Page 151
rs,
2pt-2y
NOTE
ary To check and measure the valve clearance when the
valves are in place in a car equipped with manual
transmission, turn the camshaft by pushing the car
forward or backward on the fourth gear to bring
each cam in turn into position for measurement, i.e.
pointing 180° away from the valve stem.
In cars with automatic transmission it is not possible
to move the camshaft into position for measurement
by pushing the car forward or backward. The fol-
lowing alternative methods are therefore recom-
mended for checking the valve clearance in this case:
Alternative |:
Rotate the crankshaft using special wrench No.
Grinding valves 839081 to bring the camshaft into position for
measurement. This special wrench fits the center
screw of the crankshaft belt pulley at the dash pan-
el and can be used on all Saab 99 cars of 1970 or
VALVE SEAT ANGLES $1269
The condition of the valve will decide whether it can be
machine ground or must be exchanged. The valve plate
angle must be 45°.
Smear a thin coat of grinding paste on the valve seat and
insert the valve in the cylinder head. Make a few grinding
movements with the grinding tool, clean all traces of paste later model.
off the seat, and check the fit with marking dye. Grind If the wrench is used on cars with. manual transmis-
once more if required and finish by milling if necessary. sion, the gear lever must be in the neutral position,
as the screw is otherwise liable to come loose.
Checking valve clearance Alternative II:
1. Take out the spark plugs.
Check the valve clearance with a feeler gauge (special tool 2. Disconnect the yellow cable (No. 84) from the
839141), comparing with the maximum and minimum starter and make a connection with a switch,
tolerances. The tolerance limits for purposes of valve e.g. a bell wire contact, between terminal 84 on
clearance checking are 0.006”—0.012” (0.15—0.30 mm) the starter and the positive pole of the battery.
for inlet valves and 0.014”—0.020” (0.35—0.50 mm) 3. Turn the engine over by running the starter with
for eshaust valves. the switch, switching off when a measurable cam
position is obtained.
To turn the camshaft when the cylinder head has
been removed from the engine, a grip for a hexagon
wrench has been provided on the shaft between the
fourth and fifth bearings (see illustration). This
method of rotating the camshaft must not be used
when the cylinder head is mounted on the engine.
ie
CHECKING VALVE CLEARANCE
Tool 839141
The procedure is as follows:
1. Remove the camshaft cover.
2. Lock the free wheel drive and engage 3rd gear. Push
the car forward or backward to bring the camshaft
cams into the correct measuring positions, i.e. with
the cam of the valve to be measured pointing 180°
away from the valve stem. Two cams will be in the
measuring position at the same time.
3. Try the maximum and minimum clearances with feeler
the maximum feeler should not. If this result is not ob- (2X ‘ * a
4
gauge 839141. The minimum feeler should slip in, but
tained, the clearance must be measured for adjustment.
4. Refit the camshaft cover.
ROTATING THE CAMSHAFT WITH CYLINDER BLOCK
REMOVED FROM ENGINE
Dec. 1975 SAAB 214-3
Page 152
Measuring and adjusting valve clearance
If the clearance of any valve is found on checking to be
outside the permissible limits, the clearance of all valves
must be measured.
Adjustment of valve clearance is to be based on actual
measurement. Measurements are made with tool 839145
and dial indicator 784062.
Adjust the deviation of the valve clearance from the cor-
rect value by changing the adjusting pallet.
The procedure for measurement and adjustment is as
follows:
1. Turn the cam to the measuring position (1 80° from
the valve stem).
MEASURING VALVE CLEARANCE
Tools 784062 and 839150
2. Mount tool 839145 and screw it on so that its triple
claw grips the valve depressor (see illustration).
3. Mount the indicator dial 784062 in the tool so that
the measuring point rests on the tip of the cam; zero
the dial (see illustration).
4. Lift the valve depressor with the measuring tool and
read off the deflection of the instrument pointer,
which indicates the valve clearance. Note the reading.
