Page 81
Special tools, body
Part No. Description Class Illustration Remarks
8290637| Fixture, front fender B1
~~
8291023] Installing tool, decorating strip A2
8290579] Tensioning hook, headlining A2
s4737
8290587) Hook, headlining A2
“ 7884166} Holder, door B3
By 8290561| Holder, door B3
‘ 7884182] Stay, holder, door B3
= >
8291577) Tool, spring,luggage compartment lid A2 ¢ ~ )
Dec. 1975 SAAB 101-37
cba
Page 82
Special tools, body
Part No. Description Class Illustration Remarks
|
8291767| Pad, front window A2 ae
8291775| Pad, side window A2 |
8291551| Pad, rear window A2 t ro
$4741
8471039 Installing tool, door lock A2
101-38 SAAB Dec. 1975
Page 83
or _——— —
. A, LP
Special tools, others
Part No. Description Class Illustration Remarks
7843303] Pliers, hose clamp Al
7840937 | Pliers, splice crimping Al
7860695! Pliers, unisulated cable terminals Al
$4745
7860703} Pliers,uninsulated douglas plug Al
$4746
8291395] Sleeve wrench A3
8580029] Holder, rotor A2
Dec. 1975 SUAAUBS 101-39
Page 84
SERVICE INSPECTIONS
General
To assure the car owner of trouble-free motoring at lowest
cost it is essential that the car receives the necessary care
and attention.
The Service Book supplied with every new car up to and
incl. model 1971 contains a number of vouchers listing the
jobs which are necessary in the first instance for proper
maintenance of the car. The first voucher is for the Delivery
Inspection, which takes place before the car is delivered.
The second voucher entitles the customer to guarantee
inspection after 1,200 miles (2,000 km). The remaining
vouchers are for regular servicing at intervals of 6,000
miles (10,000 km); these are billed according to a fixed
price list.
With effect from the 1972 model the former Service
Book is replaced by a Service Card (for the USA-market,
included in the Guide as from model 1973), while details
of the maintenance program are given in the Guide in-
stead. The maintenance program has also been revised and
is now divided into:
Routine service inspections
Supplementary work
Order work
Routine service inspections take place according to a basic
schedule and are to be carried out in connection with reg-
ular checkups at intervals of 6,000 miles (10,000 km).
Supplementary work can be either entrusted to the service
shop or done by the owner himself if he is able and willing
to do so. The supplementary work should however be
treated as one job offered at a fixed price. The owner can-
not therefore order individual items of supplementary
work from the service shop.
110-1
Order work covers anumber of jobs that can be ordered indi-
vidually as and when needed. If some item has recently
been attended to, e.g. a change of spark plugs, an engine
oil change or perhaps a wheel alignment checkup in con-
nection with a change of tyres, this item need not of
course be reordered.
It should however be pointed out to customers that the
division of jobs into different groups is not intended to
represent any kind of grading in order of importance.
The idea is to make sure that the car is properly main-
tained while giving the enthusiastic and capable motorist
the opportunity to save on overhaul expenses by doing
the simpler jobs himself.
NOTE
The new maintenance program is also applicable to
older cars, which means that the service shop can
operate to a standard program. Service cards may
therefore be issued to owners of older cars if they
are agreeable to this.
After each routine inspection the service shop should put
its rubber stamp on the service card.
In addition to routine inspection, the service card lists
various jobs in a system of boxes. The idea is to draw a
heavy line over boxes representing jobs that are not carried
out by the service shop.
The maintenance program is valid for markets except the
USA. For the USA market as from model 1973, a main-
tenance program according to the USA Guide is valid.
Sept. 1973
Page 85
Delivery inspection
hs
ti
10,
14.
15,
16.
,
|
>
|
:
Check the engine oil level and if necessary replenish
oil.
Check the gearbox oil level and if necessary replen-
ish oil. Check the differential oil level (cars with
automatic transmission).
Check the level of the fluid in the power steering
gear reservoir, and top up as necessary.
Check level of coolant and its freezing point.
Check function of all locks, headlights, stop lights,
direction indicators, warning flashers, back-up lights,
| indicator lights, windshield wipers/washer, headlight
wipers/washer, heater fan and signal horns.
Check, if necessary, adjust the headlight alignment.
Check the battery electrolyte level and charging
condition.
Tighten cable terminals at battery, starter motor,
voltage regulator and alternator.
Check, if necessary, adjust fan belt tension.
Check, if necessary, adjust the ignition setting.
