Page 111
REMOVAL AND INSTALLATION
1,7 and 1,85 | engines
Removing the power plant
For major work on the engine and transmission, the en-
tire power plant should be lifted out. Removal of the en-
gine by itself is not possible.
1. Remove the hood as follows:
Back off both the hood fastening screws. Lift off
the hood. For this you need a helper to hold one
side of the hood and help to lift it clear (see illus-
tration).
RADIATOR DRAIN COCK KRAN
UNDOING HOOD FASTENING SCREWS
ENGINE BLOCK DRAIN COCK
LIFTING OFF THE HOOD
2. Detach the battery cables. Unclamp and lift out
the battery.
3. Drain off coolant through the radiator and engine
block drain cocks; open the bleeder cock on the
heater core (up to and incl. model 1973).
Sept. 1973
HEATER CORE BLEEDER COCK, UP TO AND INCL.
MODEL 1973
4.
Carbureted engine:
Detach the vacuum hose of the power assist cylin-
der from the inlet manifold and pull the fuel hose
off the suction side of the fuel pump.
Injection engine:
a. Detach the vacuum hoses of the power assist
cylinder and the pressure sensor from the inlet
manifold.
b. Detach the fuel hoses from the tubes at inlet resp.
outlet of the injection valves.
201-1
Page 112
5. Carbureted engine:
Undo the cable connections to the ignition coil,
serial resistance, temperature transmitter, oil pres-
sure transmitter, radiator fan, thermostat contact,
headlights and headlight wipers.
5. Injection engine:
a. Undo the cable connections to the ignition coil,
serial resistance, temperature transmitter, radiator
fan, thermostat contact, headlights, contact on
automatic transmission and headlight wiper mo-
tor.
b. Undo the connections for the fuel injection of
distributor, injection valves, air cleaner, throttle
valve switch and at the temperature sensor and
temperature switch below the inlet manifold.
CAUTION
Do not detach the connections by pulling the cables.
Grip the connecting pieces.
6. Carbureted engine:
a. Remove the air cleaner and preheater complete
with hose and the ignition cable. As from model
1972: Remove the preheater hose, air cleaner
with valve housing and cold air hose. NOTE! Save
the spacer sleeves under the outer preheater cas-
ing.
b. Detach the throttle control linkage from the
* throttle shaft and remove the return spring. As
from model 1972: Detach the throttle control
wire from driver and bracket.
c. Detach the choke control wire and sheath from
the carburetor.
6. Injection engine:
a. Remove air cleaner complete with hoses.
b. Undo the throttle control shaft from the driver
on the throttle house. As from model 1972:
Detach the throttle control wire from driver and
bracket.
AIR CLEANER WITH HOSES, CARBURETED ENGINE
MODEL 1972
1. Air cleaner
2. Valve housing
3. Cold air hose
4. Preheater hose
201-2
Carbureted engine:
Undo the hose clamps at the connections to the
thermostat housing, radiator, inlet manifold and
water pump.
Injection engine:
Detach the hoses at the connections to the thermo-
stat housing and to the radiator and both the hoses
to the heater.
a. Remove the four fastening screws from the front’
sheet.
b. Remove the self-tapping screws holding the head-
light trim frames,
c. Remove the four lower self-tapping screws se-
curing the headlights to the edge of the body-
work. As from model 1972: Remove the head-
lights from body and front sheet.
d. Remove the hood lock operating cable from its
fastenings at the dash panel and wheel housing.
e. Remove the front sheet, lifting forward and up-
ward,
Manual transmission:
Remove the slave cylinder and hang it up in some
convenient place.
REMOVING THE FRONT SHEET
9.
10.
11,
12.
13.
14,
Automatic transmission:
Remove the protective cover on the exhaust manifold
at the exhaust pipe,
Move the free wheel lever forward to the locked
position. Release the wire clamp at the transmis-
sion and free the cable from the holder at tne right-
hand differential bearing seat. (Manual transmission)
Disconnect the exhaust pipe from the exhaust man-
ifold.
Detach the ground cable from the transmission.
Jack up the front end of the car and place blocks
under the body.
Manual transmission:
a. Put the gear lever in neutral.
b. Knock out the front taper pin from the gear
shift rod joint. (In 1970 and later models, the
rubber bellows must also be pulled free of the
groove on the gear selector rod.) Separate the
gear selector rod joint from the gear selector rod.
