Page 121
Pa
beh 4 Ta cola
19.
Injection engine:
Mount the air cleaner complete with hoses. Connect
the cables for the electronic fuel injection to the dis-
tributor, thermostat housing, injection valves, start
valve, throttle valve switch and to the temperature
sensor at the inlet manifold. Make sure that the rub-
ber 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.
22.
23.
24.
Dec. 1975
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).
Start the engine, checking oil pressure and coolant
temperature. Check the operation of the transmis-
sion. Check the operation of the radiator fan by
grounding the thermostat contact cable to the ra-
diator.
a, Mount the hood and connect the windshield
washer hose.
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.
Take the car out for a test run. Check the coolant
level after driving.
201-11
Page 122
Separating engine from manual transmission
. Clean the power plant.
. Drain the engine oil.
. Take off the clutch cover.
. Remove the starter.
. Withdraw the clutch shaft (see instructions for disas-
sembling the clutch).
. Undo the three screws of the release bearing guide
sleeve.
7. Back off the adjusting screw and disconnect the
clutch lever.
8. Undo all screws in the mating flanges of engine and
transmission and two screws accessible from under
the transmission.
9. Lift the engine carefully off the transmission (see
illustration). At the same time remove the release
bearing guide sleeve.
OfPWN=
a
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.
201-12
Separating engine from automatic transmission
1. Clean the outside of the power plant.
2. Drain the engine oil.
3. Remove the cover over the flywheel ring gear.
4. Remove the starter.
5. Disconnect the throttle wire from the throttle
housing (carburator).
6. Remove the crankcase ventilation device and all
screws (17 in number) in the mating flanges of en-
gine and transmission.
7. Undo the four screws fastening the flywheel ring gear
SCREW HOLES FOR FLYWHEEL RING GEAR — TORQUE
CONVERTER
to the torque converter. These screws can be reached
at the crankcase ventilation connecting housing.
8. Lift the engine carefully off the transmission.
9. Fit the torque converter support (special tool No.
879025).
Reassemble in the reserve order.
SAAB Dec. 1975
Page 123
ENGINE BODY
c. Fit tapping-out hammer 839027 with adapter
839057 to the water pump shaft and take out
1,7 and 1,85 | engines
the pump unit.
Disassembling the engine
1. Mount the engine in a work stand with engine hold- 3
er 839045.
a Darr
ENGINE MOUNTED IN WORK STAND
Too! 839045 si oma
REMOVING THE WATER PUMP
2. Remove the distributor cap and disconnect the ig- Tools 839027 and 839057
nition cables.
The bearing housing may be left behind in the
cylinder block. If so, expel the bearing housing
with an impact puller fitted with a nut and a
flat washer, OD 1” (25 mm).
3. Remove the carburetor. In the case of injection en-
gines, remove the throttle housing.
4. Remove the inlet manifold and distributor (and the
upper engine bracket on 1969 models).
5. Undo the hose connections from the water pump,
bypass system and crankcase ventilation circuit.
6. Remove the fuel pump (remove the thermostat
housing on injection engines).
7. Remove the cover over the oil channels complete
with oil pressure transmitter.
8. Remove the oil filter.
9. Remove the oil pump and pump shaft and discon-
nect the suction line.
10. Remove the water pump as follows:
a. Take off the cover.
b. Undo the center screw from the impeller. Hold
the impeller with polygrip pliers and unscrew
clockwise (left-hand thread). Save the washer.
REMOVING THE BEARING HOUSING
Tool 839027
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.
11. Remove the thermostat housing.
12. Unbolt the exhaust manifold.
13. Remove the camshaft cover and gaskets.
UNDOING THE CENTER SCREW OF THE WATER PUMP
Dec. 1975 SAAB 210-1
Page 124
14.
Remove the camshaft chainwheel as follows:
a. Screw a nut on to the threaded center stud of
the camshaft chainwheel and tighten the center
stud against the mounting plate provided for the
purpose.
CAUTION
Tighten the nut securely to immobilize the
center stud. Otherwise the chain tensioner
will tighten the chain and lock in a new posi-
tion so that the chainwheel cannot be re-
placed in position.
15.
b. Undo the two locked retaining screws from the
camshaft chainwheel. Separate the wheel from
the camshaft plate until it hangs free on the cen-
ter stud in the mounting plate.
SEPARATING THE CAMSHAFT CHAINWHEEL FROM THE
CAMSHAFT PLATE
a. Unscrew all cylinder head screws and nuts.
b. Remove the cylinder head screws.
c. Remove two studs, using tools 839051 and
839052, and insert these studs in two of the
cylinder head screw holes to act as locating
pins (see illustration).
NOTE! Do not forget the screws in the chain
transmission case.
d. Unscrew the other studs and lift off the cylinder
head.
REMOVING STUDS
Tools 839051 and 839052
=
STUDS AS LOCATING PINS FOR REMOVAL AND
MOUNTING OF CYLINDER HEAD Ms
16. Undo the belt pulley screw ev. with aid of sleeve
839066. Pull out the belt pulley using tapping-out
hammer 839027 and puller 839114.
