Page 131
MEASURING PUMP COVER CLEARANCE
30. Fit the fuel pump.
31. Fit the cover over the oil channels so that the loca-
ting pin engages the corresponding hole in the cover.
32. Fit the distributor (see group 3).
33. Fit the oil pump and its drive shaft.’
34. Fit the oil pump suction line. Make sure that the
suction tube gasket is the right way round.
35. Fit the oil filter.
36. Fit the inlet manifold. Connect water hoses and
crankcase ventilation hoses. Screw in the engine
lifting eye.
37. Mount the carburetor.
38. Mount the thermostat housing.
39. Fit the exhaust manifold.
40. Fit the two semicircular rubber seals and the cam-
shaft cover.
41. Mount the clutch.
Changing pistons, piston rings and big-end bearings
(Engine mounted in work stand)
Disassembly
1. Remove the oil filter.
2. Remove the camshaft cover.
3. Remove the camshaft chainwheel as follows:
a. Screw a nut on to the threaded center stud of the
camshaft chainwheel and clamp the chainwheel
against the mounting plate provided for the pur-
pose.
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 refitted.
b. Undo the two locked retaining screws from the
camshaft chainwheel. Separate the wheel from
the camshaft plate until it hangs freely by its
center stud in the mounting plate.
4. a. Unscrew all cylinder head screws and nuts.
Jan. 1971 Saas
site
CAMSHAFT CHAINWHEEL CLAMPED TO MOUNTING PLATE
CAMSHAFT CHAINWHEEL RETAINING SCREWS
. Remove the cylinder head screws.
. Remove the screws from the transmission chain.
cover.
. 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),
. Remove the other studs.
5. Disconnect hoses and cables from the inlet manifold
and carburetor. Unscrew the spark plugs.
. Lift off cylinder head with carburetor, inlet manifold
and exhaust manifold.
. Remove the big-end bearing caps and push the Pistons
complete with connecting rods out of the cylinders
(see illustration). Protect the studs with pieces of plas-
tic hose,
210-9
Page 132
STUDS AS LOCATING PINS FOR REMOVAL AND
MOUNTING OF CYLINDER HEAD
MEASURING PISTON CLEARANCE
Fitting piston rings in a new or rebored cylinder
1. Push the piston rings dowri into the cylinder one ata
time, using an inverted piston head to position them
correctly.
2. Measure the ring gap with a feeler gauge (see illustra-
tion). Correct gap sizes are given in the specifications
(group 0). If necessary, widen the gap with a special
file. :
3. Try the piston rings in their respective grooves by
rolling. Measure the clearance at a few points too.
REMOVAL PISTONS AND CONNECTING RODS
Fitting pistons
To fit pistons to the cylinder bores, use a feeler gauge
1/2” wide and 0.013—0.038 mm thick. To measure, first
oil the cylinder lining lightly and insert the piston with-
out rings in the cylinder in the position in which it will
ultimately be working. Attach the feeler gauge to a spring
balance and place it between the piston and cylinder bore
at right angles to the axis of the piston pin (see illustra-
tion). At a tractive force of 8—12 N (1.8—2.6 Ib., 0.8—
1.2 kp), the mean value of the clearance equals the thick-
ness of the feeler gauge. Repeat the test with the piston
at several different depths on the piston. Spare pistons
are stocked in both standard and oversize diameters.
Where the latter are used, the cylinder bore must be
honed or rebored to obtain the correct piston clearance.
MEASURING PISTON RING GAP
210-10 Saey Nov. 1972
Page 133
Fitting piston rings in worn cylinders
Rings to be fitted in a worn cylinder must be tried at the
lower limit of travel of the piston, as the bore-will be nar-
rowest at this point.
Assembly of piston rings
Use a piston ring tool to position the rings as illustrated.
Place the lower compression ring with the side marked
top’ uppermost. Oil the piston and rings before assem-
PISTON RING TOOL
bling. Rotate the compression rings so that the gaps are
staggered 180°, one in line with each end of the piston
pin. Make sure, too, that the spring gaps of the top and
bottom rings in the three-piece scraper ring are staggered.
s 167%
PISTON AND CONNECTING ROD
Installation
1. Install pistons and connecting rods using the piston
installing tool 839036 for 1.7 liter engines and tool
839208 for 1.85 liter engines.
NOTE
Piston marked “FRONT” (piston with offset piston
pin) are to be installed with the marking nearest
the transmission chain end of the engine.
