Page 781
Checking oil level in compressor
Dismantling
Under normal conditions, the compressor oil level need
not be checked when the system is operating satisfactorily.
However, if there has been appreciable leakage in the system or it is suspected that the oil level is low, a check
should be made. Remove one of the oil filler plugs in the
crankcase of the compressor. Insert a bent wire into the
hole until the end of the wire bottoms in the crankcase.
Remove the wire and measure the oil level, which should
be between 0.87 and 1.22 in. (22 and 31 mm).
1. Remove the 3/16" hexagonal centre bolt.
2. Remove the compressor from its suspension (9/16"
ring spanner-swivel socket wrench).
3. Fit the extractor bolt in the centre of the clutch.
4. Actuate the clutch magnet (ignition switch in position
"K"), air conditioning fan at low speed, cold control
in position "On". It may be necessary to ground the
compressor by means of a separate cable.
5. Insert the belt in the groove in the clutdl pulley and
lock it to prevent its turning (by hand).
6. Withdraw the clutch assembly from the compressor
crankshaft by further tightening of the extractor bolt
(15/16" ring spanner).
7. Switch off the ignition (key in position "G").
8. If necessary, dismantle the coil from the compressor
(3/8" ring spanner).
CAUTION
If the system is charged with gas, the compressor
crankcase will also be pressurized. The system
must then be discharged before the oil level can
be checked.
Assembly
1. Fit the coil (3/8" ring spanner).
2. Install the clutch assembly. Check the condition of the
screw and that the woodruff wedge is in its correct
position on the compressor crankshaft ( 1/2" ring spanner).
3. Turn the ignition key to position "K".
4. Secure the coil and tighten the centre bolt to the correct torque: 19.6-22 Nm (2.0-2.25 kpm) (1/2" socket and torque wrench).
5. Switch off the ignition.
6. Mount the compressor in its mountings.
7. Loosen the alternator mountings and install the fan
belt.
CHECKING THE OIL LEVEL
CHANGING
THE MAGNETIC
CLUTCH
Adjusting and testing
The work can be carried out without the system having
to be discharged of refrigerant (compressor connected).
The best method but the most time consuming is to work
with the compressor on the bench. This involves the additional operation of discharging, evacuating and charging
with refrigerant.
Equipment
Torque wrench 0-5 kpm
Socket 1/2"
Ring spanners 3/8", 1/2", 9/16", 15/16"
Swivel socket wrench 9/16"
Clutch extractor (standard bolt 5/8" x 1 " UNC)
Voltage source 12 V (battery)
Two connecting cables, 0.75 mm 2 min. with insulated
quick-release connectors 1)
Alternator V-belt
Equipment
Voltmeter 0-15 V with connecting cables
Tachometer to check engine speed
1. Start the engine and set the air conditioning system
to maximum cold and maximum fan speed.
2. Set the engine idling speed to approx. 2500 rev/min.
3. Read the voltage across the coil (+ at connection to
compressor, - to compressor housing).
4. For proper functioning, the voltage must not be below
11.8 V.
5. Insufficient voltage: Check the electric circuit (wiring
diagram in assembly instructions) and determine the
location of the greatest voltage drop.
6. Replace or adjust defective components.
1) Applicable in the case of bench work.
SANS
854-16
Page 783
BUMPERS
GENERAL
The shells of the bumpers consist of U:shaped aluminium
bars to which the bumper brackets are mounted. There
are shock-absorbant cellular blocks of polythylene in the
bars (9 blocks in the front and 10 blocks in the rear bump-
er). Outside the blocks there are polyethylene braces and
the bumpers are coated with a layer of rubber. This layer
is provided with anchorage bars on the inside and a bracing
strip on the outside. Up to and incl. model 1976, the
bracing strip is of stainless steel and, as from model 1977,
of rubber with a plastic strip with a chromium insert.
Provision has been made on the front bumper for the attachment of license plates and additional lights.
The front bumper is mounted with four brackets and the
rear bumper with three.
