Page 1
CHASSIS NUMBERS
The chassis number consists of eleven digits. The mean-
ing of the digits is shown in the following example:
ee ee 000.001
Car model —— | ]
Year of model
Place of manufacture:
2 = Trollhattan (Swetten}
3 = Arlov
6 = Nystad (Finland)
? = Malines (Belgium)
Serial number. Each ee}
year begins with 000 001,
Cars made in Sweden
Trollhattan:
Model 1975: Chassis No.
Model 1976: Chassis No.
Model 1977: Chassis No.
Chassis No.
Model 1978: Chassis No.
Chassis No.
Model 1979: Chassis No.
Chassis No.
Model 1980: Chassis No.
Chassis No.
Arlov:
Model 1978: Chassis No.
Model 1979: Chassis No.
Model 1980: Chassis No.
99752000001—99752041733
99762000001—99762040165
99771000001 —99771036086
9977 2000001—99772008024
99781000001—99781027837
99782000001—99782011345
99791000001—99791001493
99792000001—99792006401
99801
99802
99783000001—99783002208
99793000001—99793010090
99803
Cars made in Finland
Model 1975: Chassis No.
Model 1976: Chassis No.
Model 1977: Chassis No,
Model 1978: Chassis-No.
Model 1979: Chassis No.
Model 1980: Chassis No.
Cars made in Belgium
Model 1975: Chassis No.
Model 1976: Chassis No.
Model 1977: Chassis No.
~ Model 1978: Chassis No.
99756000001—99756016176
99766000001 —99766018032
99776000001—99776018461
99786000001—99786013650
99796000001—99796008264
99806
99757000001—99757006197
99767000001—99767007740
99777000001—99777004788 .
99787000001—99787001800
Page 2
ENGINE NUMBER
Engine type:
“'BI’’—gasoline engine, me-
chanical injection
Bl
20 P01
000 001
Cylinder volume in dl
PO3 Automatic transmission, |
USA Federal
P04 Manual transmission,
USA West
USA West
PO6 Manual transmission,
USA Federal —
P03 Automatic transmission,
USA Federal
P04 Manual transmission,
USA West Model 1976
PO5 Automatic transmission,
USA West
PO6 Manual transmission,
USA Federal
PO3 Automatic anenision?]
USA Federal
P04 Manual transmission,
USA California :
Model 1977
PO5 Automatic transmission,
USA California
PO6 Manual transmission,
USA Federal
PO3 Automatic transmission, |
USA Federal
P04 Manual transmission,
USA California
PO5 Automatic transmission,
USA California
PO6 Automatic transmission,
USA Federal =
PO3 Automatic transmission,
USA Federal
PO6 Manual transmission,
M
USA Federal
P04 Manual transmission, > Model 1980
USA bs | ee
Serial number 6 figures -
Model 1975
PO5 Automatic transmission, |
Model 1978
P04 Manual transmission, odel 1979
USA California a
mu
Page 3
\
Gearbox number, automatic trans- \
mission '
Gear box number, manual transmis-
siOn, up to and incl, gear box No.
817.000
Gear box number, manual Transmis-
si0n, as from gear box No, 900.001 e
resp. S 00001 Sf
Engine number
CAR MANUFACTURED BY
SAAB -SCANIA
Trotitittan - Sweden
CAA COLOUR
J57 2C091 925
SAAB
Color code and chassis number sign
——
VENICE EMISHON CONTROL INFORMATION
inp cL ey
PORE ERO tom Wane, Heat) ahh
SME IS AVIVA ARS | Wales Latins bp me
SAALURT € HEE te COW ee, Tee
ee et 1) ee
Faber CLEC Fe
SAMS VOLE WERT Haat
120098 VAC Ror 0s SEC CONRC TED
4 We PRSAA hens amet kom d tp ivi) Wiehe
at VE ok a WrveT eH HOw Rane 10h Hye mums te
vee eer SO OT Awe ew NEL Oe tev Leb e ay fom
SPIE Ars be Coe beRe
a bs a SCAN :
J
Emission control jabel
Chassis number punched in car body,
2-and 3-door models (Placed under
back seat cushion)
om
{Location of chassis number sign inside
| the windshield
/
|
Chassis humber punched in car body,
4- and 5-cloor models (Placed under
back seat cushion)
“1
i
=—
—
—
Page 4
er
| Lubricating oil, grade:
SAE 10 W 30 or 10 W 40. If no oil
} meeting these specifications is available,
| oil with a viscosity of SAE 15 W 40 or
15 W 50 may be used. (In extremely
cold conditions with temperatures con- Service SE in API-system or
stantly below —4°F (~20°C) oil with Ford spec, ESE~M2C—101C
viscosity rating SAE 5 W 20 or 5 W 30
should be used. Note! SAE 5 W 20 or
5 W 30 must not be used at tempera-
tures above +32°F (09°C),
Oil volume incl. filter 3.7 US quarts (3.5 liters)
Oil pump pressure-reducing valve opens at 4.0—5.0 bar (kp/em2, 57-71 psi.)