Check the fluid level and if necessary replenish
brake fluid in the master cylinders for brakes and
clutch.
Check, if necessary, adjust the parking brake.
Check brake hoses and lines for leakage.
Tighten the wheel bolts.
Adjust the tire pressure incl. the spare wheel.
Check, if necessary, adjust toe-in.
17. Check, if necessary, adjust the seat rails.
18. Check that tool kit, Owner’s Manual and Service Card
are in place.
' 19. Test run car on road and check its condition, espe-
cially the function of brakes and clutch.
' 20. Check and adjust idling and fast idling setting. (Car-
buretor engine).
: 21. Check and adjust idling setting. (Cars with fuel in-
, jection)
.
q
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—
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4
,
,
j
;
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;
,
,
.
Sept. 1973
ne
Guarantee service at 1,200 miles (2,000 km) covers the
following points:
:
10.
3
12.
13.
14.
15.
16.
17.
18.
19,
20.
at:
22.
23. |
24.|
25.
Check cylinder head nuts and bolts to prescribed
torque.
Check and tighten flange screws of inlet_manifold
and carburetor valve housing.
Check and tighten exhaust manifold retaining
screws and exhaust pipe flange nuts.
Check exhaust system for leaks; check and tighten
exhaust pipe clamp and suspension screws.
Check and tighten screws on all engine mounts.
Change engine oil. Owner pays for oil.
Cars with manual transmission only:
Change transmission oil and clean magnetic drain
plug. Owner pays for oil.
Cars with automatic transmission only:
Check and, if necessary adjust gear selector cable.
Check and tighten screws retaining covers under
transmission. Check oil level in transmission and
final drive.
Check the level of the fluid in the power steering
gear reservoir, and top up as necessary.
Check radiator coolant level and test cooling sys-
tem for leaks (pressure test).
Check fluid level in clutch master cylinder and
top up if necessary. Check and if necessary adjust
clutch release bearing play (cars with manual trans-
mission only).
Check function of all locks, headlights, stop lights,
direction indicators, warning flashers, back-up lights,
indicator lights, windshield wipers/washer, headlight
wipers/washer, heater fan and signal horns.
Check and if necessary adjust headlight alignment.
Check battery electrolyte level and top up if neces-
sary; grease cable clamps.
Check and if necessary adjust alternator drive belt
tension.
Check and if necessary adjust closing angle of break-
er points. Grease distributor breaker cam and lubri-
cating felt. Check and if necessary adjust ignition
timing.
Check fluid level in brake master cylinder; top up
if necessary,
Check and if necessary adjust parking brake.
Check brake fluid lines and hoses for leaks and
condition.
Check condition of rubber dust excluders on steer-
ing gear and inner and outer universal joints, and
of rubber seals for ball joints and tierod ends.
Check and tighten screws securing rear axle to
body.
Check and tighten screws securing control arms to
body (front suspension).
Check and if necessary adjust wheel alignment(cam-
ber, caster and toe-in).
Test-drive car on road and check Operation of all
systems, especially brakes and clutch,
Check and if necessary adjust engine idling speed
and the carburetor overflow valve,
110-2
Page 86
Routine Service Inspection
To be carried out by authorised Saab dealer every 6,000
miles (10,000 km).
Engine
Cleaning of air cleaner insert.
Inspect vacuum piston diaphragm in carburetor. Check
and if necessary top up oil level in damping cylinder (car-
bureted engines only).
Adjust engine idling speed and measure carbon monoxide
emission in exhaust at idling speed (if prescribed by the
authorities).
Clean fuel pump filter (carbureted engine).
Pressure test of the cooling system. Check condition of
hoses.
Electrical system
Inspect alternator drive belt and adjust belt tension if
necessary.
Inspect condition of headlights by eye.
Check headlight alignment and adjust if necessary. *
Clean and adjust spark plugs.
Check condition of contact braker points.
Check ignition timing and closing angle of points and ad-
just if necessary. Grease distributor breaker cam and lubri-
cate felt.
Transmission
Check clutch release bearing play and fluid level in clutch
master cylinder and adjust if necessary (manual transmis-
sion only). Check transmission oil level and top up if ne-
cessary (also final drive in automatic transmissions).
Brake system
Check fluid level in master cylinder and top up if neces-
sary.
Remove wheels and check thickness of brake pads.
Adjust handbrake.
Check brake lines and hoses for leaks and general condi-
tion.
Front suspension and steering
Check toe-in.