Nov. 1972
Page 113
19. 1968-1969 models:
Raise the power plant about 2” (50 mm) and sepa-
rate the inner universal joints, first the left and then
the right, with the power plant displaced as far as
possible towards the opposite side. Make sure that
the needle bearings do not come apart.
1970 and later models:
Undo the lower end piece from the control arm on
the right-hand side. Turn the steering wheel to the
left and withdraw the universal joint. Raise the pow-
er plant slightly and withdraw the left universal
joint.
GEAR SHIFT ROD JOINT TAPER PIN
14. Automatic transmission:
Remove the screw for the gear selector wire at the
transmission. Move the gear selector lever to Posi-
tion “1” and pull out the sheath from the trans-
mission. Fit tool 879038 on the wire, turn the tool
a little and pull out the wire.
UNDOING LOWER END PIECE FROM CONTROL ARM
20. Raise the power plant to a suitable height for access
to the cable connections to the starter and alterna-
tor, and disconnect the cables.
21. Hoist out the power plant. Fit protective caps over
the inner drivers and rubber bellows.
REMOVING THE GEAR SELECTOR WIRE
15. Detach the speedometer cable from the transmis-
sion.
16. Undo the engine brackets.
17. Undo the larger clips round the rubber bellows on
the inner universal joints. (In 1968—69 models
the T-pieces of the drive shafts must be rotated to
the horizontal position.)
18. Engage the lifting yoke (too! 839097) in the two
engine lifting lugs.
REMOVING THE INNER UNIVERSAL JOINT
Ll FTING YOKE
Tool No. 839097
Nov. 1972 SAAB 201-3
Page 114
Installing the power plant
1. a. Check that the inner universal joints are packed
with grease.
b. As from ch.No. 99.033.917:
Check the front engine cushion. Make sure that
the washer is properly tightened.
bild.
FRONT ENGINE CUSHION
2. Hoist the power plant with the lifting yoke (tool
No. 839097) and lower it into the engine compart-
ment.
CAUTION
Take care when installing the power plant to
avoid damaging the fuel line hose joint at the
dash panel. After installing, check that there
is at least 0.4” (10 mm) clearance between the
alternator belt pulley and the hose.
3. Lower the power plant to a convenient working
height and connect the cables to the starter and
alternator.
4. Assemble the inner universal joints as follows:
Hang the clips on the inner drivers.
For 1968—69 models the procedure is as follows:
Lower the power plant to about 2’ (50 mm) from
the engine cushions. Assemble the inner universal
joints with the T-piece horizontal. Assemble the
right-hand joint first.
With 1970 and later models, the front end must be
blocked up during installation of the power plant.
Lower the power plant to about 1” (20—30 mm)
from the engine cushions. First assemble the left-
hand universal joint, then lower the power plant
on to the cushions and assemble the right-hand
joint. Connect the end piece to the lower control
arm.
ASSEMBLING THE RIGHT INNER UNIVERSAL JOINT
5.
~o
2
©
10.
11.
12.
13.
14,
16,
16.
17.
201-4 SAAB
a. Align the engine brackets. At the same time
guide the throttle control shaft into its bearing
(up to and including model 1971).
b. Bolt the power plant to the engine cushions.
Remove the lifting yoke.
a. Push the rubber bellows over the inner universal
joint drivers and fit the clamps.
b. Wipe any surplus grease off the rubber bellows
and check that the bellows are not deformed.
a, Connect the gear shift rod joint to the gear selec-
tor rod and insert the taper pin. In 1970 and later
models, refit the rubber bellows in the groove on
the gear shift rod joint. (Manual transmission)
b. Connect the speedometer cable to the transmis-
sion,
Manual transmission:
Fit the slave cylinder and adjust the clutch.
Automatic transmission:
Connect the gear selector wire to the transmission.
Bolt the exhaust pipe to the exhaust manifold.
Lower the front end of the car.
Manual transmission:
a. Connect the free wheel cable and secure it in the
holder under the right-hand differential bearing
seat.
b. Check the operation of the free wheel control.
Connect the ground cable.
Mount the front sheet complete with radiator and
connect the hood lock operating cable to the attach-
ment at the dash panel. As from model 1972: Mount
the headlights.
Reconnect the cables to the radiator fan, thermo-
stat contact, headlights, headlight wiper motor and
clip the bundle of wiring to the front sheet.
