Page 141
13. Fit the cylinder head gasket. Two locating pins
839212 for the cylinder head shall be fitted.
CAMSHAFT MARKINGS
21. Assemble the camshaft sprocket and mounting
FITTING THE CYLINDER HEAD GASKET plate if they have been disassembled, fit the trans-
Tool 839212 mission chain over the camshaft sprocket, and
lower the transmission chain and mounting plate
14. a. Mount the cylinder head.
b. Tighten the screws in two steps, first to 59 Nm
(6 kpm, 43 ft.lb.) then to 93 Nm (9.5 kpm,
69 ft.lb.). The order is shown in the drawing
below, see page 210—23.
c. Do the final tightening after the engine has
been allowed to cool for about 30 minutes.
15. Mount the camshaft bearing assembly.
16. Mount the adjusting pallets and valve depressors.
17, Fit the camshaft.
18. Fit the camshaft bearing caps. Note the marks and
guide sleeves.
19. Mount the straight chain guide plate.
20. Check that the setting marks on the crankshaft, cam-
shaft and idler shaft are in the right position, i.e.
the ignition position for the first cylinder.
$4082
INSTALLING THE TRANSMISSION CHAIN
Past the camshaft flange until the center stud of
the sprocket is lined up with the camshaft.
22. Rotate the camshaft sprocket until the screw holes
match the threaded holes in the camshaft flange.
23. 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.
24. Guide the center stud of the camshaft sprocket
into the camshaft. Fit a new locking plate and
screws.
S —<) Go), &
IDLER SHAFT MARKING, THE BULGE IN THE HOLE ON
THE IDLER SHAFT CHAINWHEEL SHOULD LINE UP
WITH THE SMALL HOLE IN THE KEEPER PLATE.
Dec. 1975 SAO 210-19
Page 142
FITTING THE CAMSHAFT SPROCKET
25.
26.
27.
Mount the curved chain guide plate together with
the mounting plate (the chain guide plate nearest
the block) with two screws and stretch the chain
somewhat.
Check the setting ‘’camshaft-crankshaft-idler shaft’’.
Fit the chain tensioner. There are two different ver-
sions, see illustration. Fit as follows:
Earlier version:
. Before installation, remove the tensioner neck
from the chain tensioner housing.
. Tension the spring, by turning the ratchet sleeve
(actuated by the spring) clockwise and at the
same time pushing it until it locks in its innermost
position.
sae
CHAIN TENSIONER
A. Earlier version
B. Later version
210-20
LOCKING THE RATCHET SLEEVE
c. Fit the tensioner neck and a spacer piece, so that
the tensioner neck will not bottom in the chain
tensioner housing and release the self-adjuster.
CHAIN TENSIONER WITH SPACER PIECE
d. Mount the chain tensioner with guide plate on
the engine block.
e. Press the curved chain guide agaist the chain
to stretch it and push the tensioner neck against
the spacer piece. Remove the spacer piece while
the chain is kept tensioned. Then adjust to leave
a clearance of 0.02" (0.5 mm) between the hous-
ing and the tensioner neck.
Tighten the chain guides.
Dec. 1975
Page 143
a ee ee ree, ES
ADJUSTING THE PLAY
fi
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).
Later version:
a.
b.
28.
29.
30.
31.
32.
33.
34,
35.
Dec. 1975
Place the lock washer in the chain tensioner
housing.
Fit the spring, with the smaller end against the
lock washer.
. Fit the tensioner neck in the housing by simul-
taneously pressing and turning it.
. Keep the tensioner neck depressed and tighten
the chain tensioner with guide plate on the en-
gine block. The tensioner neck must be kept de-
pressed until the chain has been tightened.
. Adjust the curved chain guide plate so that the
clearance between the tensioner neck and the
chain tensioner housing will be 0.02—0.06”
(0.5—1.5 mm).
Tighten the chain guides. Rotate the crankshaft
one full turn, checking the clearance of the ten-
sioner neck.
Remove the nut from the camshaft sprocket center
stud.
Fit the transmission chain cover and alternator
support.
Fit the belt pulley.
Mount the oil pump spacing piece with gasket. Note
the guide pins!
