Page 251
Test values and wear limits
Ratio engine belt pulley—alternator, see chapter 0.
Bosch alternator
Testing at 2/3 maximum current
Connect the battery and load the alternator. Adjust the
alternator speed to exactly 2.000 rev/min. The alternator
must then deliver two-thirds of the maximum current:
For the 35 A alternator = 23 A
For the 55 A alternator = 36 A
Checking speed for maximum output
Connect the battery. Load the alternator and run it warm.
Increase speed. The maximum output of 35 resp. 55 A at
14 V should be obtained within the speed range 2700—
3.700 rev/min, (alternator speed).
Maximum permissible wear of the brushes 1.7 and 1.85 |
engines: The brushes should have a minimum length of 9
mm. When overhouling the alternator, the brushes should
be replaced if they are less than 14 mm in length.
2.0 | carburetor engine: The brushes should project more
than 5 mm from the brush unit assembly when the latter
is removed.
SEV alternator
At 3.000 rev/min., the alternator should generate
14V/48A.
At 5.000 rev/min., the alternator should generate
14V/55A.
Maximum permissible wear of the brushes:
2.0 | injection engine:
The brushes should project more than 4 mm from the
brush unit assembly when the latter is removed.
40
-
Ss
—
Charging current
ae
t
t] 1900 2000 3000 4000 5000
AMPERAGE OUTPUT IN THE ALTERNATOR
Dec. 1975
6000 7000 8000 9000 10000 Alternator rev.
S 3872
321-18
Page 252
Trouble shooting
Alternator not charging
The cause may be
. slack drive belt
. break in charging circuit and return circuit to ground
. defective electric brushes
. shorted diodes
break in exciter circuit
faulty regulator
. broken rotor winding
. grounded stator
exciter diode unit ground connection broken or shorted
rose rmoaoge
Low or irregular amperage
The cause may be
. slack drive belt
. irregular breaking in the charging circuit
- worn electric brushes
. faulty regulator
. broken or shorted rectifier diode
partly shorted rotor
stator ground connection broken or partly shorted
e©rera0cge
Abnormally high amperage
The cause may be
a. faulty regulator
b. bad contact between regulator and alternator
Noise in alternator
The cause may be
. badly worn drive belt
. pulley loose or out of true
. crankshaft and alternator pulleys out of alignment
. worn or defective bearings
a shorted rectifier diode
loose alternator retaining screws
meanogce
SAAB Sept. 1973
321-19
Page 253
STARTER 10. Pull the starter assembly off the drive and bracket
assembly.
General 11. Undo the engaging lever arm locating screw.
12. Remove the rubber and steel washers from the drive
The starter spins the engine flywheel by a starter pinion and bracket housing (17—18).
and a gear ring. The pinion slides on the rotor shaft of 13. Remove the rotor and engaging lever arm.
the starter and is brought into engagement with the gear 14. Press the stop ring towards the cog with a piece of
ring by a solenoid which thereupon trips the switch that tubing (see illustration).
supplies current to the starter. As soon as the engine fires,
the gear ring on the flywheel starts to drive the pinion.
When this happens, the pinion is released from the driver
shaft by a freewheel arrangement but remains in engage-
ment with the ring gear as long as the solenoid is energized
by the ignition key. It is disengaged by a return spring
when current to the solenoid is cut off.
Removing the starter
1. Disconnect the negative battery lead.
Cars with 55 A Bosch alternator: Undo the cooling
hose.
2. Disconnect the wiring to the starter.
3. Undo the flywheel cover retaining screws and remove
the cover.
4. Unscrew the nuts on the screws securing the starter to
engine block.
5. Withdraw the starter until it comes free and can be
lifted out of the engine compartment.
S$ 1338
PUSHING DOWN THE STOP RING
15. Remove the lock ring with lock ring pliers (see
illustration).
Installing the starter Remove the pinion and the gasket ring.
Slide the starter into place and tighten the screws.
Connect the wiring to the starter.
Fit the flywheel cover.
Connect the negative battery lead.
Cars with 55 A Bosch alternator: Fit the cooling
hose.
hbo)
a
}
Disassembling the starter
a See exploded view on the next page.
1. Disconnect the solenoid feeder cable.
2. Remove the solenoid retaining screws.
3. Unhook and remove the solenoid.
4
Undo the two retaining screws from the capsule REMOVING THE LOCK RING
bracket.
5. Remove the capsule bracket, U-washer, spacers and 16. Inspect the spiral splines on the rotor shaft for
rubber gasket (pos. 5—8). burrs. If there are any, file them off.
