Page 41
“- ——.
Nov. 1969
CONTENTS
100 General hints
101 Special tools
110 Service inspections
120 Lubrication
141 Underbody and rustpreventing treatment
Page 42
are tee
Page 43
GENERAL HINTS
Neatness and cleanliness
A neat and tidy workshop is essential for the proper ser-
vicing of vehicles. Some parts of the car need to be treat-
ed with special care and effectively protected against dirt
and contamination while work is in progress. For the me-
canic who may be new to the job should the following
points may be of help:
1. Protect fenders and other paintwork with suitable cov-
erings.
2. Lay protective coverings over the seats and upholstery
to save them from spots of oil and dirt.
3. Clean the insides of fenders and the space round the
rear axle thoroughly before starting to work on wheel
hubs and axles. This makes the job easier and prevents
grit and dirt from getting into bearings and other sus-
ceptible parts.
4. Before unscrewing spark plugs, clean the recess round
the plug thoroughly.
5. Every job must have its proper place. It is bad practice,
for example, to disassemble an engine or transmission
on a bench which is also used for filing, etc. or where
filing is done in the immediate neighbourhood.
Jacking and blocking up
The car has a rigid self-supporting body and this lacks
the natural application points for a jack that a girder
chassis provides. There are however two special engage-
ment recesses on each side designed to fit the jack sup-
plied with the car's tool kit; these are intended for use
during wheel changing, etc. The engine compartment
floor is also reinforced immediately under the cross mem-
ber that supports the engine to provide an application
point for the workshop jack. A similar reinforced lifting
point is provided underneath the floor at the back behind
the fuel tank. As most workshop jacks have a forked lift-
ing head, it is advisable to lay a wooden block of suitable
size across the fork to avoid damaging the floor of the car.
For some jobs it is necessary to raise the front or rear end
of the car. In such cases the jack engagement recesses un-
der the sills should be utilized.
Thread system and wrench sizes
width of UNC screw heads and nuts, measured across
the flats in inches, corresponds to the designation of the
wrench that fits in each case. In a few cases the UNIFIED
INE (UNF) system is used.
Exceptions to the standard thread system are found in
some components supplied by subcontractors, e.g. Bosch
and new constructions introduced as from model 1972,
where thesmetrical thread system is used. p
Nov. 1972 SAAB 100-1
Page 44
FRONT END RAISED
FRONT END BLOCKED UP ON TRESTLES
ONE SIDE JACKED UP
100—2
REAR END RAISED
REAR END BLOCKED UP ON TRESTLES
Sept. 1969
Page 45
aa
PS Pa “iD Se 2
J)
SPECIAL TOOLS
General
The 7-figure number quoted in the following list of spe-
cial tools is the part number. The number which is also
marked on the tools only includes the first six figures.
The special tools in the list are classified as follows:
Tools for engine, transmission and chassis work
Class AO—1 = Tools used very frequently in service
work (e.g. adjustment of timing)
AO-—2 = Tools used frequently in maintenance
work (e.g. replacement of brake pads)
Al = Tools necessary for simple repairs (e.g.
replacing the clutch or valves)
A2 = Tools necessary for qualified repairs
(e.g. reconditioning the gear box)
A3 = Tools which are mainly recommended
for reasons of operational efficiency
Tools for body work
Class B1 = Tools necessary for simple body work
(e.g. replacement of front fenders)
B2 = Tools necessary for qualified body work
(e.g. alignment work)
B3 = Tools which are mainly recommended
for reasons of operational efficiency
Tool racks
It is most important that special tools are kept in a suit-
able place, where they will be readily accessible and
easily found.
Dee. 1975 SAAB
101-1
Page 46
Special tools, engine
Part No. Description Class Mlustration Remarks
210 Engine body
7860794} Floor stand A2
7860877| Bench stand A2
7860885) Vise stand A2
7861479} Stand A2
8390478} Axle for stand A2
8392169] Holder, engine A2 Engine 2.01
8390452} Holder, engine A2 Engine 1.7
and 1.85 1
101-2 Saul Dee. 1975
—Z
Page 47
Special tools, engine
Part No. Description Class Illustration Remarks
7860802| Oil pan A2
a
» 8392409! Lifting hook Al
|
|
|
ea
|
‘ 8390270} Tapping-out hammer Al Also trans-
.
sane
8392136| Intermediate piece, removal, water pump | A1 Engine 2.01
3B 8390577| Intermediate piece, removal, water pump | A1 Engine 1.7
] 3 and 1.851
,
, os 8390668] Sleeve cpl., screw pulley A2
8390676] Sleeve 1 1/2’ A2 Engine 2.0 |
r 8390684| Intermediate piece 3/4’ x 1/2” A2
,
‘
8392151} Puller, pulley A3 Engine 2.01
8391146] Puller, pulley A3 Engine 1.7
; and 1.851
|
*
,
,
:
& Dec. 1975 SAAB 101-3
Page 48
Special tools, engine
Part No. Description Class Illustration Remarks
8392540 | Installing tool, crank shaft seal, flywheel Engine 2.01
end Al
8390411] Guide sleeve, crankshaft seal, transmis- Engine 1.7
sion end Al and 1.85 |
7862287 | Piston installing tool A3 Engine 2.0!
8392086 | Piston installing tool Engine 1.851
8390361 | Piston installing tool standard piston A3 Engine 1.71
8391153] Piston installing tool oversize piston A3 Engine 1.7!
8390445,| Drift, installing water pump housing A2 See also 262
water pump
8390536] Sleeve, installation, water pump A2 See also 262
water pump
8392045| Adapter cpl. ignition setting AO-1 gq } >
S 4602
8392052| Adapter, dwell angle setting A0-1 —) a ——
}
S 2364
8392185| Key, crank shaft screw A0-1 Engine 2.01
8390817] Key, crank shaft screw AO-1 Engine 1.7
ot and 1.85 |
|
8392128| Guide pin, cylinder head Al SS
101-4 SAAB Dec. 1975
Page 49
a
Dec, 1975
Special tools, engine
Part No. Description Class Illustration Remarks
8392326] Air nipple, spark plug hole A3
8391260| Crank, transmission end A3
7860513] Locktite stud lock
8343808] Locktite quickset
8809097] Tikatat, can 1 pound
8308454] Locquic activator grade T
7862014| Key, oil filter cartridge AO-1 Engine 2.01
8391914] Key, oil filter AO-1 5 Rok Engine 1.7
o and 1.85 1
8390130} Dynamometer A2 See also
$461)
SAAB
101-5
Page 50
Special tools, engine
| Part No. Description Class Illustration Remarks
8391989] Key, distributor AO-1 Engine 2.0!
8390395| Key, distributor AO-1 Engine 1.7
and 1.85 |
8391799| Key, inlet manifold A2 Engine 1.7
and 1.851
8391849] Dolly, crankshaft A3
8392367| Key, stud Al Engine 1.7
and 1.851
8392383| Key, inner part
8392375| Key, outer part
101-6 Ss Dec. 1975