Fit the oil pump suction line. Make sure that the
FITTING THE START VALVE
36.
37.
38.
39.
40.
41.
42.
Mount the thermostat housing.
Fit the exhaust manifold with a new gasket.
Mount the distributor with drive shaft for the oil
pump and make basic ignition setting. See group 3.
Fit the oil pump.
Mount the vent housing for the crankcase ventilation.
Fit the valve cover.
Mount the clutch.(Manual transmission)
Changing pistons, piston rings and big-end bearings
(Engine mounted in work stand)
Disassembly
1,
Remove the oil filter using tool 786201.
suction tube gasket is the right way round. REMOVING THE OIL FILTER
Fit the oil filter. Tool 786201
Fit the inlet manifold. Connect water hoses and
crankcase ventilation hoses. Screw in the engine 2R
iiftipa.eve, . Remove the valve cover.
r 3. Remove the camshaft sprocket as follows:
Carbureted engine: a. Turn the crankshaft to ignition position for No. 1
Mount the carburetor. ¢
cites f cylinder,
Injection engine: b. Screw a M8 nut on to the threaded center stud of
Mount the throttle valve housing and the start the camshaft sprocket and clamp the sprocket
valve. against the mounting plate provided for the pur-
pose.
SAAB 210-21
Page 144
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 refitted.
c. Undo the two locked retaining screws from the
camshaft sprocket. 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.
b. Remove the cylinder head screws and mount two
guide pins.
c. Remove the screws from the transmission chain cover.
5. Disconnect hoses and cables from the inlet manifold
and carburetor, Unscrew the spark plugs.
6. Lift off cylinder head with throttle valve housing, inlet
manifold, exhaust manifold and valve mechanism.
7. Remove the big-end bearing caps and push the pistons
complete with connecting rods out of the cylinders.
Protect the studs with pieces of plastic hose.
NOTE! Remove any crusts and deposits of soot from
the top ends of the cylinders.
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 lb., 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.
Concerning piston clearance, see Group 0.
Fitting piston rings in a new or rebored cylinder
1. Push the piston rings down into the cylinder one at a
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.
If necessary, widen the gap with a special file.
MEASURING PISTON RING GAP
3. Try the piston rings in their respective grooves by
rolling. Measure the clearance at a few points too.
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
Dec. 1975
Page 145
Installation
1, Install pistons and connecting rods using the piston
installing tool No. 786228.
NOTE
The groove on top of the piston should be facing
the transmission end.
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. Remove the guide pins and
PISTON RING TOOL refit the screws. Tighten the cylinder head screws to
the specified torque in two steps; first to 59 Nm (6
kpm, 43 ft.Ib. ) and then 93 Nm (9.5 kpm, 69 ft.Ib.).
The order of tightening is illustrated below. Tighten
“top” uppermost. Oil the piston and rings before assem- finally after the engine has been warmed up and then
bling. Rotate the compression rings so that the gaps are cooled off for about 30 minutes. Insert and tighten
staggered 180°, one in line with each end of the piston the transmission chain cover screws.
pin. Make sure, too, that the spring gaps of the top and Screws are re-tightened after 2.000 and 10.000 km
bottom rings in the three-piece scraper ring are staggered. (1.200 and 6.000 miles).
© © ® ® ®@
® © © © ©
ORDER OF TIGHTENING, CYLINDER HEAD SCREWS
: 6. Fit the camshaft sprocket to the camshaft, making
oy sure that the notches on the camshaft and bearing cap
PISTON AND CONNECTING ROD WITH BEARINGS AND are in line. Tighten and lock the retaining screws.
PISTON RINGS Remove the nut from the center stud of the camshaft
1, Piston sprocket. Check at the same time that the mark on
2. Connecting rod the flywheel is in line with the mark on the cylinder
3. Bearing block
4. Bearing cap ocr,
5. Compression rings 7. Mount the valve cover. ‘
6. Three-piece oil scraper ring 8. Connect hoses and cables to the valve cover, inlet
manifold and throttle valve housing. Screw in the
spark plugs and connect the ignition cables.