6. Undo the screws from the commutator bearing 17, Check the gear ring, starter drive cog and the
housing (1). bushings.
7. Remove the commutator bearing housing (10).
8. _ Lift the brush springs off their retainers with a wire
hook and remove the brushes.
9. Remove the brush plate, fiber washer and steel
washer (11—13).
NOTE
Check all components and exchange or repair
any that are damaged. Soak the bearing bushings
in hot oil before reassembling.
Dec. 1975 SAAB 331-1
Page 254
‘s} $3481
STARTER, DISASSEMBLED
1. Screws, bearing housing 7. Shim 13. Steel washer 19. Engaging lever arm
2. Solenoid 8. Rubber gasket 14, Field winding 20. Pinion
3. Drive housing 9. Bushing, commutator side 15. Starter housing 21. Bushing, pinion
4. Bushing, drive side 10. Commutator bearing housing 16. Rotor 22. Stop ring
5. Capsule bracket 11. Brush plate 17. Rubber washer 23. Lock ring
6. U-washer 12. Fiber washer 18. Steel washer 24. Gasket ring
Assembling 5. Fit the engaging lever arm to the cog engaging ring
and insert the assembly, together with the rotor,
1. Place the gasket ring on the rotor shaft. into the drive HOUSING: Pr, }
Lubricate the spiral splines and the drive cog engag- JE peeks the engaging lever arm'with its locating
eres ith. silicone ee 7. Place the washers in the drive housing, first the steel
Eampnat tne pinionystop-ring.and.lock -ting'on the washer and then the rubber washer. The lips must be
rotor shaft.
3. Use pliers to seat the Ieck ring in its groove in the acer owareue ek
8. Fit the starter housing with the notches above the
rotor shaft. ; 2 e
Ba ENendipieeroominaiicindia ptessonclaw puller guide pin and the lip of the rubber washer.
‘ 9. Slip the steel washer and fiber washer over the rotor
shaft.
10. Fit the brush plate. Lift the brush springs with a
wire hook and insert the brushes.
11. Mount the commutator bearing housing with the
notches above the feed cable’s rubber insulation.
12. Fit the rubber gasket, shims and U-washer.
13. Locate the capsule bracket and secure it with the
two screws.
14. Insert and tighten the bearing housing screws.
15. Check tha axial play of the shaft 0.002—0.012 in.
(0.05—0,30 mm) and correct with shims if necessary.
16. Hook the solenoid to the engaging lever arm and
secure with the two screws.
17. Connect the feeder cable.
18. Test the starter (see group 0 for specifications and
test values).
PUSHING UP THE STOP RING
331-2 SAAB
al
é ry 9 .
7 8
Dec. 1975
Page 255
Removing and refitting the solenoid
(starter removed from car)
Removing
1. Disconnect the feeder cable.
2. Remove both retaining screws and remove the solenoid.
Refitting
1. Hook the solenoid to the engaging lever arm and secure
it with the two screws.
2. Connect the feeder cable.
3. Test the starter (see group 0).
Changing brushes
(starter removed from car)
Removing old brushes
1. Remove the two screws from the capsule bracket.
2. Remove the capsule bracket, U-washer, shims and
rubber gasket (pos. 5—8).
3. Remove the screws from the commutator bearing
housing (1).
4. Remove the commutator bearing housing (10).
5. Lift the brush springs from the holders with a wire
hook and take out the brushes.
6. Remove the brush plate.
7. Unsolder the brush wiring connections from the brush
plate and field winding.
$4762
BRUSH PLATE AND FIELD WINDING
Fitting new brushes
. Wire the new brushes to the brush plate and field
winding by soldering.
. Fit the brush plate in position. Lift the springs with a
wire hook and insert the brushes.
. Mount the commutator bearing housing with the
notches above the feed cables rubber insulation.
. Fit the rubber gasket, shims and U-washer.
. Locate the capsule bracket and secure it with the two
screws.
. Insert and tighten the bearing housing screws.
. Check the operation of the starter (see group 0).
Changing the starter pinion
(starter removed from car)
Dismantling
SIR ROI =
Disconnect the feeder cable from the solenoid.
Undo the solenoid retaining screws.
Unhook the solenoid and remove it.
Undo the engaging lever arm locating screw.
Remove the commutator bearing housing screws (1).
Pull off the drive housing. Save the rubber and
steel washer (17—18).
7. Push down the stop ring towards the pinion.
8. Remove the lock ring with lock ring pliers.
9. Remove the stop ring and the pinion.
10. Check the spiral splines on the rotor shaft for burrs.
If there are any, file them off.
