Page 31
TURNING THE UPPER SPRING SEATING ACCORDING TO
THE MARKS
TURNING THE VALVE ACCORDING TO THE MARKS
14.
15.
Fit the spring and the outer spring seating.
Adjust the compressed
length of the spring to the
length measured on dismantling
(the basic length
given in the specifications
is approximate).
Replace and tighten the lock nut. Grip the outer
spring seating by means of polygrip pliers.
FITTING THE DIAPHRAGM
NUT
16.
Fit the gasket and diaphragm
17.
Fit the heat shield.
Check the charging pressure and adjust as necessary, and then seal the charge pressure regulator.
housing
cover.
ADJUSTING THE COMPRESSED SPRING LENGTH
,291-15
SA••
.L
Nov. 1977
Page 32
f'
Measuring the charging pressure
The charging pressure is measured while the car is being
, test driven and is indicated by means of a special pres-
,20'3040/
RPM_lOO
sure gauge connected
to the inlet manifold.
1. Connect pressure gauge 83 92 813 between the nipple
on the inlet manifold and the line to the pressure
switch. Run the hose into the passenger compartment
and place the pressure gauge on the left-hand corner
of the instrument
:::...-f'\
~1O' ~.
.-5
;
50
60i~
f:_ 70A
X
panel.
3
~
S 6298
I
I
I
L_
I
I
-I,
I
I
I
I
I
I
S 6297
I
3RD GEAR, ENGINE SPEED LOWER THAN 1 500 REV/MIN
4: Accelerate
at full throttle
by pressing the accelerator
down to the floor.
EQUIPMENT
FOR MEASURING THE CHARGING
PRESSURE
S 6299
DEPRESSING THE ACCELERATOR
,~
TO THE FLOOR
..I
5. As the engine speed approaches 3 000 rev/min, apply
the brakes (still keeping the accelerator pressed down)
MEASURING
THE CHARGING
PRESSURE
2. Warm up the engine properly
by driving the car on
the road.
3. To start the test, drive the car in 3rd gear at an engine
speed lower than
Nov. 1977
1 500 rev/min.
SA AB
291-16
Page 33
to put the car under full load at 3 000 rev/min and
note the maximum pressure indicated by the pressure
gauge.
Adjusting the charging pressure
(After test driving)
If the reading on the pressure gauge during test driving
deviates from the specified value, adjustment based on
the readings recorded can be carried out as follows:
1. Remove the heat shield mounted in front of the charge
pressure regulator.
2. Disconnect the exhaust line from the cover on the diaphragm housing cover.
3. Remove the diaphragm housing cover.
S 6300
APPLYING THE BRAKES WITH THE ACCELERATOR
PRESSED, ENGINE SPEED 3000 REV/MIN
DE·
REMOVING THE DIAPHRAGM
HOUSING COVER
4. Undo the lock nut using a 10 mm ring spanner. Grip
the spring seating by means of polygrip pliers.
THE MAXIMUM
SURE GAUGE
PRESSURE IS INDICATED
ON THE PRES-
CAUTION
Always grip the valve seat when removing the spindle
nut to avoid damaging the diaphragm. Never attempt
to turn the valve·.
LOOSENING THE LOCK NUT
291-17
Nov. 1977
Page 34
.:
5. Adjust
the tension
of the spring by rotating
Cleaning the charge pressure regulator
(In conjunction
with inspection)
1. Remove the heat shield.
the spring
seating clockwise (inwards) or counter-clockwise
(outwards) in accordance
with the following table. Ensure
that the valve does not turn as the spring seating is rotated.
Thereafter,
Charging
retighten
I
lout
0.82
3/4 out
0.78
1/2 out
0.74
1/4 out
0.70
CORRECT
housing
3. Dry and clean the diaphragm housing using a brush.
4. Replace the cover, exhaust line and heat shield.
Seal ing the charge pressure regu lator
To avert unauthorised
adjustment
of the charging pressure, the charge pressure regulator must be sealed. Fit
the seal to the long diaphragm
bolt which has a hole for
the purpose.