INSTALLING A PISTON
Tool 839036 (1,71) or 839208 (1.85 1)
2. Mount big-end bearing caps with bearing halves.
3. Fit the cylinder head gasket.
4. Check that the mark on the camshaft is in line with
the marks on the first camshaft bearing cap.
5. Mount the cylinder head. Screw in the studs using
tools 839051 and 839052. Tighten the cylinder head
screws to the specified torque. The order of tighten-
ing is illustrated below. See p. 211—2 for correct dis-
tribution of torque between screws and nuts. Tight-
en finally after the engine has cooled off for about
30 minutes.
Insert and tighten the transmission chain cover screws.
a
So q
Sh J
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i} |
U fa}
a!
x S9
ORDER OF TIGHTENING CYLINDER HEAD SCREWS
6. Fit the camshaft chainwheel to the camshaft, making
sure that the notches on the camshaft and bearing cap
are in line. Tighten and lock both retaining screws.
Remove the nut from the center stud of the camshaft
chainwheel. Check at the same time that the mark on
the flywheel is in line with the mark on the cylinder
block.
7, Mount the camshaft cover,
8. Connect hoses and cables to the camshaft cover, inlet
manifold and carburetor. Screw in the spark plugs
and connect the ignition cables,
9. Install the oil filter.
Dec. 1975 SAAB 210-11
Page 134
ENGINE
2.0 | engine
Disassembling the engine
1.
Mount the engine in a work stand with engine hold-
er 839216.
ENGINE MOUNTED IN WORK STAND
Tool 839216
Remove the distributor cap and disconnect the ig-
nition cables.
Carbureted engine:
Remove the carburetor.
REMOVING THE THROTTLE VALVE HOUSING
210=12
3.
Injection engine:
Undo the start valve from the throttle valve hous-
ing and let it be hanging in its hose. Remove the
throttle valve housina.
Undo the hose connections from the water pump,
bypass system and crankcase ventilation circuit.
Remove the valve cover.
Remove the distributor.
REMOVING THE DISTRIBUTOR
yi
a. Remove the inlet manifold together with the
front lifting lug.
b. Remove the alternator bracket (engines with
high position alternator).
REMOVING THE INLET MANIFOLD
10.
Remove the vent housing for the crankcase venti-
lation.
a. Remove the oil filter.
b. Remove the oil pump.
c. Rernove the oil pump spacing piece.
d. Remove the suction line to the pump.
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.
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.
Dec, 1975
Page 135
UNDOING THE CENTER SCREW OF THE WATER PUMP. REMOVING THE BEARING HOUSING
Too! 839027
c, Fit tapping-out hammer 839027 with adapter 11. Remove the thermostat housing.
839213 to the water pump shaft and take out
the pump unit.
THERMOSTAT HOUSING (INJECTION ENGINE)
1, Thermoswitch for the injection system
\ 2. Temperature transmitter for the temperature gauge
3. Temperature transmitter for the injection system
4. Auxiliary air regulator
12. Unbolt the exhaust manifold with gasket.
\
REMOVING THE WATER PUMP
Tools 839027 and 839213
d. The bearing housing may be left behind in the
cylinder block. If so, expel the bearing housing
with tapping-out hammer 839027 fitted with a
nut and a flat washer, OD 1’ (25 mm) — see
illustration.
REMOVING THE EXHAUST MANIFOLD
Dec. 1975 SAAB 210-13
Page 136
13. Remove the camshaft sprocket as follows: 16. Remove the camshaft bearing assembly.
a. Turn the crankshaft to ignition position for 17. Unscrew all cylinder head screws and insert two
No. 1 cylinder. locating pins (839212).
b. Screw a M8 nut on to the threaded center stud 18. Lift off the cylinder head and remove the gasket.
of the camshaft sprocket and tighten the center
stud against the mounting plate provided for the
purpose.
REMOVING THE CYLINDER HEAD
19. Loosen the belt pulley screw and remove the belt
pulley, using tapping-out hammer 839027 and
puller 839215.
NUT MOUNTED ON THE CENTER STUD
CAUTION
Tighten the nut securely to immobilize the center
stud. Otherwise the chain tensioner will tighten the
chain and lock in a new position so that the sprocket
cannot be replaced in position.
c. Undo the three locked retaining screws from the
camshaft sprocket. Separate the wheel from the
camshaft plate until it hangs free on the center
stud in the mounting plate.
14. Remove the camshaft bearing caps and lift out the
camshaft.
15, Remove the valve depressors and adjusting pallets
from the camshaft bearing assembly using magne- REMOVING THE BELT PULLEY SCREW
tic tool 839140.