Check condition of rubber dust excluder on steering gear
and inner and outer universal joints and of rubber seals
for ball joints and tie-rod ends.
Servo steering gear
Check servo steering gear for exterior leakage.
Check condition and tension of drive belt.
Check oil level in servo oil reservoir.
Final check
Test drive.
Supplementary work
To be performed at 6,000 miles (10,000 km) or shorter
intervals.
The owner can do this work himself or order it as part of
the 6,000 miles (10,000 km) inspection.
Check engine oil level.
Check coolant freezing point.
Check battery electrolyte level and top up if necessary.
Tighten and grease cable clamps.
Check fuel lines in engine compartment for leaks.
110-3 SAAB
Check exhaust system for condition and leaks.
Lubricate door stops, door hinges, throttle control and
hood lock mechanism.
Check depth of tire tread patterns.
Check operation of parking, stop and tail lights, license
plate illumination, direction indicators, horns, back-up
lights, hazard warning signal, interior lighting, ignition
switch illumination, warning and indicator lights, brake
warning light, instrument panel illumination, windshield
and headlight wipers and washers, trunk illumination
and ventilator fan.
Check washer jets and rubber wiper blades.
Order Work
To be carried out by an authorised Saab dealer
This can be arranged in conjunction with regular 6,000
miles (10,000 km) servicing and is carried out as needed
(consult your local Saab dealer).
B1. Change oil every 6,000 miles (10,000 km) or at
least twice a year. If the car often is driven in high-
way conditions, i.e. long distances with high speed,
it is recommended to change oil every 3,000 miles
(5,000 km).
B2. Change oil filter (every 6,000 miles /10,000 km).
B3a. Change oil in manual transmission. Clean magnetic
drain plug (every 12,000 miles/20.000 km or at
least once a year).
B3b. Change oil in final drive of automatic transmission
(every 12,000 miles/20,000 km).
B4. Change spark plugs (every 9,000—12,000 miles/
15,000—20,000 km).
B5. Change breaker points (after inspection).
B6a. Change fuel filter in cars with injection engines
(every 12,000 miles/20,000 km).
B6b. Change of air cleaner insert every 18,000 miles
(30,000 km).
B7. Check and if necessary adjust wheel angles, i.e.
camber, caster, toe-in (every 12,000 miles/20,000
km).
B8. Adjustment of toe-in.
B9. Change brake fluid (after 24,000 miles/40,000 km
or two years).
B10. Tighten cylinder head nuts and bolts to prescribed
torque (at first 6,000 miles/10,000 km inspection
only).
B11. Check and if necessary adjust valve clearance at
6,000 miles (10,000 km) inspection. On 2.0 | en-
gines also at 24,000—, 48,000— and 72,000 miles/
40,000—, 80,000— and 120,000 km inspection.
B12. Check and if necessary top up oil in steering gear.
(After 30,000 miles/50,000 km).
Sept. 1973
Page 87
LUBRICATION
NOTE
Saab Special chassis grease must be used with care,
as it is apt to discolor the paintwork of the car.
NOTE
Use only Saab Special chassis grease for greasing and
packing bearings.
Lubrication every 6,000 miles (10,000 km) or at least twice a year
Ref. Lubrication point Qty. Lubricant Direction
t
{ 1 | Brake system 1 |Brake fluid, grade SAE J 1703 | Brake fluid to be changed
i" or SAE 70 R3 every 24,000 miles(40,000
i USA: DOT 3 or DOT 4 km) or at least every 2 years.
i 2 | Hydraulic clutch 1 |Brake fluid grade as above
» 3 | Engine 1 | Follow recommendations on Change oil and oil filter cart-
j P= page 120-2 ridge
NOTE! Use only Saab original
filter cartridge.
4 | Manual transmission Follow recommendations on Check every 6,000 miles
page 120-2 (10,000 km), change every
: 12,000 miles (20,000 km)
— Automatic transmission Check every 6,000 miles
! (10,000 km)
j Final drive, automatic transmis- Follow recommendations on Check every 6,000 miles
sion page 120—2 (10,000 km), change every
12,000 miles (20,000 km)
5 | Carburetor (oil damper) As for engine Check every 6,000 miles
(10,000 km) at time of ser-
vice inspection
4 6 | Distributor, breaker cam 1 |Bosch Ft1v4 Grease cam
Distributor, lubr. felt under SAE 40 oil Oil can through hole in breaker
5 breaker plate plate
7 | Throttle control, wire bearing 1 |SAE 40 oil Oil can
Hood lock mechanism 1 |SAE 40 oil Oil can
4 Door hinges and door stops 4+4 |SAE 40 oil Oil can
(8+8)
4 6 4 4 7
—~.
