Page 611
— se eee
6. If necessary, the outer door handle can be removed
by undoing its two retaining screws, one inside the
door and one on the rear edge of the door.
Front door, 4-door model
Removal
. Crank the window all the way up.
2. Remove the inside door trim.
3. Turn the lock mechanism to the closed position and
unscrew the three retaining screws from the lock.
4. Unscrew the bottom of the rear runner so that it can
be bent forward when the door is removed.
5. Unhook the operating link to the inside handle at the
lock and remove the link to the lock button. On
model 1974, unfasten the link to the lock cylinder.
. Remove the door lock,
7. \f necessary, the outside door handle can be removed
by undoing its two retaining screws, one inside the
door and one in the rear edge of the door.
o>
Rear door, 4-door model
Safety catches
The rear doors of the 4-door model are as from the 1973
model provided with safety catches to prevent that the
doors unintended are opened from the inside by, for ex-
ample children.
Removinging
1. Crank the window all the way up.
2. Remove the inside door trim.
3. Turn the lock mechanism to the closed position and
unscrew the three retaining screws from the lock.
4. Unhook the link to the lock button on the door lock.
5, Model 1974: Unfasten the pistol grip by removing the
forward screw inside the door and back off the rear
screw behind the weather-strip on the edge of the
door halfway.
6. Unscrew the inside door handle and unhook the front
end of the operating link.
7. Push the lock into the door frame and unhook the
operating link at the lock. The lock can now be re-
moved.
On model 1974, the pistol grip must be wiggeld
slightly when the lock is removed.
8. If necessary, the outer door handle can be removed
by undoing its two retaining screws, one inside the
door and one on the edge of the door behind the
weather-strip.
Installing door locks, all models
To fit handles and locks, proceed in the reverse order.
Check before fitting that the moving parts and springs
of the lock are well lubricated with Saab Special chassis
grease. Up to and incl. model 1973: Check with the button
of the outside handle pushed in that there is a play of
about 0.04” (1 mm) when the door is closed. If the play
is less than this, adjust by filing down the part of the push-
button arm that actuates the lock. After fitting the lock,
adjust the striker plate so that the door opens and closes
easily.
FRONT DOOR WITH COMPONENT PARTS
1, Inside door handle, up to model 1969
2. Operating link, up to model 1969
3. Inside door handle, as from model 1970.
4. Operating link, as from mode! 1970
5. Door lock
Dec, 1975
6. Striker plate
7. Top hinge with door stop
8. Bottom hinge
9. Window regulator
SAAB 830-3
Page 612
S 3216
REAR DOOR WITH COMPONENT PARTS
1. Inside door handle
2. Operating link
3. Door lock
4. Striker plate
Changing door lock cylinders
. Removal and disassembly, up to and incl. model 1973
1. Crank the window right up.
2. Remove the inside trim from the door.
3. Remove the lock button as follows (two alternative
methods described): As from model 1972 only alt.
I is valid.
Alt. | Push in the two springs that lock the washer
(8, see exploded view) with polygrip pliers or
similar and take out the button.
Pry off the snap ring (9) from its groove with
a bent chisel or similar and push the snap ring
towards the driver (10), where it can be un-
hooked if the lock cylinaer (2) is pushed in.
At the same time unhook the washer (8); the
button can then be taken out.
Alt. I!
53180
TAKING OFF THE SNAP RING
830-4
5. Top hinge
6. Bottom hinge with door stop
7. Window regulator
4. Up to and incl. model 1971:
Remove the pivot (12), that holds the driver. Put aside
the button together with the lock cylinder and spring.
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PUSH BUTTON UP TO AND INCL. MODEL 1971, EXPLODED )
VIEW i
1, Key 7. Gasket
2. Lock cylinder 8. Washer
3. Push button with sleeve 9. Snap ring
4. Sleeve 10. Driver
5. Spring 11, Washers
6. Sleeve 12. Pivot
Sept. 1973
Page 613
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As from model 1972:
Remove the screw holding the push button driver (10)
and remove the push button (3) and spring (5).
WARNING
Do not press out the pivot that holds driver. The
pivot is guided by two spring loaded balls and can
not be refitted unless a special tool is used.
5. Take off the nickel-plated sleeve (4) to expose the lock
cylinder retaining pin.
