Page 261
2. Up to and including 1976 model (design I and II):
CAUTION
If the impeller is not immobilized while the center
screw is unscrewed, the gear teeth on the pump
shaft and idler shaft are liable to be damaged.
Up to and incl. model 1976 (versions I and II), the
pump bearing and seals are mounted in a separate
bearing housing, which in turn is mounted in the engine block.
As from model 1977 (version 111),the pump bearing
and seals are mounted directly in the engine block.
Up to the later model 1976, the bottom end of the
pump shaft is seated in a bush. In later engines, the
shaft end is seated directly in the engine block.
Press the pump shaft with seals and ball bearing from
the bearing housing, using tool 83 90 544. Position
the pump with the driving gear uppermost.
6. Version 111:
Dismantle the water pump using tool 83 92 649 (or
83 92 490, older design) which fits onto the threaded
end of the shaft.
CAUTION. Hammers should never be used.
DISASSEMBLING
EXPELLING
(Pump removed from engine)
THE PUMP SHAFT
Tool 8390544
1. Mount the pump in tool 8390544 and push off the
impeller using tool 8390585.
3. Remove the pump seal, O-ring, thrower (version 1)
and seal ring.
4. Free the ball bearing lock ring.
5. Place the pump shaft and bearing in tool 8390536
with the drive end downward and press the shaft from
the bearing.
FORCING OFF THE IMPELLER
Tools 8390544 and 8390585
"'
~=------=...;.;..::..:.;.:~,;,;;:_---'
EXPELLING
THE SHAFT FROM THE BEARING
Tool8390536
/
SAAB
262-3
Page 262
2
3
5
6 ---..,,_uo
7 ---4...'l.:8'.I
8
WATER PUMP, VERSION
I
8. Ball bearing
9. Oil thrower ring
10. Bearing housing
11. O-rings
12. Seal ring
13. Pump shaft
1. Pump cover
2. Gasket
3. Impeller
4. Water pump seal
5. Thrower
6. Seal ring
7. Ball bearing lock ring
WATER PUMP, VERSION
111(AS FROM MODEL 1977)
1. Pump cover
2. Gasket
3. Impeller
4. Water pump seal
5. Sealing ring
6. Ball bearing lock ring
7. Ball bearing
8. Pump shaft
ASSEMBLING
1. Fit the oil thrower ring (version I).
2. Pressthe ball bearing on to the pump shaft using tools
8390551 and:
Version I
8390569
Versions 11and 111 8392524
2
3
5
6 ---,_LI,
7 --~8',I
9
'"""
WATER PUMP, VERSION
1. Pump cover
2. Gasket
3. Impeller
4. Water pump seal
5. Seal ring
262-4
II
6. Ball bearing lock ring
7. Ball bearing
8. Bearing housing
9. O-rings
10. Pump shaft
PRESSING THE BALL BEARING
ONTO THE SHAFT
Page 263
3. Fit the bearing lock ring.
4. Up to and including 1976 model (design I and 11):
Press the pump shaft complete with bearing into the
bearing housing (see illustration) with the housing
supported in tool 8390544. Press with tool 8390551.
s,111
FITTING THE WATER PUMP SEA, UP TO AND INCL.
MODEL 1976
Tools 8390544 and 8390536
INSTALLATION
CAUTION
Tapping-out hammers etc. must never be used during
installation of water pumps of version 11and 111.
PRESSING THE PUMP SHAFT INTO THE BEARING HOUSING,
UP TO AND INCL. MODEL 1976
Tools 8390544 and 8390551
1. Version I:
a. Mount the pump in the engine block, and check
that the pump gear engages the gear on the idler
shaft. Seat the bearing housing by means of sleeve
8390536. Ensure that the flange on the bearing
housing butts against the plane of the engine block.
b. Fit the impeller with washer and screw. Tighten the
screw with the prescribed torque of 25 Nm (18 ft.lb.,
2.5 kpm) counter-clockwise (Jett-hand thread).
1. Version II:
a. Mount the pump in the engine block and check that
the pump gear engages the gear on the jackshaft.
Seat the bearing housing using tool 83 92 649 (or
83 92 490) and sleeve 83 90 536. This takes pressure off the driving gear during insertion.
5. Up to and including 1976 model (design I and II):
Fit the seal ring using tool 83 90 551.
6. Fit the 0-ring.
7. Up to and including 1976 model (design I and 11):
Fit the water pump seal using tools 83 90 544 and
83 90 536.
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262-5
Page 264
PRESSING IN THE BEARING HOUSING, VERSION II
PRESSING IN THE PUMP SHAFT AND BEARING
Tool 8392490
Tool 8392490 (or 8392649 and 8390551)
b. Mount the impeller and the nut. Position tool
8392441 over the pump with two screws, do
not tighten the screws. Then turn the tool
clockwise so that the peg on the tool engages one
of the wings on the impeller.
Tighten the two screws.
Torque
I 15±2 Nm (10.8±1.5 ft.lb./1.5±0.2
kpm)
CAUTION
If the prescribed torque is exceeded, this will damage
the pump shaft.
1. Version Ill:
a. Mount the pump shaft with bearing and circlip in
the engine block by means of sleeve 8390551 and
drift 8392490 (or 8392649, later version). Check
that the pump gear engages the gear on the idler
shaft before pressing the shaft into position.
MOUNTING THE PUMP SHAFT INTO THE ENGINE BLOCK
262-6
b. Fit the lower seal using sleeve 8390551 ).
c. Fit the upper seal using tool 8390536 and a suitable
plastic hammer.
d. Press on the impeller using tool 8392490 (or
8392649, later version) and sleeve 8392524.