Connect the coolant hoses to the radiator, thermo-
stat housing, water pump and inlet manifold.
Connect the vacuum hose and fuel hose and con-
nect cables to the temperature transmitter, ignition
coil and oil pressure transmitter.
Dec, 1975
Page 115
OQ)
17.
18,
19.
19.
Injection engine:
Also connect the vacuum hose to the pressure sensor
and the cables to the starting contact.
Connect the throttle control to the throttle control
shaft and connect the choke control to the carbu-
retor. As from model 1972: Connect the throttle
control wire to driver and bracket.
Carbureted engine:
Mount the air cleaner and preheater casing complete
with hose. As from model 1972: Connect the pre-
heater hose, air cleaner with valve housing and cold
air hoses. Connect the ventilation hose to the oil
filler pipe. Connect the ignition cable to the distri-
butor and coil.
Injection engine:
Mount the air cleaner complete with hoses. Connect
the cables for the electronic fuel injection to the dis-
tributor, injection valves, air cleaner, throttle valve
switch and to the temperature sensor and thermostat
switch below the inlet manifold. Make sure that the
rubber caps on the contact pieces are in place.
CAUTION
The connecting pieces only fit in one way and must
thus not be forced in place.
20.
21.
Install the battery and connect the cables.
Close the radiator and engine block drain cocks,
fill with coolant and oil, Bleed the heater core
(up to and incl. model 1973).
22. Start the engine, checking oil pressure and coolant
temperature. Check the operation of the transmis-
sion.
Check the operation of the radiator fan by ground-
ing the thermostat contact cable to the radiator.
23. a. Mount the hood and connect the windshield
washer and headlight washer hoses.
b. Check the fit of the hood. Close the hood, open
the doors, and check that the door jambs clear
the rear edge of the hood.
c. Check the headlight alignment.
d. Refit the headlight trim frames.
24. Take the car out for a test run. Check the coolant
Dec. 1975
level after driving.
201-5
Page 116
Separating engine from manual transmission
Clean the power plant.
Drain the engine oil.
Take off the clutch cover.
Remove the starter.
Unscrew the alternator from the alternator support.
Remove the drive belt.
Withdraw the clutch shaft (see instructions for disas-
sembling the clutch).
7. Undo the three screws of the release bearing guide
sleeve.
8. Back off the adjusting screw and disconnect the
clutch lever.
9. Undo all screws in the mating flanges of engine and
transmission and two screws accessible from under
the transmission.
10. Lift the engine carefully off the transmission (see
illustration). At the same time remove the release
bearing guide sleeve.
NP ON =
>
Reassemble in the reverse order.
Separating engine from automatic transmission
Clean the outside of the power plant.
2. Drain the engine oil.
3. Undo the screw located inside the crankcase using
a 1/2" socket and extension shank. This screw can
be reached at an inward angle through the engine
oil drain plug opening. Use a tool with a 3/8” square
grip (this applies to the 1970 model only).
4. Remove the cover over the flywheel ring gear.
Remove the starter.
6. Unscrew the alternator from the alternator support.
Take off the drive belt.
7. Disconnect the throttle wire from the throttle
housing.
8. Remove the crankcase ventilation device and all
screws (14 in number) in the mating flanges of en-
gine and transmission.
9. Undo the four screws fastening the flywheel ring
gear to the torque converter. These screws can be
reached through a recess in the starter mount.
a
SEPARATING ENGINE FROM TRANSMISSION
CAUTION
Do not mix up the screws. The screws inserted
from the block and threaded into the light alloy
transmission case have UNC threads, while the ones
inserted from the transmission and threaded into
the cast iron cylinder block have UNF threads.
201-6
SCREW HOLES FOR FLYWHEEL RING GEAR — TORQUE
CONVERTER
10. Lift the engine carefully off the transmission.
11, Fit the torque converter support (special tool
879025).
Reassemble in the reverse order.
CAUTION
If the engine and transmission fail to separate, do
not attempt to force them apart without first check-
ing that all the screws have been taken out. Do not
forget the screw inside the crankcase (1970 model
only) or the transmission ventilation attachment on
the right-hand side over the mating flanges.