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S$ 3449
PUSH BUTTON AS FROM MODEL 1972, EXPLODED view
1. Key 7. Gasket
2. Lock cylinder 8. Washer
3. Push button with sleeve 9. Snap ring
4. Sleeve 10. Driver
5. Spring 11. Washer
6. Sleeve © 12. Pivot
6. Insert the key and turn it 35° clockwise; the retaining
pin can then be pushed in and the lock cylinder taken
apart. If the key is missing, the pin can be knocked
into the lock cylinder by force with a center punch or
with a pin not more than 0.12’ (3 mm) in diameter,
after which the cylinder can be pulled out of the but-
ton. This method however ruins the cylinder, and a
new cylinder will have to be fitted.
Reassemble in the reverse order.
Fitting locks in door
1, Engage the snap ring (9) in the groove on the sleeve (6).
Check. that the washer (8) slips over the cylindrical
Part of the snap ring without sticking. If necessary,
‘bend the snap ring.
2. Fit the push button in the door but not so far that the
two springs are exposed inside the door. Place the
washer (8) inside the driver (10).
3. Hold the button from the outside and push the washer
(8) home with the aid of too! 847103, see fig.
NOTE
Check that both springs have engaged.
Dec. 1975
PUSHING HOME THE WASHER
Tool 847103
Removing the lock cylinder, model 1974
Un
ys
3.
Crank the window all the way up.
Remove the inside door trim.
Unhook the link rod from the plastic arm of the lock
cylinder.
. Remove the lock clip using polygrip pliers and remove
the entire lock cylinder.
THE LOCK CLIP IS REMOVED
$4130
Disassembly and assembly of the lock cylinder, model
1974
i
2;
3.
Pry off the driver and remove its lock ring.
Remove the plastic arm and the spring.
Withdraw the lock cylinder from the lock sleeve. Leave
the key in the lock cylinder as long as it is withdrawn
from the lock sleeve or the lock cylinder may fall apart.
. Remove the O-ring.
NOTE
The key in the new lock cylinder must not be with-
drawn before the lock cylinder is fitted in the lock
sleeve.
The lock ring should be changed after having been
removed. Re-assemble in reverse order.
830—5
Page 614
10
DOOR LOCK, MODEL 1974
1. Lock ring 6. Gasket
2. Driver 7. Locking sleeve
3. Plastic arm 8. O-ring
4. Spring 9. Lock cylinder
5. Lock clip 10. Key
Keys
Two keys are supplied with the car. Both fit the ignition
switch and all locks.
Spare parts
If the lock cylinder in the ignition switch, the trunk lock
or any door is damaged, a replacement cylinder can be
ordered by quoting the serial number of the key and the
spare part number (see Spare Parts Catalogue). The sys-
tem of master keys fitting all locks can thus be main-
tained without the need to fit a complete new set of
locks to the car.
Lubrication
If the lock cylinder is oiled or greased, the tumblers of
the lock are liable to stick. This is because dirt sticks to
the key and is deposited inside the cylinder. Lubrication
of the cylinder itself should therefore be avoided, but if
it is necessary to free a stuck lock, a little glycerine may
be smeared on the heel of the key. Work the key back
and forth a few times in the lock.
NOTE
ies serrated edge of the key must not be greased.
Removal and installation of trunk lid
Open the lid and undo the four screws by which the lid is
fastened to its hinges. The lid can then be lifted up.
Adjustment of trunk lid
The position of the trunk lid can be adjusted upward and
downward or forward and backward by loosening and
retightening the hinge screws-in the oversized holes.
ADJUSTING THE TRUNK LID
Adjusting the trunk lock striker plate
The striker plate is secured by screws in oversized holes
and can be adjusted when the screws are loosened.
Changing the trunk hinges
1. Remove the trunk lid.
2. Remove the springs at the hinges with the aid of spe-
cial tool 829157.
Dec. 1975
Page 615
ie ee in ee i ee. a as
ow
REMOVAL OF SPRING, TRUNK LID
Tool 829157
3. Bend away the side padding guards a little and remove
cotter pins and washers from the hinge pins. The hinges
can now be removed.
REMOVAL OF COTTER PINS
4. Fit the new hinges with new plastic bushings on the
pins.
5. Install the springs at the hinges with the aid of tool
829157.