S 4835
FRONT BUMPER
REAR BUMPER
860-1
Page 784
REMOVAL AND INSTALLATION
The front bumper is removed by undoing the eight screws
which hold the bumper brackets to the reinforcement
bars and the support plates in the engine compartment.
The rear bumper is removed by undoing the screws which
hold the bumper brackets to the bodywork.
Install in the reverse order.
CHANGING THE CELLULAR BLOCKS
1. Remove the bumper.
2. Remove the bracing strip. Note the spacing sleeves
under the filling plates at each end of the bracing strip.
3. Remove the anchorage bars on the side of the bumper
where the cellular block is to be changed. (If the center block on the front bumper has to be changed, both
the longer anchorage bars must be removed.)
4. Pull off ths rubber layer, after which the cellular
blocks are accessible and can be removed.
CHANGING THE CELLULAR
BLOCKS
5. Refit the rubber layer and bracing strip.
S3'311
FITTING THE BRACING STRIP, UP TO AND INCL. MODEL
1976
860-2
we
FITTING THE BRACING STRIP, AS FROM MODEL 1977
6. Mount the filling plates and their spacing sleeves together with the anchorage bars. Remount the bumper.
Page 785
TECHNICAL DATA OF PAINT SYSTEM USED IN THE
PRODUCTION OF CARS MANUFACTURED IN
SWEDEN AND FINLAND (WITH FIFTH DIGIT OF
CHASSIS NUMBER 1, 2, 3 OR 6)
Phosphatizing
Type of phosphatizing
Weight of skin
Zinc phosphatizing
approx. 2.5 g/m2
Primer
Mode of application
Curing
Supplier
Skin thickness after stoving
Electrocoati ng
15 min at 175°c
Dr Kurt Herberts
23,um
Intermediate stone-damage
coat (below waist line of
car only)
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness
22 s
Cold spraying
7 min at 110°c
Svenska Herberts AB
15,(Jm
Intermediate coat (sprayed
wet-in-wet on intermediate
stone-damage coat)
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness after storing
30 s (Saab standard 860)
Hot spraying at 5o 0 c
7 min at 110°c
AB Wilhelm Beckers
25..um
Top coat
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness after stoving
35-40 s (Saab standard
860)
Hot spraying at 50°C
15 min at 130-140°C
AB Wilhelm Beckers,
Dr Kurt Herberts
40,tim
Total skin thickness after all
coats have been applied and
stoved: 90-110,,um.
890-1
Page 786
INSTRUCTIONS FOR REPAIR OF PAINT WORK
Painting procedure
When partly or completely re-spraying, the re-painted
surfaces shall be repaired so that they equal the environmental and wear resistance of the original paint work, and
so that the colour and finish match with the car in general.
All materials used should be of the same manufacture
and suited to each other. The supplier shall provide data
sheets with technical information and method of application.
The special techniques which are used for repair of paint
work cannot be described in a short summary, therefore
we will limit ourselves to giving instructions on material,
and advice concerning the procedures which are the basis
for fulfilling thenpair requirements set.
Repair of paint work
All repair and re-spraying work shall be carried out using
the material qualities given below.
Cars that have had paint work repaired shall be ovendried at a temperature advised by the paint supplier. The
paint shops' technical resources and knowledge of application methods are the basis for a satisfactory result.
With guarantee claims it is required that all materials used are supplied by the same manufacturer, and an advantage if the part numbers of products used can be given.
Panel edges at joints and seams should be covered with
paintable sealing compound (e.g. door joints) before
spraying.
Material for solid- and metallic paint
Primer
Filler
Top coat
Self-etching zinc chromate primer
2-component filler/primer or alternatively
EP filler/primer
2-component acrylic paint
Paint of the 2-component type, together with thinner,
can be ordered from Saab-Scania AB, Spare parts dept.,
against the original article number, and is delivered by the
manufacturer. Other material should be ordered from the
general agent for the paint supplier.
All painted surfaces shall have paint coverage complying
with the coat thicknesses given in the section "Paint system, technical data".