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a
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j
‘ S 3694
Nov. 1972
Page 88
Points to be lubricated every 6,000 miles (10,000 km) or
at least twice a year
1. Brake system
The brake fluid container must always be kept well
filled. The level in the container should be checked
every three months, when the filler cap should also
be inspected to make sure that the holes are not
blocked. Follow the brake fluid recommendations
given in the lubrication table.
2. Hydraulic clutch operation
Check that the container is full.
3. Engine
Oil volume 4 US quarts, 6 Imp. pints (3.5 liters)
Oil according to API Service SE or Fords specifica-
tion ESE—M2C—101C should be used.
Oil grade SAE 10 W 30 or SAE 10 W 40
in extremely cold conditions with temperatures
constantly below —4°F (—20°C) oil with a viscosity
of SAE 5 W 20 should be used.
NOTE! This last-named oil must not be used at
temperatures above +32°F (0°C).
The engine oil level should be checked regularly.
This should be done when the engine has been at a
standstill for about one minute. The oil level must
not be allowed to fall below the lower mark on the
dipstick, nor must it be topped up beyond the up-
per mark, as this may result in abnormal oil con-
sumption, The distance between the upper and
lower marks corresponds to a volume of one liter
{roughly 1 US quart or 1 3/4 Imp. pints). Top up
as needed with oil of the recommended grade. En-
gine oil should be changed for the first time after
1,200 miles (2,000 km), for the second time at
6,000 miles (10,000 km) and thereafter every
6,000 miles (10,000 km) or at least twice a year.
Change the oil filter insert (oil filter cartridge) every
6,000 miles (10,000 km).
The engine drain plug has a recess for a square pin
spanner up to and incl. gearbox No. 6.779, and
thereafter hexagon head.
DRAIN PLUGS
1, Engine
2. Transmission
120-2
Manual transmission
Up to gearbox No. 36472 there are two drain plugs with
with specially shaped recesses requiring use of special
tool 839153, see illustration below. Both plugs must be
removed to drain the transmission of oil. The plug with
the square recess is for draining engine oil.
Check the oil level every 6,000 miles (10,000 km)
by unscrewing the level plug. If the oil level is be-
low the plug opening, add oil until it runs out of
the opening.
When changing oil, drive the car for 15—20 minutes
before draining off the old oil. Clean the magnetic
drain plug, then add fresh transmission oil through
the transmission filler plug opening until it runs out
of the level plug opening. Remember that it takes
some time for the oil to run from the primary gear
housing into the transmission case. The transmission
holds 3 US quarts of oil (5 Imp. pints, 3 liters). Oil \
should be changed for the first time after 1,200
miles (2,000 km) and thereafter every 12,000 miles
(20,000 km) or at least once a year. SAE 75 EP oil
or SAE 80 to specification API-GL—4 or API—GL—5
should be used. In cold climate SAE 75 must be used.
Automatic transmission »)
The oil in the automatic transmission does not need chang-
ing, but the level must be checked every 6,000 miles
(10,000 km). The filler tube with graduated dipstick is
located immediately behind the radiator. The dipstick
has different level graduations for hot and cold,oil.
When the oil level is measured, the following points
should be observed:
a. Check that the car is level.
b. Idle the engine for a few minutes with the gear selector
lever at P.
c. Shut off thé engine and check that the oil level is be-
tween the min. and max. markings on the dip-stick.
d. If oil needs to be added, the engine should be idled
again before the level is re-checked.
Use a nylon rag, lint-free paper or chamois leather to wipe
off the dipstick — do not use rags that may leave fluff on \
the dipstick. 4
If the transmission needs topping up, use only special auto-
matic transmission oil according to the following recom-
mendations:
Automatic transmission oil according to Ford specifica- )
tion M2C.33F.
Automatic transmission oil Type A, Suffix A and Dexron
may also be used for topping up.
The most scrupulous cleanliness must be observed during
filling.
The oil in the final drive must be checked every 6,000
miles (10,000 km) and changed every 12,000 miles
(20,000 km). Use SAE 75 or 80 EP oil to specification
AP|—GL—4 or API GL—5.
Sept. 1973
Page 89
Every 30,000 miles (50,000 km)
Steering gear as from model 1973
Check the lubricant oil level on the left and right sides.
