Page 791
temperature of 194-212°F
there for one hour.
(90-100°C).
Leave the car
CAUTION
The pneumatic springs on the rear door on Saab 99
Combi Coupe model cars must be removed before
the car is placed in the oven. The high temperature
causes a pressure increase in the springs and this can
result in damage or injury.
B. Air-drying touch-up enamel (68-176°F/20-80°C)
USE OF RADIATION
LAMP TO DRY REFINISHED PART
Procedure: First of all, clean the body and chassis of the
car thoroughly, thus ensuring that dust will not spread in
the spraying booth or drying oven. Before drying in the
oven in connection with touch-up, certain parts of the car
must be masked or removed to prevent them from beeing
damaged by the heat. Which parts should be removed is
partly depending on the oven temperature and partly the
time under which the car is exposed to heat. The measures
mentioned below consider a temperature of 194-212°F
(90-100°C) during one hour.
The following details should be removed to prevent them
from being damaged by the heat:
a. The plastic grilles of the front plate
b. The plastic strips of the fenders and the glasses of the
rear clamps.
c. Saab 99 Combi Coupe: The pneumatic springs for the
rear door.
Cover the insides of all glass windows with sheets of board
or the like to prevent the temperature from becoming too
high.
If the trunk compartment lid, engine hood or a door
must be left open during the drying, the opening must
be masked to prevent the heat in the car to rise above
167°F (75°C).
The fuel tank should contain only a small amount of fuel.
The filler cap should be removed.
When the car is being pretreated and painted it should be
at normal room temperature. When the car is placed in
the oven, the latter should have reached the prescribed
SAAB
When air-drying enamel is used, no special arrangements
are necessary other than a well heated, dustless booth.
The drying time can, however, be speeded up considerably by stoving the enamel with an infra-red radiation
lamp or in an oven with an air temperature of not more
than 176°F (80°C).
The 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 - viscosity 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).
The metal must have adopted normal room temperature
prior to pretreatment and painting.
CAUTION
A label showing a code for the colour of the body
enamel is located below the chassis number label.
This code must be quoted when enamel is ordered.
This is particularly important since there are different paint suppliers supplying enamel with the
same colour designation.
GENERAL MAINTENANCE WORK
Proper care and maintenance of the care is necessary to
retain the gloss and durability of the enamel finish and
the protective proterties of the underbody sealing. Recommendations in these respects are given in Group 1.
890-7
Page 792
r
METALLIC PAINTS
General remarks on metal-effect paints
Metal-effect paints, or metallic paints as they are more
commonly called, consist of ordinary enamel paints
doped with aluminum powder, which imparts a metallic
lustre of the finish. Metal-effect paints can only be
applied by spraying, and produce different color tones
according to the spraying technique employed. Saturated
wet spraying (with large quantities of paint) results in
dark shades, while fog and dry spraying (with small quantities) give lighter shades. To make sure that spot repairs
to paintwork match the original paint job, it is essential
that the repair is made with recommended and tested
qualities of paint.
Metallic paints can be divided into one-coat and two-coat
types. Singlecoat metallic paint, as already mentioned,
consists of enamel paint doped with aluminum powder.
A two-coat application comprises an undercoat of enamel
paint containing aluminum particles and a topcoat of
transparent varnish giving a high-gloss finish.
Repairs to metallic paintwork call for a technique that
differs in some respects from the conventional method
of applying solid paints.
Now that we have acquired some experience of metallic
painting in our production and obtained very good results with one-coat paints, we have discontinued production of two-coat painted cars. We have also found that
repairs to two-coat paint jobs can be made with exellent
results using the same technique as employed for cars
with original one-coat paintwork.
Touch-up paints that match the original paint are essential
to good repair results. Even so, slight differences in coloration are sometimes found between the original paint job
and the repair. As a rule these differences can be ascribed
to one of the folloqing causes:
Vehicle paintwork changes color with age under the influence of external factors such as solar ultraviolet radiation, extreme fluctuations in temperature, the chemical
effects of atmospheric pollution and road salt in wintertime, and many others.
Car owners sometimes use unsuitable and excessively
harsh cleaning and polishing compounds which discolor
and bleach the paintwork.
A special problem arises in the case of metallic paints, as
the finish and shade vary according to the type of paint
and the application technique. The method of spraying
influences the way in which the fine aluminum particles
distribute themselves in the paint layer; this effect can
be controlled to some extent by the choice of spraying
technique. Repainting should therefore be extended out
890-8
SAAB
to the natural boundaries of the area in need of repair,
and the car owner should be told in advance that there
may be some difference in the shade of the repainted
part.
