Page 221
WATER PUMP nator bracket to the transmission cover can be re-
moved.
Removing the pump e. Slacken the lower retaining screw slightly and turn
the bracket so that it is as far from the engine as
(Engine in the car) possible.
9. Undo the three retaining screws from the cover of the
1.
2s
. Disconnect the power assist cylinder vacuum hose
Drain off coolant through the engine and radiator
drain cocks.
Remove the battery ground cable.
from the inlet manifold, pull the fuel hose off the
carburetor and pull off the hose between the camshaft
cover and the crankcase ventilation valve.
. Remove the preheater hose and air cleaner and dis-
connect the throttle control.
. Undo the hose clamps at the connections to the pump
and inlet manifold, and the distributor vacuum hose.
. Undo the six retaining screws from the inlet manifold,
unscrew the lifting lug, and lift out the manifold com-
plete with carburetor. If necessary, disconnect the
choke control cable from the carburetor. In 1968—69
models, remove the distributor cap and torsion stay.
. Cover the openings.
- 2.0 | engine with alternator in high position:
a. Remove the alternator.
b, Remove the screw holding the alternator bracket
to the pump cover.
c. Unbolt both rear engine mountings.
d. Place a jack fitted with a wooden block under the
rear end of the power plant and raise the engine
slightly until the upper screw fastening the alter-
WATER PUMP, EXPLODED VIEW
1, Pump cover 8. Ball bearing
2. Gasket 9. Oil thrower ring
3. Impeller 10. Bearing housing
4. Water pump seal 11. O-rings
5. Thrower 12. Seal ring
6. Seal ring 13. Pump shaft
7. Ball bearing lock ring
Dec. 1975
water pump and knock the lower hose intake gently
from below with a plastic mallet to unseat the cover.
10. 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.
c. Fit a tapping-out hammer with adapter (on 1.7
and 1.85 | engines tool 839057 and on 2.0 | en-
gine tool 839213) to the water pump shaft and
take out the pump unit.
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) — see illustration
page 210—1.
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.
Disassembling
(Pump removed from engine)
1. Mount the pump in tool 839054 and push off the im-
peller using tool 839058.
FORCING OFF THE IMPELLER
Tools 839054 and 839058
2. Press the pump shaft with seals and ball bearing from
the bearing housing, using tool 839054. Place the
pump with the driving worm uppermost.
262-1
Page 222
EXPELLING THE PUMP SHAFT
Too! 839054
¥
Remove the pump seal, O-ring, thrower and seal ring.
4, Free the ball bearing lock ring.
. Place the pump shaft and bearing in tool 839053 with
the drive end downward and press the shaft from the
bearing.
a
el
8
EXPELLING THE SHAFT FROM THE BEARING
Tool 839053
Assembling
1. Fit the oil thrower ring.
2. Press the ball bearing on to the pump shaft using tools
839055 and 839056.
262-2 SAAB
PRESSING THE BALL BEARING ON TO THE SHAFT
Tools 839055 and 839056
3. Fit the bearing lock ring.
4. Press the pump shaft complete with bearing into the
bearing housing (see illustration) with the housing
supported in tools 839054 and 839055.
S12
PRESSING THE PUMP SHAFT INTO THE BEARING HOUSING
Tools 839054 and 839055
5. Fit the seal ring with tool 839055.
6. Fit the thrower using tools 839055 and 839056.
Dec. 1975
Page 223
ry
FITTING THE THROWER
Tools 839055 and 839056
gs 7. Fit the O-ring.
8. Fit the water pump seal using tools 839053 and
839054.
om
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ae.
) smn
FITTING THE WATER PUMP SEAL
Tools 839053 and 839054
9. Mount the pump in the engine block, checking that
the pump gear engages the gear on the idler shaft.
Seat the bearing housing using sleeve 839053 and a
drift. Make sure that the flange of the bearing
housing butts against the plane of the engine block.
10. Fit the impeller with washer and screw. Tighten the
screw counterclockwise (left-hand thread).