COLD 1OLING . Checking the lubricant oil level on the left side:
1. Clean the tie rod and the clamp around the protective
bellows on the left side and loosen and pull off the
clamp.
2. Insert a screwdriver between the bellows and the tie
rod along the underside of the tie rod.
3. Set the front wheels straight ahead.
4, Jack up the right side of the car so that the wheels
are suspended 2 in. (5 cm) above the floor.
5. If the steering gear contains the proper amount of oil,
the oil will begin to drip out next to the screwdriver.
6. Use an oil can to top-up the oil to the right level.
7. Re-fit the clamp. Make sure that the threaded end of
the clamp screw is fitted with a rubber cap. Follow the
same procedure on the right side.
8. Do the same check on the right side.
Servo steering gear, special version as from model 1974
Checking the lubricant oil level on the left and right sides.
1. Set the car on its wheels on a level floor. The distance
from the floor to the lower edges of the front bumper
brackets should be 1 ft. 5.7 in. (450 mm) in order for
the tie rod to be at the proper angle. Jack up or load
down the front end of the car to obtain the proper
distance.
. 2. Unfasten and remove the bellows clamps on the tie rod.
l/s 3. Set the front wheels straight ahead.
DRAIN PLUGS, AUTOMATIC TRANSMISSION 4. Insert a screwdriver into the bellows along the under-
1. Engine side of the bellows. (Same procedure on both right
2. Final drive and left sides.)
If the steering gear contains the proper amount of oil,
5. Carburetor oil damper: ___ the oil will begin to drip out.
Use the same grade of oil as for the engine. The oil 5. Use an oil can to top-up the oil to the right level.
level should be so high that the damping piston dips 6. Re-fit the clamps.
into the oil before the thread of the plastic screw
cap engages.
6. Distributor breaker cam:
Grease the cam sparingly.
Distributor lubricating felt under breaker plate:
impregnate the felt with a moderate quantity of
grease.
7. Throttle control:
All throttle contro! bearings are accessible from the
engine compartment. As from model 1972 only the
wire bearing should be oiled.
Hood lock mechanism:
Door hinges and door stops
Oil the hinges by dropping oil into the groove in the
head of the hinge pin. The hinges are accessible from
the front when the hood is open.
Sept. 1973
SAAB 12025
Page 90
Reconditioning
For reconditioning, the following lubrication points are
to be repacked with chassis grease:
Tie-rod end assemblies plus upper and lower ball joints:
Pack bellows 3/4 full.
Front wheel and rear wheel bearings:
Repack.
Inner universal joints up to and incl. the 1969 model:
Fill with 4 oz (100 g) of grease. The quantity will be cor-
rect if the needle bearing grooves are filled first and an
equal quantity is then applied to the bottom of the driver.
Inner universal joints as from the 1970 model:
Fill with grease. The cla Moda be correct if the driver
is completely filled. Wipe éff excessive grease when the
drive shaft is installed.
Outer universal joints: .
The correct quantity of grease is obtained if the cup with
the balls inside is completely filled with grease.
Clutch controls:
Coat the joint with grease.
Release bearing:
Fill the groove 3/4 full.
Handbrake bellows:
Pack the bellows 1/3 full.
Steering gear up to and incl. model 1972
Rack, pinion and all bearings should be greased. The in-
ner joints of the tie-rods are to be filled with grease.
All parts must be thoroughly cleaned before being re-
packed and dirt must be carefully excluded to prevent
unnecessary wear on the parts.
Steering gear as from model 1973
In connection with overhaul of the steering gear fill
approx. 1 cu.in. 0.15 dm3 (1.5 di) oil type EP 90.
120-4
Servo steering gear as from model 1974
Lubricant oil:
When the steering gear is overhauled, add 0.33 pints
(0.19 dm3/litres) of oil at one of the rubber bellows.
Oil grade: EP 90.
Hydraulic oil:
When making repairs on the hydraulic system, hydraulic
oil is added as follows:
1. Add oil to a level 0.4 in. (1 cm) above the lower part
of the strainer in the oil reservoir.
2. Start the engine and re-fill to the above-mentioned
level.
Oil grade: Automatic transmission oil with the same spe-
cifications as that used for the automatic transmission.
The whole servo hydraulic system contains 2.0 | pints
(1.2 dm3/litres).
Fuel
1.7 and 1.85 | engines:
Recommended grade of fuel: carburetor engines 97
octane gasoline; injection engines 91 octane gasoline.
2.0 | engine:
Carburetor engine 94 octane gasoline; injection engine
94 octane gasoline.
Sept. 1973