~ SSS EES szz0
MEASURING ADJUSTING PALLETS
Tools 784062 and 839163
214-4
5. Measure and note down the clearances of all valves
in the same manner. Proceed to adjust the clearance
of any valves in which it does not lie within the fol-
lowing limits:
Inlet valves 0.008'’—0.010" (0.20—0.25 mm)
Exhaust valves 0.016’—0.018"" (0.40—0.45 mm)
6. Remove the camshaft and the valve depressors and
adjusting pallets of any valves needing adjustment.
7. Measure and make a note of the thickness of the pallet.
(Special tool 839163.) This thickness plus the valve
clearance adds up to the total distance between the
valve and the cam.
Example:
Measured valve clearance
Measured pallet thickness
0.004” (0.12 mm)
0.099" (2,54 mm.
0.103” (2.66 mm)
The choice of adjusting pallet is determined by the
measured total distance between the valve depressor
and the cam less the specified valve clearance for an
intake or exhaust valve as the case may be.
Example:
Total distance
Less specified inlet valve
clearance 0.009" (0.23 mm)
0.094” (2.43 mm)
8. Insert the new adjusting pallet and the valve depressor
and install the camshaft.
9. Repeat the measurement procedure to check that the
clearances are now correct.
Total distance
0.103” (2.66 mm)
Required pallet thickness
CAUTION
Do not turn or tilt 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.
Measuring and adjusting valve clearance after valve
reconditioning
1, Install adjusting pallets with a minimum thickness of
0.070" (1.77 mm).
. Insert depressors and install the camshaft.
3. Measure the valve clearances, note the reading for each
valve and calculate the total distance.
4. Select new pallets to give the correct clearances.
5. Remove the camshaft and depressors, take out the
0.070" (1.77 mm) pallets and insert new pallets to
give the correct clearances.
6. Replace the depressors and reinstall the camshaft.
7. Check clearance measurements once more with the
dial indicator. To make your choice of adjusting
pallets easier, use the table on page 214—9.
nN
SAAB Dec. 1975
Page 153
—_—>
i - -~é
J
VALVE MECHANISM
2.0 | engine
Removing the valve cover
1, Disconnect the crankcase ventilation hose,
2. Detach the ignition cables from the valve cover and
spark plugs.
3. Back off the screws and lift off the cover.
Replacing the valve cover
1. Fit the gasket. The original gasket may be reused if
undamaged.
. Fit the cover.
. Connect the ignition cables.
4. Connect the crankcase ventilation hose.
Wr
NOTE
Do not tighten the screws so hard that the cover is
deformed — see 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, and lay them aside in the correct order.
4. Remove the adjusting pallets. Be careful not to mix
them up.
. Remove the camshaft bearing assembly.
. a. Depress the valve spring using a valve spring
tool, 839227,
on
ses 5) 3027
REMOVING THE VALVES
Tool 839227
b. Remove the valve locks (clips), loosen the spring
tension and withdraw the tool.
7. Remove the top valve retainer, valve spring and guide
sleeve.
8. Withdraw the valve.
ae!
VALVE MECHANISM
Valve
. Valve spring seat
Valve spring
Retainer
Lock
. Adjusting pallet
. Valve depressor
. Camshaft
PrvOTMaONS
Assembling the valves
. Insert and oil the valve spindles.
. Insert the guide sleeve before the spring.
Insert the springs and top retainers.
. Depress the spring, using a valve spring tool, and fit
the valve locks (clips). Then release the Pressure on
the spring and check that the clips are correctly po-
sitioned on the spindle. Remove the tool.
5. Mount the camshaft bearing assembly.
6. Insert adjusting pallets, replacing them in their Original
positions.
7. Insert the valve depressors, lubricating the bearing sur-
faces with engine oil.
. Install the camshaft.
9, Install the bearing caps. (NOTE the markings! )
PWN
co
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.
Dec. 1975 SAAB =A 214-5
Page 154
Checking the valve guide wear
Pull out the valve about 0.12’ (3 mm) from its seat and
check the radial play of the valve, by rocking the valve
disc. If the play exceeds 0.02” (0.5 mm), the valve guide
is to be exchanged.
CHECKING THE VALVE GUIDE WEAR
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).