Assembling
1. Lubricate the spiral splines on the rotor shaft and
the pinion engaging ring with silicone grease.
2. Mount the pinion, stop ring and lock ring on the
rotor shaft.
3. Use pliers to seat the lock ring in its groove in the
rotor shaft.
4. Push up the stop ring using a claw puller.
5. Fit the engaging lever arm to the pinion engaging
ring and put on the drive housing.
6. Secure the engaging lever arm with its locating
screw.
7. Place the washers in the drive housing, first the
steel washer and then the rubber washer. The lips
must be turned towards the rotor.
8. Mount the drive housing so that the notches on
the starter housing are above the guide pin and
the lip of the rubber washer.
9. Insert and tighten the bearing housing screws.
10. Hook the solenoid to the engaging lever arm and
secure it with the two screws.
11. Connect the feeder cable.
12. Check the operation of the starter.
Dec. 1975 SAAB
331-3
Page 256
IGNITION COIL
General
The ignition coil is made by Bosch. It is of high-output
type and requires a series resistance. When the starter is
switched on, the series resistance is disconnected and bat-
tery voltage is fed direct to the ignition coil, but when
the starter is switched off again, the series resistance
comes into function and reduces the current to the coil.
The ignition coil with series resistance is located on the
left front wheel housing.
Removing and installing the ignition coil
Removing
1. Disconnect the wiring from the coil.
2. Undo the clamping screws and withdraw the coil.
Installing
1. Tighten the two screws to clamp the oil in position.
2. Connect the wiring. See fig.
Inspecting the ignition coil
1
. Disconnect the wiring.
. Connect test equipment and check the coil as follows:
a. Measure the primary winding resistance between
terminals 1 and 15. Test value, see group 0.
b. Measure coil performance in volts or spark length.
Note: Check that the breaker gap and closing angle
of the distributor are correct.
NOTE )
Faults, if present, can often only be detected when
the coil has warmed up. In case of doubt, leave the
coil connected under load on the test bench for
half an hour; it should still function perfectly at
the end of this time. )
341-1 SAAB
Dec. 1975
Page 257
Removing and refitting the solenoid
(starter removed from car)
Removing
pb
2.
Disconnect the feeder cable.
Remove both retaining screws and remove the solenoid.
Refitting
1.
Zz
3.
Hook the solenoid to the engaging lever arm and secure
it with the two screws.
Connect the feeder cable.
Test the starter (see group 0).
Changing brushes
(starter removed from car)
Removing old brushes
1.
2.
os.
Remove the two screws from the capsule bracket.
Remove the capsule bracket, U-washer, shims and
rubber gasket (pos. 5—8).
. Remove the screws from the commutator bearing
housing (1).
. Remove the commutator bearing housing (10).
. Lift the brush springs from the holders with a wire
hook and take out the brushes.
. Remove the brush plate.
. Unsolder the brush wiring connections from the brush
plate and field winding.
$4762
BRUSH PLATE AND FIELD WINDING
Dec. 1975
Fitting new brushes
. Wire the new brushes to the brush plate and field
winding by soldering.
. Fit the brush plate in position. Lift the springs with a
wire hook and insert the brushes.
Mount the commutator bearing housing with the
notches above the feed cables rubber insulation.
. Fit the rubber gasket, shims and U-washer.
. Locate the capsule bracket and secure it with the two
screws.
. Insert and tighten the bearing housing screws.
. Check the operation of the starter (see group 0).
Changing the starter pinion
(starter removed from car)
Dismantling
1. Disconnect the feeder cable from the solenoid.
2. Undo the solenoid retaining screws.
3. Unhook the solenoid and remove it.
4. Undo the engaging lever arm locating screw.
5. Remove the commutator bearing housing screws (1).
6. Pull off the drive housing. Save the rubber and
steel washer (17—18).
7. Push down the stop ring towards the pinion.
8. Remove the lock ring with lock ring pliers.
9. Remove the stop ring and the pinion.
10. Check the spiral splines on the rotor shaft for burrs.
If there are any, file them off.
Assembling
1. Lubricate the spiral splines on the rotor shaft and
the pinion engaging ring with silicone grease.
2. Mount the pinion, stop ring and lock ring on the
rotor shaft.
3. Use pliers to seat the lock ring in its groove in the
rotor shaft.
4. Push up the stop ring using a claw puller.
5. Fit the engaging lever arm to the pinion engaging
ring and put on the drive housing.
6. Secure the engaging lever arm with its locating
screw.