Removable parts shall be removed from the area, and the
vicinity of the area which is to be painted. Rubber strips
shall be lifted up with 6 mm (circum) string.
Otherwise, plastic parts should be removed and necessary
masking carried out.
Page 787
Undersealing
Compound
Mode of application
Curing
Skin thickness
Binder
Supplier
Spraying
20 min at material temperature of
150°C
200µm min.
Polyester
Sv Herberts AB
Anti-corrosion agent for cavities
Mode of application
Type of material
Skin thickness
Spraying
Thixotropic, penetrating
Covering
Anti-corrosion agent
Mode of application
Type of material
Skin thickness
Automatic spraying
Thixotropic, non-penetrating
Approx. 500µ m •
GENERAL DESCRIPTION OF BODYWORK TREATMENT
Phosphatizing
The entire car body undergoes the phosphatizing process.
The layer of phosphate enhances the protection against
corrosion provided by the other coats and also improves
adhesion between the primer and the base metal. The
layer of phosphate is also a good indication that the surface of the metal has been thoroughly degreased.
Primer
Application of the primer takes place in an electrocoating plant. This process ensures that all of the body parts
receive a layer of primer of nigh-on uniform thickness.
The method also makes it possible to apply the primer
in the panel joints and cavitites.
Intermediate coat, stone damage protection
This coat is applied on the outside of the body below the
waist line on the front panel, the bonnet and the upper
section of the bulkhead. The elasticity of this layer increases the resistance of the paintwork to impacts and,
consequently, more effectively prevents stones chipping
the enamel down to the metal.
Intermediate coat
On surfaces already having received a coat for stone
damage protection, this intermediate coat is applied wet
on wP.t. In other cases, the coat is applied on top of the
primer.
..,.
890-3
Page 788
7
Top coat
An alkyd melamine is used as a binder in solid-colour
enamels and an akrylate in metallic-effect enamels.
Both types of enamel are of the one-coat type.
Norms for finished bodywork
All external and clearly visible interior surfaces are
sprayed with top coat. The exceptions to this are piercings in the bonnet and luggage compartment door, the
inside of the rear edge of the front wheel housing and
the leading edges of the front doors.
Interior surfaces over which trim or upholstery has been
fitted have not been sprayed with top coat. In versions
where no cladding has been fitted to the wheel housing
inside the luggage compartment, the primer will therefore be visible.
7
_j_
-J
..-··
I
Undersea! protection
The polyester-type undersea! is applied under the wheel
housings, sill beams and recesses in the bottom plate,
and inside the rear axle shaft.
S6!M6
UNDERSEAL, POLYESTER TYPE
Anti-corrosion agent for cavitites
Thin penetrating oil is sprayed around the sub-frame
member between the front and intermediate bottom panels,
inside the rear axle shaft, inside the lower body cavities
and inside the bottom parts of the doors.
S6!M7
ANTI-CORROSION
OIL, PENETRATING
Anti-corrosion agent
Thick (non-penetrating) oil is applied to the underside
of the car excluding the wheel housings.
Refer also to Group 1 section 141 and the section on
anti-corrosion treatment.
....
ANTI-CORROSION OIL, NON-PENETRATING
890--4
_J
Page 789
TECHNICAL DATA ON PAINT SYSTEM USED IN THE
PRODUCTION OF CARS MANUFACTURED IN BELGIUM WITH 7 AS FIFTH DIGIT IN THE CHASSIS
NUMBER
Phosphatizing
Type of phosphatizing
Iron phosphatizing
Primer
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness after stoving
22 s (Saab standard 860)
Cold spraying
15 min or longer at
120-130°c,
15 min at 150-16o 0 c
Dr Kurt Herberts
10;Um
Intermediate coat (sparyed
wet-in-wet on primer)
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness after stoving
22 s (Saab standard 860)
Cold spraying
15 min or longer at
120-130°c,
15 min at 150-16o 0 c
Dr Kurt Herberts
50;Um
Top coat
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness after storing
35-40 s (Saab standard
.860)
Hot spraying at 50°c
13 min or longer at
110°c,
13 min at 130°c
AB Wilhelm Beckers,
Dr Kurt Herberts
40AJm
Total skin thickness after all
coats have been applied and
stoved: 90-11 0;um.