REMOVING THE VALVE GUIDE
Tool 839043
214-6 SAAB
Installing
First flush the cylinder head with hot water. Insert the
guide from the camshaft end using special tool 839043
attached on the combustion chamber end. For outlet
valves, use sleeve 839037 and for inlet valves, use sleeve
839214. See illustration.
INSTALLING THE VALVE GUIDE
Tool 839043
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
MILLING VALVE SEATS
Tool 839219
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 emery cloth, After being ground
clean, the valve seat will usually be found to be too wide
Dec. 1975
Page 155
a 75° correcting cutter and from outside with an 11—12°
correcting cutter. Adjust the reduction so that the con-
tact surface of the valve seat touches the valve plate as
close as possible to the center of the seat. This can con-
veniently be checked by the use of a marking dye. After
adjustment, the seat width of both inlet and exhaust
| and must therefore be reduced. Reduce from inside with
valves should be 0.04—0.08” (1—2 mm).
1-2 mm
VALVE SEAT ANGLES
The condition of the valve will decide whether it can be
machine ground or must be exchanged. The valve plate
angle must be 44.59.
Grinding valves
Smear a thin coat of grinding paste on the valve seat and
insert the valve in the cylinder head. Make a few grinding
movements with the grinding tool, clean all traces of paste
off the seat, and check the fit with marking dye. Grind
once more if required and finish by milling if necessary.
Valve clearance
General
The valve clearance is stable and adjustment is needed
only after a long time or when the valves are renovated,
However, the valve clearance is to be checked at 6.000,
25.000 and 50.000 miles (10.000, 40.000 and 80.000
km).
Dec, 1975
Checking valve clearance
Check the valve clearance with a feeler gauge, comparing
with the maximum and minimum tolerances. The toler-
ance limits for purposes of valve clearance checking are
0.006’’—0.012" (0.15—0.30 mm) for inlet valves and
0.014” —0.020" (0.035—0.050 mm) for exhaust valves,
The procedure is as follows:
1, Remove the valve cover.
2. Engage 3rd gear. Push the car forward or backward
to bring the camshaft cams into the correct Measuring
Positions, i.e. with the cam of the valve to be measured
pointing 180° away from the valve stem. Two cams
will be in the measuring position at the same time.
3. Try the maximum and minimum clearances with feeler
gauge. The minimum feeler should slip in, but the
CHECKING VALVE CLEARANCE
maximum feeler should not. If this result is not ob-
tained, the clearance must be measured for adjust-
ment.
4. Fit the valve cover.
Measuring and adjusting valve clearance
If the clearance of any valve is found on checking to be
outside the permissible limits, the clearance of all valves
must be measured.
Adjustment of valve clearance is to be based on actual
measurement. Measurements are made with tool 839145
and dial indicator 784062.
Adjust the deviation of the valve clearance from the cor-
rect value by changing the adjusting pallet.
The procedure for measurement and adjustment is as
follows:
1, Turn the cam to the measuring position (180° from
the valve stem).
2. Mount tool 839145 and screw it on so that its triple
claw grips the valve depressor.
Saas 214-7
Page 156
MEASURING THE VALVE CLEARANCE
Tools 784062 and 839145
3. Mount the indicator dial in the tool so that the mea-
suring point rests on the tip of the cam; zero the dial.
4. Lift the valve depressor with the measuring tool and
read off the deflection of the instrument pointer,
which indicates the valve clearance. Note the reading.
5. Measure and note down the clearances of all valves
in the same manner. Proceed to adjust the clearance
of any valves in which it does not lie within the fol-
lowing limits:
Inlet valves 0.008"’—0.010" (0.20—0.25 mm)
Exhaust valves 0,016’’—0.018” (0.40—0.45 mm)
6. Remove the camshaft and the valve depressors and
adjusting pallets of any valves needing adjustment.
7. Measure and make a note of the thickness of the pallet.
(Special tool No. 839163.) This thickness plus the
valve clearance adds up to the total distance between
the valve and the cam.