REMOVING THE VALVE DEPRESSORS REMOVING THE BELT PULLEY
Too! 839140 Tools 839027 and 839215
SAAB Dec. 1975
210-14
Page 137
20. Remove the chain transmission cover, 24, Remove the idler shaft sprocket. See illustration.
a
REMOVING THE CHAIN TRANSMISSION COVER REMOVING THE IDLER SHAFT SPROCKET
21. Remove the chain tensioner, 25. Unscrew the idler shaft keeper plate and carefully
22. Undo the chain guides, the Mounting plate with the withdraw the idler shaft.
camshaft sprocket and transmission chain.
REMOVING THE TRANSMISSION PLANT
REMOVING THE KEEPER PLATE
23. Remove the crankshaft sprocket using universal
puller and dolly 839184.
26. Carefully remove any crusts and deposits of soot
from the top ends of the cylinders.
27. 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
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 page 210—21.
REMOVING THE CRANKSHAFT SPROCKET
Tool 839184 and universal puller
Dee. 1975 SAAB 210-15
Page 138
REMOVING PISTON AND CONNECTING ROD
28.
29.
29.
30.
Replace the big-end bearings and caps loosely on
the connecting rods from which they came.
Manual transmission:
Dismantle the clutch and flywheel.
Automatic transmission:
Remove the driver disc.
Remove the gable plate and shaft seal.
210-16 SAAB
31.
32.
33.
REMOVING THE GABLE PLATE
Undo the main bearing screws and remove the bear-
ing caps.
Lift out the crankshaft.
Remove the bearing halves and thrust bearing wash-
ers and put them carefully aside so that they can be
reassembled in their original positions.
Nov. 1972
Page 139
Assembling the engine
Instructions for measuring the main bearing and big-end
bearing clearance and choice of bearing halves, see sec-
tion 216.
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.
MARKS ON CONNECTING RODS, MAIN BEARINGS AND
CYLINDER BLOCK
5. Tighten the screws to the specified torque.
LOCATION OF THRUST BEARING WASHERS
3. Locate the thrust bearing washers, making sure
that the oil grooves face the crankshaft bearing sur-
faces. Check the axial play with a feeler gauge.
TIGHTEN THE MAIN BEARING SCREWS
6. Fit the gable plate with the crankshaft seal, using
guide sleeve 839197. Lubricate the inner surface
of the seal ring.
INSTALLING THE THRUST BEARING
4. Mount the main bearing caps with bearing halves
already in position and oiled. (NOTE! Make sure
the markings match up! ) The main bearing caps
are numbered; No. 1 goes at the transmission chain
end and the others run consecutively to the fly-
wheel end with the bearing locks facing each other.
To each number on the bearing caps, corresponds
a cast number on the crankcase.
GABLE PLATE FITTED
Dec. 1975 SAAB 210-17
Page 140
:
7. Fit the flywheel (driver disc). Apply Loctite Pipe 9. a. Fit the big-end bearing caps so that the figures
Sealant 68 or the equivalent to the screw threads. face the same way as those on the connecting
rod, i.e. away from the idler shaft.
b. Tighten to specified torque.
10. a. Assemble the idler shaft and fit the keeper plate.
b. Mount the sprocket on the idler shaft.
11, Install the pump shaft with bearing housing with-
out impeller in the engine block. Check that the
cogs of the pump shaft engages with the idler shaft
sprocket. Position the bearing housing with aid of
drift 839044, sleeve 839053 and hammer, so that
the flange of the bearing housing is flush with the
engine block. Fit the impeller, the gasket and the
water pump cover.
TIGHTEN THE FLYWHEEL SCREWS TO SPECIFIED TORQUE
8. Install the pistons and connecting rods using tool
786228. Make sure that the studs are still pro-
tected by their plastic sleeves. The connecting rods
and big-end bearing caps are numbered to match
the corresponding cylinders. Instructions for fitting
piston rings are given on page 210—22.
INSTALLING THE WATER PUMP.
Tools 839044 and 839053
12. a. Mount the sprocket on the crankshaft. )
Nee b. Align the 0 degree mark on the flywheel with
INSTALLING PISTON AND CONNECTING ROD the mark on the cylinder block.
Tool 786228
NOTE \
The groove on top of the piston should be facing
the transmission end.
PISTON MARKINGS FLYWHEEL AND CYLINDER BLOCK MARKINGS
210-18 SAAB, Dec. 1975