The same materials and methods
are used in touched-up work in
production as those employed
in normal top-coat spraying.
890~
Page 790
16 in. (40 cm) from the metal. After drying, fill as necessary, applying the putty in thin layers and allowing the
stipulated drying time for each layer before the next application.
TOUCH-UP AND REFINISH INSTRUCTIONS
General
For all touch-up or refinish jobs, use synthetic stoving or
airdrying enamel of the same quality type as that for the
original paintwork.
For perfect results, it is essential that the premises in
which the work is to be done, i.e. the paintshop, be kept
absolutely free of dust. It should also be free of drafts
and must naturally not be used as a means of access to
other departments. The floor should be kept thoroughly
damp while spraying. A paint job ruined by dust cannot
be restored by polishing - flatting and respraying will be
necessary.
Rubbing down
Rub down the primed and filled surface with wet abrasive paper P400 and then with grade P600. After removing all water, rewash the surfaces with spirit or cellulose
and wipe with a piece of gauze drenched in slow-drying
varnish (tack-ragging).
EQUIPMENT AND PROCEDURE FOR REFINISHING
A. Stoving touch-up enamel
Oven: A convection oven with an air temperature of
194-212°F (90-100°C) is needed. A radiation oven
can be used, and in this case the metal temperature
should be about 176°F (80°C). It is important for the
air temperature to be even throughout the oven and for
the temperature to be continuously checked. For this
purpose, it is appropriate to use, for example, a calibrated
max. and min. thermometer or a thermo-element with a
compensator. Only this latter measuring method can be
used to check the plate temperature.
Body finishing
Before undertaking any partial refinishing, always spray
a test area to check that the shade used is indentical with
the color of the parts that are not to be refinished. Any
deviations must be corrected by toning the paint. The
painting job involves the following operations:
Removal of rust and old paint
Rubbing down
Cleaning with a solvent
Priming of bare metal surfaces, for instance with wash
primer
c:11: ...,..
·s. ____ ..,___ .,..,.
••••••
•••
-~
·---
......-,
Enamel: Hardener must be added to the touch-up paint
u~i:ii.ij,i iriil iim6i.in'i; si:ipuiai:ecioy me paint supplier. I he
1
Flatting
Application of intermediate coat, for instance Surfacer
or Non Sanding, if necessary
Flatting, if necessary
Finishing
Air-drying, stoving with infra-red radiant heat or in a
drying oven, depending on the type of enamel used.
enamel can be sprayed either hot or cold, and the viscosity should be adjusted accordingly with the thinner recommended by the paint supplier to the following:
Hot spraying - vi-scosity approx. 35 sec.
Cold spraying - viscosity approx. 21 sec.
Measure the viscosity with a beaker according to the method described in the Saab Standard 860 at a temperature
of approx. 74°F (23°C).
Cleaning
If the old paintwork shows defects such as cracking, pitting due to the impact of flying stones, etc., apply a paint
remover or flatten down to the bare metal. After removal
of the old paintwork by one or the other of these methods, degrease the metal with spirit, thinner or some other
suitable solvent. In principle, the same procedure should
be used even if the old paintwork has merely been rubbed
down instead of being removed. Realign any distorted panels and grind, for instance with a disc grinder, if necessary,
before flattening with wet abrasive paper P400. Finally,
reclean the parts with spirit or cellulose thimmer. Thorough
ness in this respect is vital to good adhesion.
Priming
Coat all bared metal surfaces with primer. The drying
time and temperature for oven-drying or air-drying
should be as prescribed by the paint suppliers. An infrared radiation lamp may also be used for drying, but care
must be taken to keep it at a distance of not less than
890-6
MEASURING VISCOSITY WITH AN SIS BEAKER
5'lW