Example:
Measured valve clearance
Measured pallet thickness
0.004” (0.12 mm)
Total distance 0.103” (2.66 mm)
827210
MEASURING ADJUSTING PALLETS
Tools 784062 and 839163
The choice of adjusting pallet is determined by the
measured total distance between the valve depressor
and the cam less the specified valve clearance for an
intake or exhaust valve as the case may be.
214-8
=!
= ae _
Example:
Total distance
Less specified inlet valve
clearance
0.103” (2.66 mm)
0.009" (0.23 mm)
Required pallet thickness 0.094” (2.43 mm)
. Insert the new adjusting pallet and the valve depressor
and install the camshaft.
. Repeat the measurement procedure to check that the
clearances are now correct.
TURNING THE CAMSHAFT
Measuring and adjusting valve clearance after valve
reconditioning
3
Install adjusting pallets with a minimum thickness of
0.070” (1.77 mm).
. Insert depressors and install the camshaft. \
. Measure the valve clearances, note the reading for each
valve and calculate the total distance.
. Select new pallets to give the correct clearances.
. Remove the camshaft and depressors, take out the
0.070” (1.77 mm) pallets and insert new pallets to )y
give the correct clearances.
. Replace the depressors and reinstall the camshaft.
. Check clearance measurements once more with the
dial indicator. To make your choice of adjusting
pallets easier, use the table on the next page.
Dec. 1975
Page 157
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214-9
Nov. 1972
Page 158
Replacement of valve springs without removing cylinder
head, 1.7, 1.85 and 2.0 | engines
1. Remove the valve cover (camshaft cover).
2. Rotate the crankshaft until the No. 1 cylinder is in
the ignition position.
3. Fit a nut to the camshaft sprocket center stud and
tighten the camshaft sprocket against the retaining
plate.
WARNING
Tighten the nut fully, so that the center stud is held
securely immobilized. Otherwise the chain tensioner
will tighten the chain and lock in a new position so
that the sprocket cannot be refitted.
4. Remove the screws holding the camshaft sprocket to
the camshaft.
. Unscrew the camshaft caps and remove the camshaft.
. Remove the valve depressors and adjusting pallets.
. 2.0 | engine: Remove the camshaft bridge.
. Take out the spark plug for the cylinder requiring a
new valve spring and fit an air hose connector (tool
839232) in the spark plug hole. Connect the cylinder
to a compressed air supply to prevent the valve drop-
ping into the cylinder.
9. Apply the valve spring tool (tool 839230) as shown in
the illustration. Compress the valve spring and pick up
the valve spring retainers using a magnetic tool. Re-
move the valve spring and the valve spring seat.
ONO
Reassemble in the reverse order.
REMOVING VALVES, 1.7 AND 1.85 L ENGINES
Tools 839230 and 839232
—
REMOVING VALVES, 2.0 L ENGINE
Tools 839230 and 839232
214-10 SAAB
Dec. 1975
Page 159
a ee
TRANSMISSION
Instructions for transmission chain, camshaft and idler
shaft settings will be found in section 210.
Checking the chain tensioner
In order to prevent transmission damage caused by the
chain tensioner running out to far, the position of the
chain tensioner can be checked with the engine mounted
in the car.
1. Remove the valve cover.
2. Insert a steel rule down against the rubber neck on the
chain tensioner and measure the distance to the level
of the cylinder head cover.
1.7 and 1.85 | engines:
The distance should be more than 10.8 in (275 mm). If
the distance is less than 10.8 in (275 mm), the engine
should be removed as soon as possible for correction. For
completely tight chain tensioners (newly adjusted trans-
missions), the distance should be about 11.3 in (287
mm).
2.0 | engines:
The distance should be more than 11.8 in (300 mm). If
the distance is less than 11.8 in (300 mm), the engine
should be removed as soon as possible for correction.
For completely tight chain tensioners (newly adjusted
transmissions) the distance should be about 12.3 in
(313 mm).
Sept. 1973 SPB
CHECKING THE CHAIN TENSIONER ON 1.7 AND 1.85 L
ENGINES
CHECKING THE CHAIN TENSIONER ON 2.0 L ENGINES
215-1
Page 160
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