11 1.7 and 1.85 | engines:
There should be a clearance of 0.01—0.02" (0.25—
0.50 mm) between the center screw of the impeller
and the cover. Adjust the clearance if necessary as
follows:
a. Place an 0.02” (0.5 mm) shim between the impeller
center screw and the cover; then use a feeler gauge
to measure the gap between the cover and the en-
gine block.
b. Remove the shim and fit one or two new gaskets
with a total thickness equal to the measured dis-
tance between cover and block. Gaskets of three
different thicknesses are available for the purpose,
viz. 0.01, 0.02 and 0.03” (0.25, 0.50 and 0.75 mm).
Screw the cover on tight.
MEASURING PUMP COVER CLEARANCE, 1.7 AND 1.85 L
ENGINES
S 1674
MEASURING PUMP COVER CLEARANCE, 1.7 AND 1.85 L
ENGINES
11. 2.01 engine:
Fit the gasket and the pump cover. Tighten the
cover.
Dec. 1975
SAAB 262-3
Page 224
FAN MOTOR
Removing the fan motor
1. Remove the battery.
2. Unscrew the expansion tank and lay it to one side (see
illustration. (Up to and incl. model 1970.)
REMOVING THE FAN MOTOR
3. Disconnect the wire connector from the fan motor.
4. Remove the headlight wiper motor. (As from model
1971.)
5. Unscrew the fan housing with the fan and lift it out.
6. Unscrew the nut on the fan motor shaft and remove
the fan.
7. Undo the two retaining screws and remove the fan
motor.
Assembling
1. Locate the fan motor in the fan housing and tighten the
screws.
2. Mount the fan on the motor shaft, making sure that
the locating stud on the shaft engages the recess in the
fan hub.
3. Install the fan housing. On cars up to and incl. model
1970, mount the expansion tank on the radiator.
4. Connect the wires to the fan motor and thermoswitch
by their connector.
5. Mount the headlight wiper motor. (As from model
1971.)
. Connect the battery cable.
Check the operation of the radiator fan by grounding
the connecting wire to the thermoswitch.
NO
Nov. 1972
on ee a ee
Page 225
4
THROTTLE CONTROLS
Up to and including model 1971
Disassembling
1, Free the panel plate from the pedal lever by driving
out the rivet.
. Unhook the return spring.
. Remove the throttle control damper assembly.
. Release the locking clip from the lower control link.
. Release the locking clip from the upper control link
and remove the rubber joint complete with control
shaft.
. Undo the screws of both lever bearings.
7. Remove the rubber seal from the dash panel and
withdraw the pedal and seal forward into the engine
compartment.
OPWHN
cor}
Assembling
Worn or otherwise damaged parts must be exchanged
for new ones.
1, Mount the shaft in its journal in the bracket on the
dash panel and connect the other end with the rub-
ber joint to the carburetor.
2. Work the rubber seal on to the pedal lever and mount
the lever in the dash panel, inserting it from the en-
gine compartment side.
3. Connect the lower control link between the lever and
the shaft.
. Fit the throttle control damper assembly.
. Hook on the return spring.
. Rivet the pedal plate to the pedal lever.
. Check that the throttle shaft makes a full stroke when
the pedal is depressed.
8. After adjusting the engine idling speed, turn the throt-
tle adjusting screw out or in so that the movements of
the accelerator pedal are transmitted to the throttle
shaft without any noticeable play.
NOos
Inspection
There should be a clearance of about 4.9’ (124 mm) bet-
ween the accelerator pedal and the bottom of the dash
panel. Check that the throttle in the carburetor is wide
open when the pedal is fully depressed. If the lever has
been deformed, it must be bent back to the correct shape
but take care to avoid overstraining its bearings.
Lubricate throttle control joints and bearings with oil.
Dec. 1975
$2218
THROTTLE CONTROL
As from model 1972
Double return springs for the throttle have been intro-
duced on model 1974 on both the carburetor and injec-
tion engines. The springs are fitted to the throttle shaft
on either side of the carburetor housing (throttle housing).