To avoid trouble with complaints, we would advise all
bodywork painters to follow the instructions given below:
a. Stir the paint thoroughly.
b. Check that all cans of paint used on the same car are
marked with the same batch number.
c. Always test-spray a specimen piece. Comparison with
the color of the paint in liquid form is not reliable, as
the color changes during drying and may also be influenced by the method of application.
d. Always match up the colors in daylight (but not in
direct sunlight) before you start painting.
General recommendations
1. The temperature
in the paint shop should be less than
64°F (18°C). Vehicles that have stood out of doors
must have come to room temperature before painting
starts. The same applies to the paint itself.
2. Take care over the preparations. The surface must be
free from rust and grease and must be dry. Degreasing
with a damp rag is not good enough; wash the surface
using plenty of grease dissolver. Take special care with
areas close to trim and panel edges.
3. Do not touch degreased and sanded surfaces with bare
hands. Perspiration contains salt compounds that will
cause the finished coat of paint to swell. Old, blistered
paintwork must be completely removed.
4. The water used for grinding must not exceed 5 German
degrees in hardness. It may be necessary to soften the
water in a desalination unit. In any event, great care
must be taken and the surface must be thoroughly
cleaned. Do not let any drops of grinding water dry on
the surface - wipe them off with a chamois leather.
Remove all traces of grinding dust. Before proceeding
further, dry off all moisture thoroughly in a drying
oven or with--a heat lamp.
_______
_
5. Compressed air must be dry and clean. Spraying pressure should be 45-70 psig (3-5 atmospheres gauge
pressure) unless otherwise specified.
6. Spray boxes and drying ovens must be provided with
fresh-air intake, dust filter and air extractor.
7. The top coat must not be applied until all traces of
solvent have evaporated from the surface, as pores
may otherwise form in the paintwork.
Page 793
Products for paintwork spot repairs
Priming materials
Du Pont Hi-Speed Primer-surfacer 30 S (233-1940)
drying (gray)
Du Pont Thinner 3608 S (145010)
Du Pont Universal Putty 2284 R (228-BS 146)
Priming
air
Top coat materials
Du Pont LuciteR Spot Repair 945-line metallic
Coral Metallic YR1 & YR4 1/4 gal. Ordering No. 8451148
Coral Metallic YR1 & YR4 1/8 lit. Ordering No. 8470254
1/4 gal. Ordering No. 8436800
Sepia Metallic YR2
1/8 lit. Ordering No. 8470262
Sepia Metallic YR2
1 lit.
Ordering No. 8475204
Sepia Metallic YR5
1 lit.
Ordering No. 8470486
Silver Crystal SK1
1 lit.
Ordering No. 8451155
Du Pont Thinner 3632
1 lit.
Ordering No. 8470270
Du Pont Thinner 3602
Other materials
Prep-SolR 3919 S
Emery paper No. 400 or finer
Metal conditioner 5717 S
Du Pont Rubbing Compound 202 (hand rubbing)
Du Pont Rubbing Compound 303 (machine rubbing)
Synthetic thinner 621 R (T -3810)
Adhesive rags
PreparakoteR primer-surfacer 3012 S
Uniforming finish 200 S
Prime all bare metal surfaces with Hi-Speed primer-surfacer (for whole panel painting, primer with PreparakoteR
primer-surfacer 3012 S). Fill as necessary with Universal
Putty.
Cover painting
Topcoat with LuciteR Spot Repair acrylic paint, diluting
with 100% thinner 3602 S. Apply three wet coats with
flash-off between the first three coats and a fourth halfwet coat straight on top of the third. Each coat of cover
paint and primer should be 30-50 microns thick.
One or two thicker coats cannot take the place of three
or four thinner ones. Ground-through or almost groundthrough spots must be reprimed with the recommended
primer. Spray pressure should be 45-50 psi. (approx. 3.5
atmospheres) gauge.
To further enhance the initial gloss and make an invisible
transition to the original paintwork, two or three coats
of Uniforming Finish 200 S should be sprayed on and
around the resprayed area.
Drying
Uses
LuciteR Spot Repair is intended for spot repairs, as well
as partial and total respraying.
Surface preparation
Clean off old paint with Prep-Sol R 3919 S. Smooth edges
of paintwork with emery paper No. 400 or finer. Treat
bare metal surfaces with Metal conditioner 5717 S.
Polish round the damaged spot with Du Pont Rubbing
Compound 202 to remove grinding scratches and to obtain good adhesion to original paintwork. Wash off the
whole surface with Synthetic thinner and wipe off with
adhesive rags.
Large areas should be allowed to air-dry for four hours,
preferably overnight, before being polished.
Alternatively, the paint can be force-dried for 15 minutes
at 175°F (80°C) before polishing of small areas (spot
repairs) or for about 45 minutes before polishing of complete resprays.