Oil pressure warning light comes on at 0.3—0.5 bar (kp/cm2, 4.2—7.1 psi.)
Oil pressure at 2 000 rev/min (oil SAE
10 W 40 at 176°F/g0°C) Min. 3.0 bar (kp/cm2, 43 psi.)
Oil pump:
cs é Axial clearance between rotor and housing 0.002—0.003" (0.05—0.09 mm)
FUEL SYSTEM
‘ ; Components
Injection valve up to and incl. model 1979 Bosch 0 437 502 004 As from model 1980 0 437 502 012
Cold start valve Bosch 0 280 170 401
Mixture control unit:
Federal, up to and incl, model 1977,
and California, up to and incl. model
-
ai aan asin al mince
j 1976 Bosch 0 438 040 007
j Alternative on Non-catalyst cars,
; manual transmission, model 1977 Bosch 0 438 040 004
Non-catalyst cars, as from model 1978 Bosch 0 438 040 049
Catalyst cars, model 1977 Bosch 0 438 140014
7 Catalyst cars, as from model 1978 Bosch 0 438 140 051
Air flow sensor:
j Federal, up to and incl. model 1977,
and California, up to and incl. model
1976 Bosch 0 438 120 009
Pa Alternative on Federal, manual trans-
) mission, model 1977 Bosch 0 438 120 013
Non-catalyst cars, as from model 1978 Bosch 0 438 120071
Catalyst cars, model 1977 Bosch 0 438 120 025
Catalyst cars, as from model 1978 Bosch 0 438 120 073
rs Fuel distributor:
| J Federal, up to and incl. model 1977,
and California, up to and incl. mode!
| 1976 Bosch 0 438 100 005
Non-catalyst cars, as from model 1978 Bosch 0 438 100 023
| Catalyst cars, model 1977 Bosch 0 438 100 018
Catalyst cars, as from model 1978 Bosch 0 438 100 032
Warm up regulator:
Up to and incl. model 1976 Bosch 0 438 140 013
Non-catalyst cars, as from model
| 1977 (can also be installed in models
| 1975 and 1976) Bosch 0 438 140 020
Catalyst cars, as from model 1978 Bosch 0 438 140 032
TURBO Bosch 0 438 140 051
Test values
1, Electric fuel pump, capacity up to and 45.7 cu.in./30 s (750 cm3/30 s) min.,
incl. model 1979 measured in the return fuel line
| as from model 1980 900 cm3/30 s).
SAAB 020-5
Page 5
2.
WARM-UP REGULATOR 0 438 140 013 AND
Control pressure, cold engine
kpie
25
20 ie
is
=
10
at rio
MEE
o 10 2 ct) 4 %
§ 6243
0 438 140 020 (UP TO AND INCL. MODEL
1976 AND NON-CATALYST CARS AS FROM
MODEL 1977)
3.
4.
Control pressure, warm engine
Line pressure:
Test value
Setting value
. Leakage check:
Minimum pressure after 20 minutes
As from 1978 model
_ Injection valve:
Opening pressure up to and including
date code 828 (1978)
Opening pressure as from date code
829 (= 1979 model)
Opening pressure © 1980
model
Maximum variation within group
. Adjustment of idling speed:
Idling speed
CO-content:
Non catalyst up to and incl. model
19781)2)
Non catalyst as from model 19801)2)
Catalyst up to and incl. model 19792)3)
Catalyst as from model 19803)
Canada2)
Tightening torques
Air flow sensor:
Stop bracket retaining screws
Counterweight retaining screw
Air flow sensor plate retaining screw
Fuel distributor retaining screws
Line pressure regulator screw plug
M8 bolt
M 10 bolt
M 12 bolt
M 14 bolt
M 12 cap nut
M 14 cap nut
kien
25 + 25
20 it 20) =
Tt Hi
18-4 15
19 1,0
05 os
0 w 20 3%» 40 & o 10 20 n 4
$ 6244 $6318
WARM-UP REGULATOR TURBO
0 430 140 051
WARM-UP REGULATOR 0 438 140 032
(CATALYST CARS AS FROM MODEL 1977)
3.4—3.8 bar (* kp/cm2, 48.5-54.0 psi.)