CABLE CONTROL, MODEL 1972, CARBURETED ENGINE
271-1
Page 226
Removing
1. Undo the control link from the driver.
2. Turn the driver clockwise and detach the wire from
its anchorage by opening the clip behind the wire
stop.
Punt
CHANGING THE THROTTLE CONTROL WIRE, MODEL 1972
3. Undo the wire from the bracket.
4. Take off the locking washer and remove the driver and
tension spring.
5. Remove the bracket.
6. Undo the wire from the pedal by first removing the
locking pin. See under “’ Removing of accelerator
pedal’.
7. Unscrew the wire from the grommet on the dash panel.
CABLE CONTROL, MODEL 1973, INJECTION ENGINE
REMOVING THE WIRE FROM THE GROMMET ON THE
DASH PANEL
271-2 SAAB _ Nov. 1972
Page 227
Installing
1. Screw the wire to the grommet on the dash panel.
. Mount the bracket.
3. Fit the tension spring, the driver and the locking
washer, so that the driver is pressed against the stop
on the bracket.
4. a. Fit the wire to the groove on the driver, and bend
the clip behind the wire stop so that the wire can
run in its groove.
N
Ss Rees
FIT THE CONTROL WIRE INTO THE LOWER GROOVE OF
THE DRIVER, MODEL 1972
b. Fit the wire sheath onto the bracket.
5. Fit the wire to the pedal and replace the locking pin
in the anchoring point on the pedal.
6. Connect the control link to the driver. Check that the
driver and the throttle shaft lever press against their
respective stop positions. If this is not the case, ad-
just the control link (valid for the 1972 model).
7. Adjust the tension of the wire with the adjustment
nuts on the wire anchorage in the bracket so that
there is no play on the pedal.
8. a. After adjusting the wire, check that the driver and
the throttle shaft lever press against their respec-
tive stop positions.
b. Press the accelerator pedal right down to the floor
and check that the throttle is fully open.
Changing the control wire
1. Remove the wire as explained under ‘Removing of
the wire control, points 2, 3, 6 and 7.
2. Fit a new wire as explained under “Installing”, points
1, 4, 5, 7 and 8,
NOTE
Avoid hand manipulating the throttle control at the
carburetor end (throttle housing), as there is a risk
that the wire will come out of its slot and disengage
itself from the driver.
Dec, 1975
Accelerator pedal as from the 1972 model
ACCELERATOR PEDAL
Removing
1. Remove the left (in R.H.D.-cars, the right) protective
panelling from under the instrument panel.
2. Remove the throttle control damper assembly (does
not apply to cars with automatic transmission).
3. Hook off the return spring.
4. Remove the locking pin at the anchorage point of the
wire on the accelerator pedal.
—
CONTROL WIRE LOOSENED FROM ACCELERATOR PEDAL
5. Pull the wire loose from the accelerator pedal.
6. Undo the upper covering of the dash panel and fold it
out of the way.
7. Remove the accelerator pedal from the dash panel.
SAAB 271-3
Page 228
Installing
1. Mount the accelerator pedal onto the dash panel.
2. Fold back the dash panel covering.
3. Fit the wire to the accelerator pedal and insert the
locking pin at the anchorage point of the wire on
the accelerator pedal.
4, Hook on the return spring.
5. Fit the throttle control damper assembly (does not
apply to cars with automatic transmission).
6. Replace the protective panelling under the instru-
ment panel.
7. Make any necessary adjustments to the throttle con-
trol.
271-4 SAAB
Nov. 1972
Page 229
Dec, 1975
CONTENTS
300
311
321
331
341
342
344
346
351
361
362
363
364
371
381
General
Battery
Alternator
Starter
Ignition coil
Distributor
Spark plugs
Interference suppressors
Lighting
Direction indicators
Horns and horn controls
Windshield wipers and -washers, headlight
wipers and -washers
Electric controls and switches
Wiring and fuses
Instruments and controls
Page 230
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