Jan, 1971
Page 117
REMOVAL AND INSTALLATION
2.0 | engine
q Removing the power plant
tire power plant should be lifted out. Removal of the en-
gine by itself is not recommended.
| For major work on the engine and transmission, the en-
$3615
INJECTION ENGINE, SEEN FROM RIGHT
Remove the hood as follows:
Back off both the hood fastening screws. Lift off
the hood. For this you need a helper to hold one
side of the hood and help to lift it clear (see illus-
tration). RADIATOR DRAIN COCK
LIFTING OFF THE HOOD
HEATER CORE BLEEDER COCK, UP TO AND INCL.
MODEL 1973
2. Detach the battery cables, Unclamp and lift out
the battery. 4. Carbureted engine:
3. Drain off coolant through the radiator and engine Detach the vacuum hose of the power assist cylin-
block drain cocks; open the bleeder cock on the der from the inlet manifold and pull the fuel hose
heater core (up to and incl. model 1973). off the suction side of the fuel pump.
Sept. 1973 SAAB 201-7
Page 118
4. Injection engine:
a. Detach the vacuum hoses of the power assist
cylinder and the pressure sensor from the inlet
manifold.
b. Detach the fuel hoses from the tubes at inlet
resp. outlet of the injection valves.
5. Carbureted engine:
Undo the cable connections to the ignition coil,
temperature transmitter, oil pressure transmitter,
radiator fan, thermostat contact, headlights, head-
light wipers and the switch on the gear box on
cars with automatic transmission.
5. Injection engine:
a. Undo the cable connections to the ignition coil,
temperature transmitter, radiator fan, thermo-
stat contact, headlights, headlight wiper motor
and the switch on the gear box on cars with au-
tomatic transmission.
b. Undo the connections for the fuel injection of
distributor, thermostat housing, injection valves,
start valve, throttle valve switch and at the tem-
perature sensor at the inlet manifold.
CAUTION
Do not detach the connections by pulling the cables.
Grip the connecting pieces.
Carbureted engine:
a. Detach the connections between the preheater
hose and the valve housing.
b. Detach the hose for the crankcase ventilation
from the air cleaner.
c. Remove the air cleaner, together with the valve
housing and the cold air hose.
d. Remove the preheater casing with hose and the
asbestos protection at the exhaust manifold.
e. Detach the throttle control wire from driver and
bracket.
f. Detach the choke control wire and sheath from
the carburetor.
AIR CLEANER WITH HOSES, AS FROM MODEL 1973
1. Air cleaner
2. Valve housing
3. Cold air inlet
4, Preheater hose
201-8
Injection engine:
a. Remove air cleaner complete with hoses.
b. Detach the throttle control wire from driver and '
bracket on the throttle valve housing.
Carbureted engine:
Detach the hoses at the connections to the thermo-
stat housing, radiator, inlet manifold and water ,
pump.
Injection engine:
Detach the hoses at the connections to the thermo-
stat housing, radiator, water pump and valve at the
heater core.
a. Remove the four fastening screws from the front
sheet.
b. Remove the headlight trim frames.
c. Remove the headlights.
REMOVING THE FRONT SHEET
10.
at}
12.
13.
d, Remove the hood lock operating cable from its
fastenings at the dash panel and wheel housing.
e. Remove the front sheet, lifting forward and up-
ward,
Manual transmission: )
Remove the slave cylinder and hang it up in some
convenient place.
Automatic transmission:
Remove the protective cover from the exhaust
manifold. )
Disconnect the hose pipe from the exhaust mani-
fold.
a. Disconnect the ground cable from the transmis-
sion.
b. Remove the alternator if it is mounted in the
high position.
Jack up the front end of the car and place blocks
under the body.
Manual transmission:
a. Put the gear lever in neutral,
b. Knock out the front taper pin from the gear
shift rod joint and pull the rubber bellow free
of the groove on the gear selector rod. Separate
the gear selector rod joint from the gear selector
rod.
Nov. 1972
Page 119
-— i = - =a ee ee
13.
GEAR SHIFT ROD JOINT TAPER PIN
Automatic transmission:
Remove the screw for the gear selector wire at the
transmission. Move the gear selector lever to posi-
tion 1” and pull out the sheath from the trans-
mission. Fit tool 879038 on the wire, turn the tool
a little and pull out the wire.
REMOVING THE GEAR SELECTOR WIRE
Tool 879038
+) 14.
15.
16.
17.
18.
Dec. 1975
Detach the speedometer cable from the transmis-
sion.