Polishing
LuciteR Spot Repair has a high initial gloss and needs
only light polishing to smooth off color edges and blend
into the original paintwork. Polish small areas by hand
with Rubbing Compound 202. Mashine-polish larger areas
with Rubbing Compound 303.
Please note
LuciteR Spot Repair should not be applied by brushing
as it contains metal particles. It can however be used to
fill small pits by flying gravel.
890-9
J
Page 794
TWO-CANTOUCH-UPPAINT
2 K Standocryl - Autolack is a two-can acrylic enamel
which is cured by means of a chemical reaction between
a hardener and the binding agent (acrylic). This reaction
will take place at room temperature. The enamel will also
harden at lower temperatures but the reaction or curing
will be slow. An increase in temperature will speed up
the curing time for which reason forced drying or stoving may be used to advantage.
Product:
2 K Standocryl - Autolack
2 K Spezialhiirter
Mixing;
2 K Standocryl - Autolack should be mixed at a ratio
of 2:1 with
2 K Spezialhiirter
Thinning:
Thin using approximately 20 % type 11012 Standoxthinner
Spraying viscosity:
Approx. 16 sat 68°F (20°c) (SIS 4)
Spraying pressure:
3-5 bar (kp/cm2)
Nozzle:
0.04-0.047
If the spraying is excessively slow and dry, the surface
of the different coats will dry rapidly and, if the skin is
fairly thick, this may result in blistering during stoving
owing to residual solvent. No airing time is required before stoving. When only parts of the car are to be resprayed, the colours must first be matched.
Curing:
a. At a workshop temperature of 68°F (20°C):
Dust dry
20 min
Tack dry
90 min
Masking dry
8h
b. Stoving (no airing time):
Masking dry
30 min at 140°F (60°C)
15 min at 176°F (B0°C)
Touching-up:
Flatting by means of wet abrasive paper (P 600) of any
poor areas or runs can be carried out after air-drying overnight or after a cooling period following stoving, after
which the surface may be polished or resprayed.
N.B.
Since 2 K products may react to moisture, all tools,
mixing vessels,etc., must be scrupulously dried.
Spraying at a relative humidity above 80 % must
never be carried out.
in. (1-1.2 mm)
Metallic paints
Can life:
Approx. 12 h at 68°F (20°C)
Surface:
Prepare the surface in the usual way. Old air-dried enamel
must be thoroughly cured. All moisture resulting from
wet flatting must be allowed to dry completely. Syntheic Non-Sanding products cannot be used as a base for 2 K
Standocryl - Autolack.
Spraying:
Three coats are sprayed. Spray a saturated first coat but
ensuring that there is satisfactory flow and then apply
the next two coats quickly allowing only short airing
times depending on the size of the area to be sprayed.
890-10
Metallic single coat:
Two generous coats should be sprayed with no consideration given to mist formation. Thin the remaining paint
further using Standox type 11 and 12 thinners to a viscosity of 13 s/SIS 0.16 in. (4 mm). After an airing time of
about 5 minutes, apply a coat of the thinned paint which
will produce a mist-free and smooth surface without fog
spraying being necessary. If the metallic effect achieved
is not satisfactory, a further application of the same paint
may be made after a short airing period. This applies to
difficult metallic colours.
If it is desired to convert the coat into a double-coat application, then after drying but within 24 hours and without flatting, 2 K Standocryl - Klarlack may be sprayed
on.
Page 795
CONTENTS
930
RADIO INSTALLATION
952
TOWING ATTACHMENT
Page 797
RADIO INSTALLATION
Mounting kits are available for Blaupunkt and Philips car
radios. All necessary mounting details and suppression
components are enclosed.
A special mounting panel has been produced for installation on the floor below the instrument panel. It has recesses for radio and loudspeaker, and is also provided
with a storage compartment.
PARCEL SHELF MEMBER WITH HOLES FOR LOUD
SPEAKERS
Saab 99 EMS (as from model 1977) and Saab 99 GLE
cars have been provided with a special 8-pole junction
box to facilitate the installation of a radio. Cables, which
are part of the standard electrical system of the car, run
to the+ and - battery terminals and to the speakers located at the front doors. The junction box is located inside the right-hand trim panel below the instrument panel.