REMOVING THE BELT PULLEY
Tools 839027 and 839114
Dec, 1975
Page 125
17.
18.
19.
20.
DISASSEMBLING THE CRANKSHAFT SPROCKET
PULLER No. 839185
245
22.
IDLER SHAFT KEEPER PLATE
Remove the chain transmission cover.
Remove the chain tensioner.
Undo the chain guide screws. Remove the mounting
plate with the camshaft chainwheel and transmis-
sion chain.
Remove the chain guides.
oo
Remove the oil thrower ring and pull the sprocket
Off the crankshaft using puller 839185. Pullers
839118 and 899525 may also be used.
Unscrew the idler shaft keeper plate and carefully
withdraw the idler shaft.
25.
23. Carefully remove any crusts and deposits of soot
from the top ends of the cylinders.
24. Note the markings on the connecting rods and big-
end bearing caps so that they can be reassembled
later in their original positions. Remove the nuts
Dec. 1975 SAAB
26.
and bearing caps and push the pistons complete
with connecting rods out of the cylinders (see illus-
tration). Protect the stud threads with pieces of
plastic hose when dismantling pistons and con-
necting rods.
For instructions with regard to exchanging pistons see
p. 210-9,
DISASSEMBLING PISTON AND CONNECTING ROD
Replace the big-end bearings and caps loosely on
the connecting rods from which they came.
Dismantle the clutch and flywheel (see illustration).
Engine, automatic transmission: Remove the driver
disc.
REMOVING THE FLYWHEEL
210-3
Page 126
27. Remove the seal cap and shaft seal. 4. Mount the main bearing caps with bearing halves
28. Undo the main bearing screws and remove the bear- already in position and oiled. (NOTE! Make sure
ing caps and bearings. the markings match up! ) The main bearing caps
29. Lift out the crankshaft. are numbered; No. 1 goes at the transmission chain
30. Remove the bearing halves and thrust bearing wash- end and the others run consecutively to the fly-
ers and put them carefully aside so that they can be wheel end with the bearing locks facing each other.
reassembled in their original positions.
Assembling the engine
1. Place the bearing halves in the main bearing jour-
nals and lubricate the bearings with engine oil.
2. Locate the crankshaft carefully in the bearing jour-
nals.
MAIN BEARING CAP MARKINGS
5. Tighten the screws to the specified torque.
6. Fit the seal cap with the crankshaft seal, using guide
sleeve 839041. Lubricate the inner surface of the
seal ring.
CRANKSHAFT LOCATED IN BEARING JOURNALS
3. Locate the thrust bearing washers, making sure
that the oil grooves face outward (see illustration).
FITTING THE CRANKSHAFT SEAL
Tool 839041
7. Fit the flywheel. Use new screws.
Engine, automatic transmission: Fit the driver disc,
Using new screws.
NOTE!
The retaining screws have not the same length.
Short screws for the flywheel. Long screws for the
driver disc. Do not mix them up.
When refitting the flywheel (driver disc), always use
new screws.
When fitting a crankshaft with six holes together
with a flywheel (driver disc) with four holes, a thin
tayer of Tikatat or the equivalent must be applied
POSITION OF THRUST BEARING WASHERS to the contact surfaces.
210-4 En SAAB Dec. 1975
‘ee
Page 127
Lae") a ee
8. Install the pistons and connecting rods using tool 11. a. Mount the chainwheel on the crankshaft.
No. 839036 for 1.7 liter engines and tool No. b. Align the 0 degree mark on the flywheel with
839208 for 1.85 liter engines. Make sure that the the mark on the cylinder block.
studs are still protected by their plastic sleeves. The
connecting rods and big-end bearing caps are num-
bered to match the corresponding cylinders. Instruc-
tions for fitting piston rings are given on p. 210—10.
NOTE
Pistons marked “FRONT” (pistons with offset
piston pin) are to be installed with the mark-
ing nearest the transmission chain end of the
engine.
—~
FLYWHEEL AND ENGINE BLOCK MARKINGS
' 12. Fit the cylinder head gasket.
13. Line up the camshaft setting mark with the notch
on the bearing cap. If the camshaft is in any other
position, the valves will be damaged when the cyl-
inder head is mounted on the cylinder block.
S 1664
INSTALLING A PISTON
Tool 839036 (1.7 |) or 839208 (1.85 |)
9. Fit the big-end bearing caps so that the figures face
the same way as those on the connecting rod, i.e.
away from the idler shaft.
10. Assemble the idler shaft and fit the keeper plate.
=
) Turn the shaft until the marked line on the chain-
wheel is horizontal.
J
CAMSHAFT MARKING
14. a. Mount the cylinder head.
b. Tighten the nuts and screws to the prescribed
torque in the order shown in the drawing below
see p. 211—2.
c. Do the final tightening after the engine has been
allowed to cool for about 30 minutes.
IDLER SHAFT CHAINWHEEL MARKING
Dec. 1975 SAAB 210-5
Page 128
ORDER OF TIGHTENING CYLINDER HEAD SCREWS
15. a. Mount the straight chain guide plate with the
long screw in the bottom hole.