4.5—5.1 bar (= kp/cm2, 64,0—72.5 psi.)
4.7—4.9 bar (= kp/cm2, 66.9-69.7 psi.)
1.0 bar (* kp/cm2, 14.2 psi.)
1.5 bar ( kp/cem?, 21.3 psi.)
2.5—3.6 bar (= kp/cm2, 35.6—49.8 psi.)
2.7—3.8 bar (= kp/cm?, 38.4—54 psi.)
3.0—4.1 bar (* kp/cm?, 42.6-58.3 psi.)
0.6 bar (= kp/em?, 8.5 psi.)
875 + 50 rev/min
1.25 + 0.75 %
0.75 + 0.25 %
+ 0.25
al 0.5 (sensor disconnected,
after catalyst)
1.0 + 0.25 % (sensor disconnected,
before catalyst)
1.5+05%
1) Pulse air disconnected and plugged
2) Charcoalcanister disconnected
3) Check value with sensor connected,
after catalyst. Max. 0.4 %
4.7—5.3 Nm (3.4—3.8 ft.lb., 47-53 kpcm)
4.7—5.3 Nm (3.4—3.8 ft.lb., 47—53 kpcm)
5.0—5.5 Nm (3.6—4.0 ft-lb. 50—55 kpem)
3.2—3.8 Nm (2.3—2.7 ft.lb., 32—38 kpcm)
13—15 Nm (9.4—10.8 ft.lb., 130—150 kpcm)
10—12 Nm (7.28.7 ft.lb., 100-120 kpem)
13—15 Nm (9.4—10.8 ft.Ib., 130—150 kpcm)
20—24 Nm (14.4—17.4 ft.lb., 200—240 kpem)
15—20 Nm (10.8—14.4 ft.Ib., 150—200 kpcm)
15—20 Nm (10.8—14.4 ft.|b., 150-200 kpcm)
25—30 Nm (18.1—21.8 ft.lb., 250—300 kpcm)
Page 6
Test results
Mechanical:
Brush spring pressure
Backlash
Distance from pinion to ring gear
Contact reserve
Axial play of rotor
Pinion free wheel torque
Electrical:
No load, 11.5 V and 35-55 A
Loaded, 9 V and 205-235 A
Locked starter
Lowest engagement voltage for solenoid
DISTRIBUTOR €
Ignition system with breaker points
Make
Type designation
Ordering No.:
With idler shaft of steel (12-tooth gear)
With idler shaft of cast-iron (20-tooth gear),
up to and incl. model 1976
With idler shaft of cast-iron (20-tooth gear),
as from model 1977
Capacitor
Capacitance
x Basic ignition advance, Federal, up to
and incl. model 1976
yp Basic ignition advance, California, up to
and incl. model 1976
Basic ignition advance, as from model
1977
Basic ignition advance, Canada, manual
transmission as from model 1977
Basic ignition advance, Canada, auto-
matic transmission, as from model 1977
Order of firing
UBreaker gap
Dwell angle
Contact pressure
Direction of rotation
Axial play, distributor shaft
Rotor resistance
Ignition advance curves, see Group 3.
~
11.3-12.8 N (41—46 0z., 1150—1300 p)
0.014—0.024” (0.35—0.60 mm)
0.098—0.118" (2.5—3.0 mm)
0.039" (1 mm)
0.002—0.012" (0.05—0.30 mm)
0.13—-0.18 Nm (1.1—1.6 in.lb., 1.3—1.8 kpem)
6,500—8,500 rev/min
1,000—1,300 rev/min
6 V 325-375 A
8V
Bosch
Bosch JFU 4
Bosch 0 231 170 122
Bosch 0 231 170 158
Bosch 0 231 170 197
Bosch 1 237 330 280
O.2uF + 10%
14%BTDC at 800 rev/min max. and
with vacuum hose disconnected
12° BTDC at 800 rev/min max. and
with vacuum hose disconnected
20° BTDC at 2,000 rev/min and with vacuum
hose disconnected and transmission in neutral
20° BTDC at 2.000 rev/min and
with vacuum hose disconnected
23° BTDC at 2,000 rev/min and with
vacuum hose disconnected and trans-
mission in neutral
1—3-—4-2
0.016” (0.4 mm) min.