RADIO INSTALLATION
As from model 1977, Saab 99 L, 99 G L, 99 G LE and 99
EMS have been made ready for the fitting of recessed
speakers in the parcel shelf through the provision of two
holes in the parcel shelf frame member. For fitting fo the
speakers, two holes must be cut in the parcel shelf.
w
Efil[jJ
[fil [[] rn[[]
Efj
S 5510
JUNCTION BOX, RADIO INSTALLATION, SAAB 99 EMS
(AS FROM MODEL 1977) AND SAAB 99 GLE (FROM THE
WIRE SIDE
LOUDSPEAKER INSTALLATION,
PARCEL SHELF
JUNCTION BOX
930-1
Page 798
,,
H
l 5 2 6 3 7 4 8
+ 340 RD
- 3 l SV
345 BL/VT
344 RD/VT
GR
RD
343 GN/VT
3 2 BR/VT
GR
RD
V
S5509
WIRING DIAGRAM, RADIO INSTALLATION
SUITABLE ANTENNA
LOCATION
A. SAAB 99 (99 L), 99 L (99 GL) AND 99 EMS
B. SAAB 99 COMBI COUPE
930-2
SAAB
Page 799
TOWING ATTACHMENT
6. Tighten all bolts to the prescribed torque and apply
sealing compound behind the bumper bracket mounting point in the body.
FITTING, SAAB 99 (99 L), 99 L (99 GL), 99 GLE AND
99 EMS
The wiring harness connecting kit for a 7-pole trailer connector is available as an accessory.
Fit the harness in accordance with the wiring diagram and
fitting instructions included in the kit, and drill two holes
in the body as directed ( 1.0 in./25 mm dia. and 0.15 in./
3.8 mm dia.).
Towing attachments with ordering Nos. 117167007 and
117136002 (retractable) for Saab 99 Sedan cars are designed for a maximum trailer weight of 1 500 kg. Mounting holes are provided in the body, and the installation
kit contains all the necessary parts.
Fit the attachment as follows:
1. Remove the bumper bracket retaining bolts (8) and
the rubber seals located between the brackets and the
body, one side at a time. Refit the brackets loosely.
N.B. Scrape away the undersea! from all areas of the
body coming into contact with the towing attachment.
2. Lift cross member ( 1) of the towing attachment into
position, and fit bolts (2) and nuts in the bumper
brackets first.
3. Leave the nuts slack to facilitate alignment of the towbar.
4. Fit towbar (3) to cross member (1) as shown in illustration.
5. Place tapped plate (7) behind the jacking point, install
the necessary number of spacers (6), and fit bolts (4)
with spring washers (5).
The assembly kit comprises:
7-pole socket
Bolt
Nut
Spring washer
Wiring harness
Grommet
Clip
Self-tapping screw
- N.B.
Cars with automatic transmission to be used for towing a trailer must be fitted with an oil cooler (see
Section 440).
7
1
Release device for
retractable towing
attachment
Saab's wheel
nut key
S 6158
TOWING ATTACHMENT,
,.......
:❖:•:❖:
11111
SAAB 99 (99 Ll, 99 L (99 GL).
99 GLE AND 99 EMS
111111
11111
111111
11111
SAAB
952-1
111111
UN,'
·11111
11111,
,1111,,
..J}lt•
Page 800
FITTING, SAAB 99 COMBI COUPE AND 99 GLE
4. Fit towbar (3) to the cross member as shown in illustration.
5. Position tap plate (4) behind the jacking point, fit the
necessary number of spacers (5) and fit spring washers (6) and bolts (7).
6. Tighten all bolts to the prescribed torque.
Towing attachments with order Nos. 117168005 and
117139006 (retractable) for the Saab 99 Cambi Coupe
are designed for a trailer weight of 1 500 kg. Mounting
holes are provided in the car body and the installation
kit contains all the necessary parts.
The wiring harness connecting kit for a 7-pole trailer connector is available as an accessory.
Fit the attachment as follows:
1. Remove bumper bracket retaining bolts ( 1) and the
rubber seals between the brackets and the body, one
side at a time. Replace the flat washers with the spring
washers included in the installation kit. Tighten the
bolts and seal the insides using a sealing compound.
Remove the towing hook.
N.B. Scrape away the undersea! from all areas of the
body coming into contact with the towing attachment.
2. Lift the cross member of the towing attachment into
position and fit bolts (2) and nuts to the bumper
brackets first. If the clearance at the bumper bracket
is greater than 0.08 in. (2 mm), fit the necessary number of spacers(~ 0.40 in./10 mm x ~ 0.71 in./18 mm x 2)
on the bolts between the cross member and the bumper bracket.
Fit the harness in accordance with the wiring diagram
and fitting instructions included in the kit, and drill two
holes in the body as directed (~ 1.0 in./25 mm, and~
0.15 in./3.8 mm).
The assembly kit comprises:
7-pole socket
Bolt
Nut
Spring washer
Wiring harness
Grommet
Clip
Self-tapping screw
N.B.
Cars with automatic transmission to be used for
towing a trailer must be fitted with an oil cooler
(see Section 440).
3. Leave the bolts slack to facilitate alignment of the
towbar the bolts slack to facilitate alignment of the
towbar.
Release device for
retractable towing
attachment
Saab's wheel
TOWING ATTACHMENT,
99 GLE
952-2
SAAB 99 COMBI C:::OUPEAND
SA-"EI
S 6159