MOUNTING THE TRANSMISSION CHAIN
17. Rotate the camshaft chainwheel until the screw
holes match the threaded holes in the camshaft
flange.
18. Fit the transmission chain over the other sprockets
so that it hangs straight from the camshaft to the
crankshaft.
NOTE! The shaft settings must not be altered.
MOUNTING THE STRAIGHT CHAIN GUIDE PLATE
b. Mount the curved chain guide plate loosely with
a short screw in the hole nearest the idler shaft.
—s Bee $3123
PLACEMENT OF TRANSMISSION CHAIN ON SPROCKETS
MOUNTING THE CURVED CHAIN GUIDE PLATE
16. Assemble the camshaft chainwheel and mounting
plate, fit the transmission chain over the camshaft
chainwheel, and lower the transmission chain and
mounting plate past the camshaft flange until the
center stud of the chainwheel is lined up with the
camshaft.
210-6 SAAB Jan, 1972
Page 129
19. Guide the center stud of the camshaft chainwheel b. Slacken the chain by loosening ‘the screws of the
into the camshaft. Fit the locking plate and insert curved chain guide.
one screw. c. Mount the chain tensioner with guide plate on
the engine block.
d. Press on the curved chain guide to stretch the
chain over the tensioner neck. Tighten the chain
guide screws,
o*
GUIDING THE CENTER STUD
20. Fit the screws for the chain guides and the mount-
ing plate.
21. a. Rotate the crankshaft one full turn in the direc- tIG HE
tion of rotation of the engine, insert and tighten IGHTENING THEICHAIN GUIDE
the camshaft chainwheel screws, and lock the ‘ : 3
. A e. Apply spring pressure to the chain tensioner by
screws with the locking plate. turning the clamping sleeve clockwi ith a
: 1
b. Check the setting, “Camshaft — Crankshaft’. 9 eee) be - eg eee bat
rs e " 5 hexagon pin spanner. A distinct click will be
22. Mount the chain tensioner according to the following A 7 A 2
aeetintion heard as spring pressure is applied. Fit and lock
. the screw on the back of the chain tensioner.
f. Rotate the crankshaft one full turn in its normal
sense and check the chain tension. The move-
ment of the tensioner neck from its butted posi-
= tion must be at least 0.02” (0.5 mm) and not
/ more than 0.06” (1.5 mm).
=
j
APPLYING SCREW PRESSURE TO THE CHAIN TENSIONER
23. On engines with serial numbers up to and including
2954, fit the chain tensioner as follows:
a. Undo the screw on the back of the chain ten-
sioner, Relieve the spring pressure on the tension
plate by turning the clamping sleeve clockwise
with a hexagon pin spanner to the “mounting
position’.
SELF-TRIGGERING CHAIN TENSIONER
Jan. 1971 SAAB 210-7
Page 130
24. Onengines with serial numbers of 2955 or higher,
fit the chain tensioner as follows:
a. Relieve the spring pressure on the tensioner neck
by turning the clamping sleeve clockwise to the
‘mounting position”.
b. Fit a shim 0.118” (3 mm) thick on the tensioner
neck. (The chain tensioner is supplied with this
shim as a spare part.) Push the neck into the
chain tensioner.
c. Mount the chain tensioner with guide plate on
the engine block.
d, Remove the shim. Press the curved chain guide
against the chain to stretch it and push the ten-
sioner neck into the housing. Then adjust to
leave a clearance of 0,02” (0.5 mm) between the
housing and the tensioner neck.
Tighten the chain guides.
INSTALLING THE WATER PUMP
Tools 839044 and 839053
drift 839044, sleeve 839053 and hammer, so that
the flange of the bearing housing is flush with the
engine block. See illustration. Fit the impeller.
29. The clearance between the center screw of the im-
peller and the cover must be 0.01 —0.02” (0.25—
0.50 mm). Adjust the clearance as follows:
a. Place a washer 0.02” (0.5 mm) thick between
the center screw of the impeller and the pump
cover, see illustration. Use a feeler gauge to mea-
sure the gap between the cover and the engine
block.
b. Remove the washer and fit one or two new gas-
kets corresponding in thickness to the measured
gap between cover and block. There are three
different gasket thicknesses to choose from, viz.
0.01", 0.02, and 0.03” (0.25, 0.50 and 0.75
mm). Tighten the cover.
ADJUSTING THE CHAIN TENSIONER CLEARANCE
e. Rotate the crankshaft one full turn in its normal
sense and check the chain tension. The move-
ment of the tensioner neck from its butted posi-
tion must be at least 0.02” (0.5 mm) and not
more than 0.06” (1.5 mm).
25. Remove the nut from the camshaft chain wheel
center stud.
26. Fit the oil thrower ring, transmission chain cover
and alternator suppo/t.
27. Fit the belt pulley.
28. Install the pump shaft with bearing housing with-
out impeller in the engine block. Check that the MEASURING PUMP COVER CLEARANCE
cogs of the pump shaft engages with the idler shaft
sprocket. Position the bearing housing with aid of
210-8 SAAB Dec. 1975