Undo the engine brackets.
Undo the larger clips round the rubber bellows on
the inner universal joints.
Fit the lifting yoke to the two engine lifting lugs.
(On power units with the alternator located in the
high position, attach the rear hook of the yoke to
the alternator bracket after removing the alterna-
tor.)
Undo the lower end piece from the control arm on
the right-hand side and turn the steering wheel to
the left. Raise the power plant from the rear engine
cushions (the front bracket may rest on the cushion)
and withdraw the left universal joint, by moving
the power plant to the right. Move the power plant
to the left and withdraw the right universal joint.
SEPARATING THE INNER UNIVERSAL JOINT
19. Lift the power plant to a convenient height for
access to the cable connections on the starter and,
on cars with alternators fitted in the low position,
to the alternator cable terminals. Remove the cables.
20. Hoist out the power plant. Fit protective caps over
the inner drivers and rubber bellows.
201-9
Page 120
Installing the power plant
1. a. Check that the inner universal joints are packed
with grease.
b. Check the front engine cushion. Make sure that
the washer is properly tightened.
FRONT ENGINE CUSHION
2. Raise the power plant with the lifting yoke (tool
829217) balancing the engine in such a way that
the engine mounting at the flywheel end comes
into position before the other two mountings. Po-
sition the power plant in the engine compartment.
3. Lower the power plant to a convenient height for
fitting the starter and alternator cables (low posi-
tion alternator). Connect the cables.
4. Assemble the inner universal joints as follows:
Hang the clips on the inner drivers. Lower the
power plant until it is about 2—2 1/2” (50—60 mm)
from the engine cushions. Assemble the right-hand
universal joint, then lower the power plant until it
is about 1’ (20—30 mm) above the engine cushions
and push the power plant to the right. Lower the
pover plant and position it over the engine cushions
while guiding the left-hand universal joint into place.
Connect the end piece to the lower control arm.
ASSEMBLING THE RIGHT INNER UNIVERSAL JOINT
201-10
5,
a. Align the engine brackets.
Model 1974:
Cars built to U.S. specifications and other cars with
servo-assisted steering are equipped with special rear
engine cushions. The cushions are designed to pre-
vent the power plant from hitting the steering gear
and damaging it in the event of a collision. A wire
runs between the rear edge of the upper retaining
plate and the front edge of the lower retaining plate
in the cushions. The position of the cushions is de-
termined by guides in the engine bracket and the
cushion,
10.
11.
12.
13.
14,
15,
16.
17.
18.
19.
b. Bolt the power plant to the engine cushions.
Remove the lifting yoke.
a. Push the rubber bellows over the inner universal
joint drivers and fit the clamps.
b. Wipe any surplus grease off the rubber bellows
and check that the bellows are not deformed.
Manual transmission:
a. Connect the gear shift rod joint to the gear se-
lector rod and insert the taper pin. Refit the
rubber bellows in the groove on the gear shift
rod joint.
b. Fit the slave cylinder and adjust the clutch.
Automatic transmission:
Connect the gear selector wire to the transmission.
Connect the speedometer cable to the transmission.
Bolt the exhaust pipe to the exhaust manifold.
Lower the front end of the car.
a. Connect the ground cable.
b. Fit the alternator (if located in the high position).
Mount the front sheet complete with radiator and
connect the hood lock operating cable to the attach-
ment at the dash panel.
Mount the headlights and their trim frames.
Reconnect the cables to the radiator fan, thermo-
stat contact, headlights, headlight wiper motor and
clip the bundle of wiring to the front sheet.
Connect the coolant hoses to the radiator, thermo-
stat housing, water pump, inlet manifold and heater.
Connect the vacuum hose and fuel hose and con-
nect cables to the temperature transmitter, igni-
tion coil and oil pressure transmitter. On injection
engine also connect the vacuum hose to the pressure
sensor and the cables to the start inhibitor switch.
a. Connect the throttle control wire to driver and
bracket.
b. Carbureted engine:
Connect the choke control wire to the carbu-
retor,
Carbureted engine:
a. Mount the air cleaner with valve housing and
cold air hose.
b. Fit the preheater casing, complete with hose.
Fit the asbestos casing on the exhaust manifold
and connect the hose to the throttle valve hous-
ing.
c. Connect the hose to the crankcase ventilation
between air cleaner and vent housing.
Dec. 1975