50° + 3°
4.9—6.2 N (18-23 oz, 500-630 p)
Counter-clockwise
0.004—0.012” (0.10—0.30 mm)
5,000 ohm
Page 7
RATIOS MANUAL TRANSMISSION AS FROM MODEL 1975
=
as
Er
Mode! / Year| Gearbox Tires Dyn. | Wheel Primary |Counter-| Final| Total Gear ratio Speed/1000 rpm
design- diam.. gear shaft drive = =.
ation 1st |2nd | 3rd | 4th | Sth |Back! Ist | 2nd [3rd [4th [Sth
99 —77 | Running Pirelli 75: 4 1/2" 11 18:33 | 9:35
No upto T55.SR 15 310 76—:5" | 1,00 1,83 3,89 | 13,9/8,1 | 5.4 3,9 |- 14,7|8,7 | 14,5!21,6! 30,0 |—
- and incl. = A p
peng iced 305 id ” ” o” “ o” © a7 <a ” 8.6 14,3 21,2 29.6 i.
se ~ ri Pirelli,
Good year 312 " o ” ‘ " ” ” ” = " 8.8 14.6 21,7 30,2 Hf
165 SR 15
sid . . Pirelli,
Good year 306 " “” ” er ” id “ o“ = ” 8.6 14,3. 21,3 23.6 x
175/70HR15
Ore cee lass |-a a7 (iss, |ese|t2ol7e [52 |ae|= lraaleo liolsoalsiaL.
ol oes 305 ” “ 7 oi o * a ” i ” 88 14,7 22,0 30,6 =
“” ” re Pirelli,
Good year 312 ‘* ” " 4 oy 1, - 2 9,1 | 15,1; 22,5] 31,3 |—
165 SR 15
, ri as Pirelli,
Good year 306 ” ” . . ” a” “ ” == ” 89 14.8 22,1 30,7 ow
_[175/70HR15 |
99 Turbo | 78 | T+running Pirelli, 30:27 | 18:33 | 9:35
No. Good year 306 5” 0,90 1,83 3.89 | 12,0 |7,2 | 49 | 3,5 | ~ 13,2/ 9,6 | 15,9) 23,7) 33,0 |—
is - 175/70HR15
ii ial Yin ‘soon te [310 | os" ag7 |1a3" |sa0|129/78 |52| 38 |— |142/ 90:1 10/223 91.4 1_
ie . " Good year oe id 7 o id 7 7” “ | ” o o o”
) 155SR 15 | 305 r s
ae - 7 Pirelli, ’
Good year 312 ” ” “” ‘e “ ” .” ” x a id or “ “ an
165 SR 15
r ss 1d Pirelli,
Good year 306 ae 7 oe a ” oe ia “ —= 7” “ id aa ” Lon
md i 178/70HR15
99 Turbo | 79— | G44601 Pirelli, 31:26 | 17:33
Good year 306 5 1/2" 0,84 1,94 “a 1.9/7.2 |} 48) 3,3 |— 13,1} 9,7 | 16,1} 23,9) 35,3
____ | 175/70H1R15 _ F’
99 Turbo | 8O— | G45701 Pirelli, 32:25 | 15:34
Good year 306 51/2" 0,78 2,27 -m 12.9/7,8 |5,2| 38 |3,0 14,2) 8.9 | 14,8] 22.0) 30,6 37,9
a 175/70HR15. i
Page 8
Ee
C
Test values
1. Electric fuel pump, capacity
2. Control pressure, cold engine
kp/cm
25
2,0
0 10 20 30 40 %
$ 6243
WARM-UP REGULATOR 0 438 140 020
NON-CATALYST CARS
3. Control pressure, warm engine
4. Line pressure:
Test value
Setting value
5. Leakage check:
Minimum pressure after 20 minutes
6. Injection valve:
Opening pressure, 1979 model up
to date code 828
Opening pressure, 1979 model as
from date code 829
Opening pressure, 1980 model
Maximum variation within group
7. Leakage test
8. Adjustment of idling speed:
Idling speed
CO value
Non-catalyst cars:
0.75 + 0.25 %
Catalyst cars Model 1979:
0.75 + 0:25 %
Catalyst cars Model 1980:
1.0 +0.25%
Canada cars (excl. Turbo):
1.5 +05 %
Tightening torques
Air flow sensor:
Stop bracket retaining screws
Counterweight retaining screw
Air flow sensor plate retaining screw
Fuel distributor retaining screws
Line pressure regulator screw plug
(900 cm3/30 s) min.,
measured in the return fuel line
kp/cm { ——
25 He 25
2.0 - fF ote
1,5 $ : a Bs
10 1,0
0,5 ~ oC
“0 10 2 30 40 % 0 Sei ie
S 6244 $ 6318
WARM-UP REGULATOR 0 438 140 032 WARM-UP REGULATOR TURBO
(CATALYST CARS} 0 438 140 051
3.4—3.8 bar (= kp/em2, 48.5—54.0 psi.)