7. Place the washers in the drive housing, first the
steel washer and then the rubber washer. The lips
must be turned towards the rotor.
8. Mount the drive housing so that the notches on
the starter housing are above the guide pin and
the lip of the rubber washer.
9. Insert and tighten the bearing housing screws.
10. Hook the solenoid to the engaging lever arm and
secure it with the two screws.
11. Connect the feeder cable.
12. Check the operation of the starter.
331-3
Page 258
IGNITION COIL
General
The ignition coil is made by Bosch. It is of high-output
type and requires a series resistance. When the starter is
switched on, the series resistance is disconnected and bat-
tery voltage is fed direct to the ignition coil, but when
the starter is switched off again, the series resistance
comes into function and reduces the current to the coil.
The ignition coil with seriesresistance is located on the
left front wheel housing.
Removing and installing the ignition coil
Removing
1. Disconnect the wiring from the coil.
2. Undo the clamping screws and withdraw the coil.
Installing
1. Tighten the two screws to clamp the oil in position.
2. Connect the wiring. See fig.
Inspecting the ignition coil
1. Disconnect the wiring.
2. Connect test equipment and check the coil as follows:
a. Measure the primary winding resistance between
terminals 1 and 15. Test value, see group 0.
b. Measure coil performance in volts or spark length.
Note: Check that the breaker gap and closing angle
of the distributor are correct.
NOTE
Faults, if present, can often only be detected when
the coil has warmed up. In case of doubt, leave the
coil connected under load on the test bench for
half an hour; it should still function perfectly at
the end of this time.
341-1 SAAB Dec. 1975
Page 259
DISTRIBUTOR, CARBURETOR ENGINE
General
The distributor is made by AC Delco and is mounted on
the front of the engine block, i.e. at the clutch end of the
engine, It rotates counterclockwise and is driven by a
worm gear from the idler shaft. The distributor is designed
for centrifugal- and vacuum regulation; the centrifugal
regulator controls the ignition setting relative to the en-
gine speed, while the vacuum regulating system controls
the ignition setting in relation to the load. The order of
firing is 1-3—4—2 (cylinders numbered from rear to
front).
Directions for lubricating the distributor are given in
group 1.
Removing and installing the distributor
Removing
1. Disconnect the ignition cables.
2. Release the spring clips and take off the distributor
cap.
3. Disconnect the low-voltage wire from the ignition coil.
4. Pull off the vacuum hose.
5. Crank the engine until the flywheel marking is at the
ignition position on cylinder No. 1. (See group 0,
basic ignition advance.)
6. Undo the screws that secure the distributor to the en-
gine block, using wrench 839039.
7. Pull the distributor away from the engine.
DISTRIBUTOR
. Distributor cap
. Rotor
- Vacuum control unit
. Breaker plate
Low-voltage wire
. Spring clip
. Drive gear
NOOSDWN=
Installing
1. Check the flywheel Position, (see group 0, basic
ignition advance), which shall correspond with the
ignition position on cylinder No. 1.
2. Turn the distributor shaft until the rotor arm points
away from the flywheel along the fore-and-aft line
of the engine.
3. Locate the distributor in the engine block with the
vacuum control unit facing the flywheel.
4. Engage the drive gears. Rotate the crankshaft back
Dec. 1975 SAAB 342-1
Page 260
$235;
POSITION FOR INSTALLING THE ROTOR,DISTRIBUTOR
FULLY ENGAGED
10.
11.
and forth slightly until the distributor shaft engages
the oil pump drive.
On account of the cog bevelling the rotor must be
turned 25—30° counterclockwise.
. Check that the basic ignition advance mark on the
flywheel matches the mark on the flywheel cover
{ignition point for No. 1 cylinder).
. Tighten the screws slightly (but not so hard that the
distributor cannot be turned).
. Connect the low-voltage wire to the ignition coil.
. Connect the cam angle meter, switch on, and check
and adjust the cam angle at starter speed.
. Put on the distributor cap, secure it with the spring
clips, and connect the ignition cables.
Connect a stroboscope lamp; adjust the ignition point
at starter speed or at 800 rev/min and with the
vacuum hose disconnected. A higher engine speed
will give a wrong ignition setting, as the centrifugal
governor of the distributor then begins to act.
Tighten the distributor retaining screws using wrench
839039 for 1.7 and 1.85 | engines or 839198 for 2.0 |
engine. Connect the vacuum hose.
12. Adjust the idling speed setting.
TIGHTENING DISTRIBUTOR RETAINING SCREWS
Tool 839039 (1.7 and 1.85 | engines)
Dec. 1975