Page 2
SERVICE MANUAL
rdering number 310813
Supplement to Service Manual 310763
'to .
;.
SAAB-SCANIA AKTI EBOLAG
Saab Car Division
NVkOPING
SWEDEN.
Copyright SAAB-SCANIA
Page 3
FOREWORD
This supplement to Service Manual 310763 describes the
Saab TURBO 1978 model. It should be read together with
the Service Manual. The grouping employed corresponds
to the appropriate sections of the Service Manual.
/
SAAB·SCANIA AKTIEBOLAG
Saab Car Division
NYKOPING SWEDEN
Copyright SAAB-SCAN IA
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Page 4
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CONTENTS
, Technical deviations from standard version
Technical data
Special tools
Additional inspection points
Oil cooler
Fuel boosting, full load
Exhaust system
Exhaust emission control
Radiator fan
Turbo system
Supercharging, general
Turbocharging
Charging pressure regulation
'
Over-pressure guard
Turbo unit
Charge pressure regulator
Pressure switch
Turbo pressure gauge
','
Fault diagnosis chart, Turbo
Electrical system, general
Alternator. . . . . . . . . . . . . . . . . . . .
Breakerless ignition system
Operating principle .•................
Ignition coil and compensating resistor
Distributor
Electronic control unit
Fault tracing, electronic ignition system
Headlight wiper system
Wiring diagram
Wheels
. 020-1
. 020-2
. 101-1
. 110-1
. 223-1
. 240-1
. 252-1
. 254-1
. 262-1
. 291-1
. 291-1
. 291-2
. 291-4
. 291-6
. 291-7
. 291-8
. 291-18
. 291-19
. 291-20
. 300-1
. 321-1
. 340-1
340-2
. 341-1
. 342-1
. 342-1
. 342-4
. 363-1
. 371-1
. 771-1
"
.
I
Page 5
·.
TECHNICAL
SION
DEVIATIONS
Cars with turbocharged
version as follows:
FROM STANDARD
VER-
engines deviate from the standard
Turbocharging system
Cars with turbocharged engines are equipped with a turbo
unit of make Garrett AiResearch. The charging pressure
. from the turbo is governed by a charge pressure regulator
fitted on the exhaust side of the engine and regulated by
the exhaust pressure.
To protect it from overloading, the engine is equipped
with a pressure switch and a pressure gauge actuated by
the charging pressure, and an overpressure guard to prevent over-revving of the engine.
The engine
Altered compression ratio, special pistons.
Special camshaft.
Water pump with 8-vane irnpeller.
Injection system
Mixture control unit with increased capacity
Fuel boosting at full load
Cooling system
Radiator with greater number of cooling passages.
Radiator fan, new design and new location.
Thermostatically controlled air-cooled oil cleaner for engine lubricating oil.
Cooling of battery by means of special air intake
Nov. 1977
Exhaust emission control
Mechanically controlled deceleration system (dash pot).
Echaust system
Larger-bore exhaust pipe.
New type of flanged pipe joints.
Electrical system
Smaller, service-free battery with new location. Removable battery shelf.
Larger alternator with built-in charging relay.
Breakerless ignition system.
New fan motor.
Transmission
Heavier-duty clutch with greater compressive force.
Primary gear with special ratio and chain transmission.
Stronger gear wheel for third gear {increased surface hardness.
Modified mounting of speedometer drive in transmission.
Brakes
Special brake pads, front.
Suspension
Shock absorbers of same type as for Saab EMS.
Wheels
5 1/2-inch light alloy. wheels with hub centring.
020-1
Page 6
TECHNICAL
DATA (DEVIATlONl?'FROM
STANDARD
VERSION)
.,
EnqineNo.
BSI 20 P02 000 001S 00001-
Gearbox No.
Engine
Power rating
Maximum torque
Compression ratio
.·l~ Pistons
Piston rings
Special design, make Mahle
Compression rings of nodu lar iron
0.35 in (9.1 mm)
0.41 in (10.5 mm)
Exhaust valve
Valve timing:
.
'.
145 hp SAE net (107 kW) at 5000 rev/min
174 Ib-ft (235 Nm) at 3000 rev/min
7.2:1
\
Camshaft
Cam Iifting height at valve clearance 0:
Inlet valve
Inlet, nominal valve clearance
;
.,
r
Starts
.
Ends .