4.5—5.1 bar (= kp/em?, 64.0—72.5 psi.)
4.7—4.9 bar (* kp/cm2, 66.9-69.7 psi.)
1.5 bar (= kp/cm2, 14.2 psi.)
2.5—3.6 bar (~ kp/cm2, 36,0—52.0 psi)
2.7—3.8 bar (~ kp/cm2, 38.0—54.0 psi)
3.0—3.8 bar (® kp/cm2, 43.0—54.0 psi)
0.6 bar (= kp/cm2, 8.5 psi.)
By a pressure of 2.4 bar (~ 33.8 psi.)
no drop should fall within 15 sec
875 + 50 rev/min
(Sensor discon. After Cat.)
(Sensor discon. Before cat.)
4.7—5.3 Nm (3.4—3.8 ft.lb., 47—53 kpcm)
4.7—-5.3 Nm (3.4—3.8 ft.lb,, 47-53 kpcm)
5.0—5.5 Nm (3.6—4.0 ft.lb., 50-55 kpem)
3.2—3.8 Nm (2.3—2.7 ft.lb., 32—38 kpem)
13-15 Nm (9.4—10.8 ft.lb., 130—150 kpem)
SAAB 022-7°
Page 9
its
iy
Ning
JU
thane aly
uta hin f \|
Mirae , ae
Poon 1
| ithe ain \
S 3476
WATER CIRCULATION IN THE COOLING SYSTEM, 1.7 AND 1.85 L ENGINES, MODEL 1971—1972
ih .
Wii
ge
fin i Shs
Hiatt r
tin Jy f
La My Tyt2arany iin
ny ly a eT Nitra
or em any
UL ogni nt;
Ly
UU
i J
Uy
WATER CIRCULATION IN THE COOLING SYSTEM, 2.0 L ENGINE, AS FROM 1973 MODEL
Page 10
Trouble
Cause
Remedy
Engine runs irregularly,
one cylinder not firing,
exhaust white.
One injector sticking.
Exchange.
Connection to injector or injector coil not in
order.
Check connections, exchange injector. Test
with instrument EFAW 228 S 10.
Engine misfiring but not
caused by ignition
system.
Loose connections, main ground cable has
poor connection to car body.
. Check connections, tighten up ground con-
nection.
Engine not reaching full
power.
Fuel pressure too low.
Check pressure regulator.
Pressure sensor defective.
Exchange.
Throttle valve does not open sufficiently.
Check throttle valve.
Fuel consumption too
high.
“Information” sensors or the control unit not
functioning correctly or the electrical con-
nections have too high contact resistances.
Test the system according to section 3.
Throttle valve switch incorrectly adjusted.
Adjust with test instrument EFAW 228 S 10.
Fuel pressure incorrect.
Check pressure regulator, if necessary ex-
change.
Engine hunts excessively
at idle (between 1,000
and 1800 rev/min)
Hose between auxiliary air regulator and in-
duction manifold detached or defective.
Push hose into position or replace.
Throttle valve stop incorrectly adjusted (too
wide open).
Readjust throttle valve stop.
Idling speed set too high.
Adjust idling speed.
Engine misfires when
accelerating.
Temporary enrichment device in throttle valve
switch not functioning or plug incorrectly
connected.
Check throttle valve switch (test instrument
EFAW 228 S 10).
Too high idling speed.
Idling speed cannot be
adjusted.
234—23
1. Idling air system leaks.
1. Check idling air system.
2. Small rubber sealing ring (item 32, spare
parts list) under the injector leaks.
2. Replace rubber sealing ring.
3. Throttle valve adjustment incorrect.
3. Readjust throttle valve.
Nov. 1972