9. Install the oil filter.
Sept, 1973 SAAB 210-23
Page 146
CYLINDER HEAD
1,7 and 1,85 | engines 12." a. Unscrew all cylinder head screws and nuts.
Disassembly (Engine in car) b. Remove the cylinder head screws.
cosas be c.- Using tools 839051 and 839052, remove two
“ Disconnect the battery cables.
Drain off coolant through the radiator and engine
block drain cocks, and open the heater core bleeder
studs and insert these in two of the cylinder
head screw holes to act as locating pins (see
illustration).
Sock. * - d. Remove the transmission cover screws. r
ax Disconnect the p pS assist cylinder vacuum hose e. Remove the other studs and lift off the cylinder
from the inlet manifold and pull the fuelhose off head
the fuel pump. !n the case of injection engines, dis-
connect the fuel hoses from the nipples at the inlets
and outlets of the injection valves.
4 Disconnect the cable from the temperature trans-
mitter.
5. Remove the preheater cover.arid hose, takeoff the
air cleaner and disconnect. the throttlecontrol.
6. Undo the hose clamps at the connections to the
thermostat housing, water pump and inlet mani-
fold.
—#-—Bisconnect the choke control cable from the car-
buretor on carburetor engines. .
Unbolt the exhaust pipe from the exhaust mani-
fold.
a Remove the distributor cap and ignition cables. In \
1968—69 models, remove the side and torsion stays REMOVING STUDS
as well. Tools 839051 and 839052
Remove the camshaft cover and gaskets.
iM Remove the camshaft chainwheel as follows:
a. Screw a nut on to the threaded center stud of
the camshaft chainwheel and clamp the center
ju* stud against the mounting plate provided for the
5 i b 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 chain wheel cannot be re- |”
fitted. The chain tensioner cannot be reset
without lifting the engine out of the car.
© Undo the two locked retaining screws from the
camshaft chainwheel. Separate the wheel from
the camshaft plate until it hangs free in the
mounting plate by the center stud.
STUDS AS LOCATING PINS FOR REMOVAL AND
MOUNTING OF CYLINDER HEAD
_. CAMSHAFT CHAINWHEEL RETAINING SCREWS
-
- 211-1 SAAB Dec. 1975
Page 147
Assembling
ya Carefully scrape off old gasket material from the
contact surfaces (emery cloth must not be used).
Check that the contact surfaces are plane.
2: Fit the new cylinder head gasket over the two studs
acting as locating pins.
cts Make sure that the markings on the camshaft and
bearing cap are in line with each other.
Check that the flywheel mark is in line with
mark on the cylinder block and that te fantfon i7_)
set on No. 1 cylinde .
~ Mount the cylinder head. Screw in the studs using
tools 839051 and 839052. Tighten the cylinder
head screws and nuts to the specified torque. The
order of tightening is shown in the illustration.
Insert ang tighten the transmission chain cover
screws.
funn
ORDER OF TIGHTENING FOR CYLINDER HEAD SCREWS
a. Tighten the cylinder head nuts and screws in
two stages in the order indicated below.
The following torques apply:
Ist stage Nuts (top row) 30Nm 22 ft.lb. (3 kpm)
Screws 5Nm 31/2 ft.lb. (0.5 kpm)
2nd stage Nuts 74Nm 54 _ ft.lb. (7.5 kpm)
Screws 74Nm 54 ft.lb. (7.5 kpm)
b. Warm up the engine, then let it cool off for about’;
30 minutes. Tighten to 74 Nm (54 ft.lb., 7.5 kpm)*
in the prescribed order. Loosen each screw and nut
before tightening to the prescribed torque.
c. Cylinder head screws and nuts should be retight-
ened as in b. above after 1,200 miles (2,000 km)
and 6,000 miles (10,000 km) driving.
Pas Hikes the camshaft chainwheel on the camshaft.
) Unscrew the nut from the center stud of the chain-
wheel and lock both the retaining screws.
CAUTION
The nut on the camshaft chainwheel center
stud must not on any account be unscrewed.
before the chainwheel is'tightly screwed to
the camshaft.
Sept. 1973
7. Fit the gaskets and camshaft cover.
8. Fit the distributor cap complete with ignition ca-
bles.
29> Bolt the exhaust pipe to the exhaust manifold.