Exhaust, nominal valve clearanceStarts
Ends
Valve
120 BTDC
400 ABDC
620 BBDC
20 ATDC
Sodium-cooled exhaust valve
NOTE. Sodium-cooled valves require special handling and should not
be mixed with other scrap. Please refer to the 'service manual 1975-1978
•
FtJel/minimum
octane number
RON 97
Oil volume when changing oil, including .filter change"
Total oil volume, including oil
cleaner (the oil cleaner is not
'drained when changing oil)
Crankcase ventilation
3.0 Imp quarts (3.5 litres)
3.5 Imp. quarts (4 liters)
Hose connection between valve cover
and air cleaner
'Oil cooler, opening temperature
'/ of thermostat
,0
Turbo system
Turbo compressor, make
Maximum charging pressure
(see Measuring the charging
pressure)
Approximate length of spring
in charge pressure regulator
_.•.... (basic setting)
'-'Actuating pressure of pressure
Garrett Ai Research
10.0 ± 0.7 psi (0.70 ± 0.05 bar)
Approx. 0.708 in (ea. 18 mm)
'=::;1·
,switch
020-2
12.8 ± 1.4 psi (0.9 ± 0.1 bar)
Nov. 1977
Page 7
Fuel system
Line pressure:
Test value
Setting value
Device for fuel boost
Throttle valve switch (valve opening
when circuit is closed).
Speed transmitter (actuatinq speed)
Pressure regulator (reduced control
pressure
CO value with throttle valve switch
depressed (CO value at idling speed
set to 1.0-2.0 %)
Deceleration device
Delay time from 3 000 rev/min to
idling speed (warm engine)
Termostatically controlled air preheating
Temperature when valve change
position
j
Electrical system
Battery, capacity
Alternator
Type designation
Rated voltage
74.0-82.5
76.8-79.6
psi (5.2-5.8
psi (5.4-5.6
bar)
bar)
'.,
620
80.0 ± 3.1 mph (130± 5 km/h)
35.6-41.2
psi (2.5-2.9
bar)
approx. 4-6 % CO
"
3-6 s
.. /
60 Ah
'
Bosch Kl-14
14 V
V 65 A 21
Rated speed (speed at which
alternator shall produce at
'least 2/3 of maximum current, i.e. 60 Ah)
Maximum permissible continnuousload
Resistance in rotor winding
Resistance in stator winding
Ignition system
Type
200 BTDC at 2 000 rev/min
and with disconnected
vacuum hose
Distributor
Type
Ordering No. Bosch
Electronic controlunit
Type
,
65A/14V
2.8 ohm ± 10 %
0.10 ohm ± 10 %
Electronic ignition system
without breaker points
Basic setting
v
2 100 rev/min
Ordering No. Bosch
Compensating resistor
at starter motor rpm
total, when driving
Over-revving guard
IGFUD 4
0237005001
TSZ-2 g/l 4/SI
0227 100014
0.6 ohm
1.0 ohm
Rotor with built-in centrifugal
switch which cuts out ignition
when engine speed exceed
6000
+ 200 rev/min
- 100 rev/min
,
Nov. 1977
s.
Page 8
Radiator fan motor
Output
Bosch
190-290
speed)
Speed
About 2 500 rev/min
Type
W (depending on car
The fan switch is directly connected
to battery VOltage, i.e. not across
the ignition switch. This implies
that the fan may continue, or start
to run after the engine has been
switched off.
Headlight wiper motor
Make, type left hand and right
hand design
Output rpm (double-strokes/min)
idling
Current consumption
Current consumption blockated
motor (e.g. frozen wiper blades)
Bosch, AHO 12 V
50-60 strokes
0.75-1.5 A
4.0-5.5
A
The motor is protected against
damage by means of a built in
"PTC" series resistance.
Transmission
Clutch
Type
Diameter
Disc thickness (new), corn-
Single dry-plate clutch with
diaphraqrn spring
81/2 in. (216 mm)
pressive force 4 230 N (948 lb.,
430 kg) between parallel plane
surfaces
The disc must move freely
when the clutch is disengaged
Transmission
1
Oil quantity
Reduction ratio primary gear
Total reduction-ratio (engine:
drive shaft)
1st gear
2nd gear
3rd gear
4th gear
Reverse
Speed at 1 000 rev/min (tyres
12.0 in. (305 mm) radius):
0.26-0.29
in. (6.8-7.4
mm)
0.05 in. (1.3 mm)
2.6 Imp quarts (3.0 litres)
0.9:1
12.0:1
7.2:1
4.9:1
3.5:1
13.2:1
1st gear
2nd gear
3rd gear
9.55 km/h
15.85 km/h
23.62 km/h
4th gear
Reverse
32.85 km/h
8.69 krri/h
Brakes
Brake pads, front
Outer pads (indirect acting)
DM 115 (semi-metallic lining
Inner pads (direct acting)
of make Delco Moraine)
DB 820 (make Dan Block)
·1
020-4
Nov. 1977
-.
Page 9
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Page 10
Special tools, engine
~'----------------------~-----r,
Part No.
8392805
Description
Guide pin, milling of valve seat, charge
Class
Remarks
Illustration
(F@
'.
=:J) )
pressure regulator
8392813
Pressure gauge, charqinq pressure, Turbo
8392912
Sealing pi iers, charge pressure regulator
S5."
101-1
Nov. 1977