Turn the tightening bolt 1/4 turn at a time, unscrew
it and then tighten down 1/4 turn again until the
impeller is finally in position.
CAUTION
To avoid damaging the water pump bearing, do not
use more force than necessary to fit the impeller.
Ensure that the pump shaft and impeller hole have
been thoroughly cleaned before assembly.
2. Fit the gasket and the wat~r pump cover.
3. Fit the alternator mounting, lower the power unit and
secure the engine mountings.
4. Fit the inlet manifold and alternator.
5. Connect the battery; fill the radiator with coolant.
Page 265
FAN MOTOR
ASSEMBLY
REMOVAL
1. Remove the battery.
2. Drain off the coolant through the radiator drain cock.
3. Disconnect the head I ight wiper push rod from the
crank arm in front of the radiator.
4. Undo the radiator retaining screws and the radiator
hoses.
5. Disconnect the electric cables from the ignition coil,
headlight wiper motor, fan and thermal switch. Disconnect the cable harness from the fan housing.
6. Lift the radiator and fan housing and wiper motor.
THE RADIATOR
1. Mount the fan motor and fan in the fan housing.
2. Mount the fan housing on the radiator.
3. Mount the headlight wiper motor to the fan housing
and radiator.
4. Mount the radiator and connect the hoses.
5. Connect the cables to the headlight wiper motor, fan,
thermal switch and ignition coil and clamp the cable
harness to the fan housing.
6. Fit the headlight wiper push rod.
7. Install the battery and fill the radiator with coolant.
IS LIFTED AWAY
7. Unbolt the headlight wiper motor.
8. Remove the fan housing and dismantle the fan and
fan motor.
""'
UNSCREWING THE FAN HOUSING
262-7
Page 267
THROTTLE
CONTROLS
S4533
THROTTLE
CONTROL
THROTTLE
CONTROL
CABLE
CABLE CONTROL, SINGLE-CARBURETOR
ENGINE
CABLE CONTROL, TWIN-CARBURETOR
SA.4'B
ENGINE
271-1
Page 268
CABLE CONTROL,
INJECTION
ENGINE
THE CONTROL CABLE MOUNTED TO THE ACCELERATOR
PEDAL
t=lemoval
1. Disconnect the cable at the carburetor (throttle valve
housing) and from the..retaining bracket.
2. Remove the left-hand (in RHO-cars the right-hand)
panel from beneath the instrument panel.
3. Remove the locking pin from the accelerator pedal
and disconnect the cable.
3. Fit the panel beneath the instrument panel.
4. Connect the cable to the driver (throttle arm).
5. Fit the cable anchorage to the bracket and adjust the
cable tension to eliminate any play in the accelerator
pedal.
6. Press the accelerator pedal right down to the floor and
check that the throttle valve is fully open.
ACCELERATOR PEDAL
Removing
1. Remove the left (in R.H.D.-cars, the right) protective
panelling from under the instrument panel.
2. Remove the throttle control damper assembly (does
not apply to cars with automatic transmission).
3. Hook off the return springs.
4. Remove the locking pin at the anchorage point of the
wire on the accelerator pedal.
5. Pull the wire lo_osefrom the accelerator pedal.
6. Undo the upper covering of the dash panel and fold it
out of the way.
7. Remove the accelerator pedal from the dash panel.
CONTROL WIRE LOOSENED FROM ACCELERATOR
PEDAL
4. Unscrew the cable from the grommet in the dash panel.
Installation
1. Screw the cable to the grommet in the dash panel.
2. Connect the cable to the accelerator pedal and replace
the locking pin.
271-2
Installing
1. Mount the accelerator pedal onto the dash panel.
2. Fold back the dash panel covering.
3. Fit the wire to the accelerator pedal and insert the
locking pin at the anchorage point of the wire on
the accelerator pedal.
4. Hook on the return springs.
5. Fit the throttle control damper assembly (does not
apply to cars with automatic transmission).
6. Replace the protective panelling under the instrument
panel.
7. Make any necessary adjustments to the throttle control.
Page 269
TURBO SYSTEM
Supercharging,general
In contrast to conventional engines, a supercharged engine provides improved charging on the induction stroke,
which produces more effective combustion of the mixture and an increase in power output and torque. Wi,th a
supercharged engine, it is possible to achieve performance
that is comparable to that of a larger engine, while, at the
same time, maintaining the advantages of a smaller engine
with respect to fuel economy, space, weight, etc.
3
\
'\
I
\
'·-·
/
7
2
8
1
5
TURBO ENGINE
1. Turbocharger
2. Wastegate boost control·
3. Pressure transducer
4. Turbo gauge
5. Hose, air cleaner to
turbocharger
6. Hose, turbocharger to
inlet manifold
7. Bellows
8. Exhaust outlet pipe
SAMS
S6270
9. Oil supply line
10. Oil return line
11. Cooling air pipe
12. Exhaust pressure I ine
291-1
Page 270
the turbine wheel to rotate. The turbine wheel is mounted
on the same shaft as a compressor impeller which rotates
at the same speed.
The compressor is located in the induction system where
it effects an increase in the charging pressure in the combustion chamber.
Turbocharging
Turbocharging is achieved by means of a turbo-compressor which implies utilizing the exhaust gases from the engine to drive the turbine.
The exhaust gases are led to an exhaust gas turbine, causing
S 5865
TURBO-COMPRESSOR
291-2
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