6. Install and adjust the trunk lid.
Changing the trunk lock cylinder
1. Open the trunk lid and remove the lock mechanism by
undoing the two retaining screws.
2. Undo the two securing the handle to the lid.
3. Up to and incl. model 1973: Proceed in the same manner
as for changing door lock cylinders as from model 1972.
WARNING
Do not press out the pivot that holds driver. The
pivot is guided by:two spring loaded balls and can
not be refitted unless a special tool is used.
Deo 1876 SAAB
3. Model 1974:
a. Pry the plastic disc loose with a suitable tool and
remove the compression spring and push button
from the handle.
b. The driver and the torsion spring can be removed
after the lock ring has been taken off.
c. If the lock cylinder is withdrawn from the push
button sleeve, the key must first be inserted in the
lock cylinder so the cylinder does not fall apart.
Reassemble in reverse order.
TRUNK LID WITH LOCK, STRIKER PLATE AND HINGES
(LOCK UP TO AND INCL. MODEL 1973)
1. Reinforcing plate 6. Spring
2. Striker plate 7. Sleeve
3. Lock 8. Sleeve
4. Handle 9. Lock cylinder
5. Pin 10. Key
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TRUNK LOCK, MODEL 1974
1, Plastic disc
2. Compression spring
3. Lock ring
4. Driver
5. Torsion spring
6. Push button sleeve with lock cylinder
7. Handle
8. O-ring
830-7
Page 616
DISCONNECTING THE MAIN CONNECTION
REMOVING THE LOCK FROM THE TRUNK LID
ADJUSTING THE STRIKER PLATE
TRUNK DOOR, SAAB 99 COMBI COUPE
Dismantling
1. Remove the cable clip and cut off the cable between
the body and the door, and disconnect the main con-
nection from the body.
830-8
2. Mark the position of the door at the hinge mounting
if the door is to be refitted, and back off the insex
screws slightly.
3. Remove the two pneumatic springs and place a suit-
able support at the rear edge of the door.
4. Remove the insex screws and lift away the door with
the aid of an assistant.
$4812
LIFTING AWAY THE TRUNK DOOR
NOTE
The pneumatic springs must not be dismantled.
The pressure in the spring is more than 60 bar
(kp/cm2, 850 psi.), which means that in the event
of the lock ring being removed, the internal com-
ponents will be forced out at a force sufficient to
cause injury.
Dec. 1975
Page 617
Fitting
1. Place suitable spacers under the hinge plates.
SPACERS UNDER THE HINGE PLATES
2. With the help of an assistant, lift the door and secure
it to the hinges. Simplify the lift by placing a suitable
support at the rear edge of the door.
3. Remove the spacers under the hinges before lowering
the door.
NOTE
The pneumatic springs can be damaged if they re-
main fitted to the body and if the door is closed
without the springs being secured to the door.
4. Adjust the fit of the door at the hinges, and if neces-
sary, adjust the lock mechanism.
. Fit the pneumatic springs.
) 6. Connect the electric cable by means of joint sleeves
and insulate the joint with black insulating tape.
Clamp the table to the body. Connect the main con-
nection.
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Dec. 1975 SAAB 830-9
Page 618
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Page 619
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WINDOWS
General
The windshield is made of laminated glass and all other
windows of toughened glass. When fitting new windows,
use only Saab original parts to ensure approved glass
quality and a perfect fit.
Changing the windshield
To change the windshield without removing the rubber
strip from the body, proceed as follows.
Removal
. Raise the windshield wiper arms. Crank the door
windows down.
. Remove the joint piece from one side of the wind-
shield moulding and mark the end position of the
moulding on the rubber strip with a pen. Remove
the moulding.
. Remove the rubber strip from the windshield by in-
serting a properly bent special tool under the strip
and moving it around the strip.
. Push out the upper left corner of the windshield by
pressing carefully from the inside.
. Free the upper edge and the sides of the windshield
from the rubber strip.
. Free the bottom edge of the windshield. Remove the
windshield.
Installation
10.
Dec. 1975
Adjust the rubber strip so it follows the windshield
frame.
Apply paraffin oil to the rubber strip to facilitate
the installation of the windshield.
Place the new windshield on the rubber strip and
align the windshield in its proper position in the
frame.
