
8V
(conventional)
Bosch
Make
Bosch
JFU 4
Type designation
Ordering No.:
Cars with carbureted engines, model 1975,
Bosch O 231 170 115
with idler shaft of steel (12-tooth gear)
Cars with carbureted engines with idler
shaft of cast-iron and cars with injection
engines as from model 1976 (20-tooth gear) Bosch O 231 170 145
Cars with injection engines, model 1975,
with steel jackshaft ( 12-tooth gear)
Bosch O 231 170 122
Cars with injection engines, model 1975,
with cast iron jackshaft (20-tooth gear)
Bosch O 231 170 158
Cars as from model 1977 (20-tooth gear)
Bosch O 231 170 197 alt.
Bosch B 231 041 079
Capacitor
Bosch 1 237 330 280
Capacitance
0.2).JF ± 10 %
Basic ignition advance:
Model 1975
17° BTDC at 800 rev/min max. and
with vacuum hose disconnected
Model 1976, manual transmission
Model 1976, automatic transmission
As from model 1977, manual transmission
As from model 1977, automatic transmission
24° BTDC 2 000 rev/min and vacuum hose disconnected
27° BTDC 2 000 rev/min and vacuum hose disconnected
20° BTDC 2 000 rev/min and vacuum hose disconnected
Order of firing
Breaker gap
Dwell angle
Contact pressure
Rotation
Axial play, distributor shaft .
Rotor resistance
Ignition advance curves, see Group 3.
1-3-4-2
0.016" (0.4 mm) min.
50± 3°
4.9-6.2 N (18-23 oz, 500-630 p)
· Counter-clockwise
0.004-0.012"
(0.10-0.30 mm)
5,000 ohm
020-14
23° BTDC 2 000 rev/min and vacuum hose disconnected
Page 29
IGNITION
COIL (conventional)
Type designation
Resistance of primary winding at 68°F
(+20°C) (between connections 1 and 15)
Length of starting spark at 6 V 600
sparks/minute ( 150 distributor revolutions)
Median current through primary winding
at 4,000 sparks/minute (1,000 distributor
revolutions)
DISTRIBUTOR
2.6-3.1 ohm
0.4" (10 mm)
1.9 A
(breakerless ignition system) Turbo
Make
Type designation
Order number
Direction of rotation
Firing order
Rpm governor
Electronic control unit (brakerless
ignition system)
Electronic control unit, order no.
Compensating resistor
With starter motor connected
Total, when driving
Basic setting (disconnected and plugged
ignition vacuum pipe):
Turbo, Sweden
Turbo, Europe
Rotor arm resistance
IGNITION
Bosch KW 12 V
Bosch
JGFUD 4
Bosch O 237 011 002
Clockwise
1-3-4-2
Rotor with built-in centrifugal switch
which cuts out ignition when engine
speed exceeds 6,000 + 200 r.p.m.
-100 r.p.m.
• TSZ-2g/1 4/SI
0 227 100 014
0.6 ohm
1.0 ohm
20° BTDC at 2,000 r.p.m.
23° BTDC at 2,000 r.p.m.
5,000 ohm
COIL (brakerless ignition system)
Type de~ignation
Order number
Primary winding resistance at 68°F
(+ 20°c) approx. (between connections 1 and 15) ,
Secondary wYnding resistance
Length of starting spak
Median current\through primary winding
with distributor rotating at 1,000 r.p.m.
Bosch kW 12 V
Bosch O 221 122 014
1-1.4ohm
5.5-8.5 kohm
Min. 0.47 in. (12 mm)
3.2 A
SPARK PLUGS
Type
Thread
Thread length
Electrode gap
Tightening torque
NGK BP-6ES
Hard driving (e.g. motorway/freeway)
Bosch W 175 T30~,;.::Champion N_:8f~- •·
M 14 x 1.25
0.7" (19 mm)
0.024-0.028" (0.6-0.7,mm)
2.5-3.0 kpm)
25-29 Nm (18.1-21.!tft.lb.,
SA_t\B
NGK BP-7ES
020-15
Page 30
IGNITION CABLES
Resistance:
Cables to cylinders 1 and 2
Cables to cylinders 3 and 4
Cable between ignition coil and
distributor incl. connections
Up to and incl. model 1976
As from model 1977
14,500 ohm ± 20%
13,500 ohm ± 20%
3,250 ohm ± 20 %
3,000 ohm ± 20 %
1,000 ohm ± 20%
1,000 ohm± 20 %
FUSES
In the main fuse box:
Number, up to and
incl. model 1976
2
7
3
Number, as from
model 1977
4
5
3
Rated current
5A
8A
16 A
Lentgh x Diameter
1 x 0.25" (25 x 6 mm)
1 x 0.25" (25 x 6 mm)
1 x 0.25" (25 x 6 mm)
The 3 A glasstube fuse for the headlight wipers is located
in a separate fuse holder.
DIRECTION INDICATOR FLASHER
Type
Flashing frequency
Tungsol 550-12 V
Hella 91/1 P3 V 2 x 21 W - 12 V
60-120 impulses/minute
LIGHT BULBS
Headlights
Front direction indicators
Front direction indicators, as from
model 1977
Power
60/55 W
21 W
Cap
p 43t-38
BA 15 S
Oty.
2
2
21/5
BAY15d
2
BA 15 S
2
BAY 15 d
2
BA 15 S
6
BA 15 S
BA 15 S
BA 15 S
2
2
2
BA 15 S
2
2
Front parking light, up to and incl.
5W
model 1976
Cornering lights/parking light, as from
21/5
model 1977
Rear direction indicators, stop and
21 W
back-up lights
Rear direction indicators, as from
21 W
model 1977
5W
Tail lights, up to and incl. model 1976
21 W
Side reversing light, as from model 1977
Number plate light, Saab 99 (99 L). 99 L
5W
(99 GL), 99 GLE and 99 EMS
Number plate light, Saab 99 Cambi Coupe 5W
10W
Dome light
Trunk light, Saab 99 (99 L), 99 L (99 GL).
5W
99 GLE and 99 EMS
10W
Trunk light, Saab 99 Cambi Coupe
1.2 W
Heater control illumination
2W
Ignition switch illumination
5W
Rear view mirror light
1.2 W
Instrument and indicator lights
1.2 W
Hazard warning signal switch
Switch, electrically heated rear window
Saab 99 Cambi Coupe
(Model 1975: Only Saab 99 Cambi Coupe.
Model 1976: Not Saab 99 L)
Switch cornering light
020-16
sv 8.5-8
sv 8.5-8
sv 8.5-8
sv 8.5-8
W2 x 4.6 d
BA9 S
sv 8.5-8
W2 x 4.6 d
W2 x 4.6 d
1.2 W
W2 x 4.6 d
1.2 W
W2 x 4.6 d
SA.Ml
1
9
(Twin-filament lamp with
one wire used)
(Twin-filament lamp)