10. Connect the throttle and choke control cables. (Car-
buretor engines)
11. Connect the hoses to the thermostat housing, water
pump and inlet manifold and tighten the hose
clamps.
12. Mount the preheater cover, hose and air cleaner.
13, Mount the air cleaner and connect the throttle con-
trol.
14. Connect the cables to the ignition coil and tempera-
ture transmitter.
15. Connect the vacuum hose from the intake manifold
to the power assist cylinder. Connect the fuel hoses.
16. Close the drain cocks and fill with coolant. Bleed
the heater core.
17. Connect the battery cables.
* ‘& Mail Head
ToRQUES
(p. 620410
sms
A 5 a
Trdales Mechel Heat 18 Lt- Ib
CAMSHAFT REARING Caps ATR- bk
CAMSHAPr COVER LS
Spark PLves (5 by~|
CAMSHAFT CHAWWHCEL : a
* ath
Permostrr tlousie j
211-2
Page 148
CYLINDER HEAD
2.0 | engine
Disassembiy
(Engine in car)
1. Disconnect the battery cables.
2. Drain off coolant through the radiator and engine
block drain cocks, and open the heater core bleeder
cock.
3. Remove the aircleaner and the throttle control
wire. (Also the choke control wire on carbureted
engines.)
4. Disconnect the cable from the temperature trans-
mitter.
5. a. Detach the vacuum hose of the power assist cyl-
inder from the inlet manifold.
b. Carbureted engine:
Detach the fuel hose and the vacuum hose from
the carburetor.
b. Injection engine:
Detach the fuel hoses from the nipples at the
inlets and outlets of the injection valves.
6. Undo the hose clamps at the connections to the
thermostat housing, water pump and inlet mani-
fold.
7. Unbolt the exhaust pipe from the exhaust mani-
fold.
8. Remove the distributor cap and ignition cables.
9. Remove the valve cover.
10. Remove the camshaft sprocket as follows:
a. Screw a M8 nut on to the threaded center stud
of the camshaft sprocket and clamp 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 position so that the sprocket
cannot be refitted. The chain tensioner cannot be
reset without lifting the engine out of the car.
b. Undo the retaining screws from the camshaft
sprocket. Separate the wheel from the camshaft
plate until it hangs free in the mounting plate
by the center stud.
11. a. Unscrew and remove all cylinder head screws.
b. Mount two guide pins (tool 839212), in two of
the cylinder head screw holes.
c. Remove the screws at the transmission cover.
d. Lift off the cylinder head.
211-3 SADE
LIFTING OFF THE CYLINDER HEAD
Assembling
1. Carefully scrape off old gasket material from the
Check that the contact surfaces are plane.
2. Fit the new cylinder head gasket over the two
guide pins.
3. Make sure that the markings on the camshaft and
bearing cap are in line with each other.
4. Check that the flywheel mark is in line with the
mark on the cylinder block and that the ignition is
set on No. 1 cylinder.
5. a. Mount the cylinder head. Tighten the cylinder
head screws to the specified torque in two stages.
The order of tightening is shown in the illustra-
tion on page 210—23. Insert and tighten the
transmission chain cover screws. Retighten after
the engine has been warmed up and then cooled
off for about 30 minutes.
b. Screws are retightened after 2.000 and 10.000
km(1.200—6.000 miles).
6. Mount the camshaft sprocket on the camshaft. Un-
screw the nut from the center stud of the sprocket.
CAUTION
The nut on the camshaft sprocket center stud must
not on any account be unscrewed before the sprocket!
is tightly screwed to the camshaft.
7. Fit the valve cover. Undamaged gasket can be re-
mounted.
8. Fit the distributor cap complete with ignition ca-
bles.
9. Bolt the exhaust pipe to the exhaust manifold.
10. Connect the throttle control cable.
11, Connect the hoses to the thermostat housing, water
pump and inlet manifold and tighten the hose
clamps.
12. Connect the vacuum hose from the inlet manifold
to the power assist cylinder. Connect the fuel hoses.
13. Connect the cables to the ignition coil and tempe-
rature transmitter.