Fit the windshield into the bottom edge of the
rubber strip and the lower part of the short side
using the special tool.
Fit the windshield in the top edge of the rubber
strip. Begin by pulling out a small bit of the rubber
edging from the inside of the windshield about 6 in.
(about 15 cm) from a corner. Complete the fitting
of the rubber strip and make any necessary adjust-
ments.
Apply paraffin oil to the slot for the windshield
moulding to facilitate fitting.
Fit the moulding using tool 829102. Begin at the
mark made previously on the rubber strip. Com-
plete the fitting of the moulding.
Inject sealing compound between the rubber strip
and the glass and between the rubber strip and
the frame.
Clean off any excess sealing compound with a
wooden putty knife.
Clean the glass and the strips with undiluted spirits.
APPLYING THE WINDSHIELD MOULDING
Tool 829102
11. Clean the inside and the outside of the glass with
window cleaning liquid.
If the rubber strip has been removed from the frame,
the procedure used for the rear window should be fol-
lowed.
Changing the rear window
Removal
1,
Remove the padding around the rear window. Protect
the headlining from becoming soiled by applying mask-
ing tape to the edge above the window.
Saab 99 Combi Coupé: Disconnect the heating wire
connections for the rear window.
. Free the rubber strip from the frame and push out the
rear window from the inside.
. Clean the contact surface for the rubber strip round
the frame and clean away the old sealing compound.
Installation
bs
Fit a new rubber strip round the window and lay a
piece of string in the slot in the rubber strip. Leave
the ends of the string at the middle of the bottom
of the window.
. Apply paraffin oil to the window frame and the rub-
ber strip and put the window in place.
- Pull on the string from the inside of the car so that
the edge of the rubber strip will be bent inwards and
over the edge of the frame. Start from the middle
and work towards the sides while pushing the glass
down towards the edge of the frame. Continue around
the whole rear window and ensure that the inside
flange of the rubber strip overlaps the inside of the
frame all the way around.
. Fit the trim moulding using tool 829102. Apply par-
affin oil to the slot to facilitate fitting.
Saab 99 Combi Coupé: Connect the heating wires for
the rear window.
. Inject sealing compound between the rubber strip
and the glass and between the rubber strip and the
frame.
. Clean off any excess sealing compound with a wood-
en putty knife.
. Clean the glass and the strip with undiluted spirits.
843-1
Page 620
8. Fit the padding.
9. Clean the inside and the outside of the window with
window cleaning liquid.
Changing front door window, 2-door and 4-door models
The door window is clamped at the bottom in a U-shaped
retainer with a slot for the operating arms of the window
regulator. The leading and trailing edges of the pane are
located in U-shaped runners.
Removal
1. Take off the door inside trim.
2. Remove the inner longitudinal weatherstrip atthe
bottom of the window opening.
3. Undo the two screws fixing the front regulator arm
to the window retainer.
REMOVING FORWARD OPERATING ARM OF WINDOW
REGULATOR
4. Turn the pane so that its front part slopes down and
move it forward so the plastic runner is facing the
guide slot in the operating arm.
5. Pry carefully with a screwdriver between the operating
arm and the guide rail so that the plastic runner comes
out through the slot.
FREEING THE PLASTIC RUNNER FROM THE GUIDE SLOT
6. Turn the pane veriically and remove it.
7. \f necessary, remove the pane from the retainer.
Installation
1. If the pane has been removed from its retainer, begin
by placing the rubber pad in the U-shaped retainer and
Pressing in the pane. Make sure that the retainer grips
the pane securely. The measurements stated on the
sketch below must be followed carefully. If not, the
function can be jeopardized.
When installing, check that the retainer is evenly
pressed on. If far instance the middle part of the
retainer is pressed harder on than the ends, the
retainer can be curved. The glass can in that case slip
out of the retainer.
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267 +1 S 3213
MEASUREMENT FOR MOUNTING THE WINDOW PANE
RETAINER, DOOR WINDOW OF 2-DOOR MODEL
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180 +1
S 3214
MEASUREMENT FOR MOUNTING THE WINDOW PANE
RETAINER, FRONT DOOR WINDOW OF 4-DOOR MODEL
2. Lower the pane vertically into the door with the re-
tainer to the rear and work it into the horizontal posi-
tion.
Dec. 1975
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