14. Mount the air cleaner.
15. Close the drain cocks and fill with coolant. Bleed
the heater core.
16. Connect the battery cables.
Sept. 1973
—
Page 149
VALVE MECHANISM
1,7 and 1,85 | engines
Removing the camshaft cover
1. Remove the preheater hose.
. Disconnect the crankcase ventilation hose.
3. Detach the ignition cables from the cover and spark
plugs.
4. Back off the six slotted screws and lift off the cover,
nN
Replacing the camshaft cover
1, Fit the gasket. The original gasket may be reused if
undamaged.
. Fit the cover, insert and tighten the slotted screws.
. Connect the ignition cables.
. Connect the crankcase ventilation hose.
. Install the preheater hose.
OWN
NOTE
-Do not tighten the screws so hard that the cover is
deformed — se tightening torques, group 0.
Disassembling the valves
(Cylinder head removed from cylinder block)
1. Remove the camshaft bearing caps.
2. Lift out the camshaft.
3. Withdraw the valve depressors, using the magnetic
tool 839140, and lay them aside in the correct order.
S 1679
WITHDRAWING VALVE DEPRESSOR
Tool 839140
4. Remove the adjusting pallets. Be careful not to mix
them up.
5. Depress the valve spring using tool 839227 (see illus-
tration).
Dec. 1975
REMOVING VALVE SPRING
Tool 839227
6. Remove the valve locks (clips) and withdraw the tool.
7. Remove the top valve retainer, valve spring and spring
seat.
8. Withdraw the valve spindle.
7
Assembling the valves
. Insert and oil the valve spindles.
- Insert the spring seats.
. Insert the springs with top retainers.
- Depress the spring, using tool No. 839230 (see illustra-
tion), and fit the valve locks (clips). Then release the
Pressure on the spring and check that the clips are cor-
rectly positioned on the spindle. Remove the tool.
PBWN-
SAAB 214-1
Page 150
5. Insert adjusting pallets, replacing them in their original
positions.
6. Insert the valve depressors, lubricating the bearing sur-
faces with engine oil.
7. Install the camshaft.
8. Install the bearing caps. (NOTE the markings! )
CAUTION
Do not turn or tip the cylinder head after inserting
the valve depressors, as these will then slide out and
the adjusting pallets will fall out of position and be
randomized.
Changing valve seats
Changing the valve seats is only made by workshops, spe-
cialized on engine renovations. Valve seats are available
as spare parts.
Changing valve guides
Removing
Before removing a valve guide, flush the cylinder head
through with hot water. Withdraw the valve guide from
the camshaft end using special tool 839043 with pull
rod and nut (see illustration).
Installing
Install the new valve guide in the corresponding manner.
First flush the cylinder head with hot water. Insert the
guide from the cylinder end using special too! 839043
with pull rod, sleeve and nut (see illustration). Then
ream the guide using special reamer 839038 to standard
size.
Milling valve seats
Clean all parts and remove all traces of soot and dirt from
the valve and cylinder head duct.
Insert the guide spindle, part of the set of cutters 839219,
into the valve guide from the valve seat end and tighten
the clamping screw until the guide spindle is securely
clamped in the valve guide. The valve seats in the cylinder
head are to be milled clean with a 45° cutter. It may be
necessary to break up the hard surface of the exhaust
valve seat first with an abrasive cloth. After being ground
clean, the valve seat will usually be found to be too wide
and must therefore be reduced. Reduce from inside with
a 75° correcting cutter and from outside with an 1° cor-
recting cutter. Adjust the reduction so that the contact
surface of the valve seat touches the valve plate as close
as possible to the center of the seat. This can conveniently
be checked by the use of a marking dye. After adjustment,
the seat width of both inlet and exhaust valves should be
0.087—0.098" (2.2—2.5 mm).
NOTE!
starting work on the seat.
Machining the valve seat will only give the desired
result if the valve guide is in good condition. So al-
ways check the play of the valve in its guide before
NOTE!
off unnecessarily.
Correction milling must always be restricted to an
absolute minimum. Material must never be milled
REMOVING VALVE GUIDE
Tool 839043
INSERTING VALVE GUIDE
Tool 839043
214-2 SAAB
Dec. 1975