Authorized
Saab workshops
wiH be supplied with sealing
pliers and special seals.
-
Screw the spring seating
in or out the following
number of turns
0.86
line and the diaphragm
cover.
pressure
Charging pressure reading from test driving
(bar)
2. Remove the exhaust
the lock nut.
f----------,--- f--~----------
r---- ~~2- - - - -'/2;~- -
:
1/4 .
066
r- - -
•
VALUE
0.56
3/4 in
0.5f
1 in
-f-
--
,.
SEALING THE CHARGE PRESSURE REGULATOR
Pressure switch
ADJUSTMENT
1. Counter-clockwise
2. Clockwise
6. Replace the cover.and
gasket, exhaust Iine and heat
shield.
7. Test drive the car and check the charging pressure ..
8. Seal the charge pressure regulator.
PRESSURE SWITCH
Checking
1., Start the enqine and have it idle.
2. Disconnect..~he
Nov. 1977
hose to the pressure
switch at the inlet
; 291-18
Page 35
-
----
---------------~------~-----~------~---------
"
manifold and connect gauge 83 92 813, together with
a suitable pump (e.g. cooling system tester) to the
pressure switch hose.
3. Increase the pressure by means of the pump and check
the pressure at which the engine cuts out. Refer to the
specifications in section O.
I'
I
Checking
Check the turbo pressure gauge following the same procedure as that for checking of the pressure switch. At
maximum charging pressure, the needle should be within
the wide orange zone.
At the pressure switch actuating pressure, the needle
should be in front of the limit between the orange and
the red zones.
Removal and installation
1. Remove the three screws at the bottom of the safety
padding on the instrument panel side of the car.
2. Pull the safety padding away to release the spring clips
(see Service Manual, section 853).
3. Disconnect the hose at the joint below the padding
and disconnect the electric cables. Undo the nut underneath the safety padding and remove the instrument.
I
-
..
CHECKING THE PRESSURE SWITCH
Changing the pressure switch
To change the pressure switch, remove the rubber cover
and~bles and then unscrew the pressure switch from its
rnountinq,
Turbo pressure gauge
TURBO PRESSURE GAUGE INSTALLATION
Refit in the reverse order.
To dismantle the instrument, e.g. to replace a bulb, etc.,
remove the screw at the front of the casing.
TURBO PRESSURE GAUGE
291-19
Nov. 1977
,
Page 36
Fault diagnosis chart, Saab Turbo
FAULT
CAUSE
Noise or vibration from
the turbo compressor
Poor lubrication
bearing
Insufficient
pressure
charging
.
Excessive charging pressure
REMEDY
of the turbo shaft
Check the oil pressure and flow to the
turbo. If the fault should persist after
remedial action (permanent bearing
damage) exchange the turbo compressor.
Leakage in the induction or exhaust
system
Tighten leaking connections and replace
defective seals and gaskets
Unbalanced turbo shaft owing to
damage
Exchange the turbo compressor
Leakage between the compressor and
cylinder head or between the cylinder
head and turbine
Tighten leaking connections and replace
defective seals and gaskets
Incorrect setting of charging pressure
Adjust the charge pressure regulator
Valve in charge pressure regulator sticks
in open position
Overhaul the charge pressure regulator
Partially clogged exhaust system
Clean or replace exhaust system
Clogged air cleaner
Change cartridge
Binding turbo shaft
Exchange turbo compressor.
-
Leakage at exhaust pressure line connections
Tighten; if necessary, replace nipples
Clogged exhaust pressure line
Remove and clean
Damaged diaphragm in charge pressure
regulator
Replace diaphragm
Valve in charge pressure regulator sticks
in closed position
Overhaul the charge pressure regulator
Ice formation in exhaust pressure line.
(Excessive pressure occurs 1-2 min
after cold start when ambient temperature below freezing)
Avoid heavy loading of engine immediately after cold starting
Incorrect setting of charging pressure
Adjust charge pressure regulator
I
.
-
Nov. 1977
Page 37
.~~
"
FAULT
CAUSE
REMEDY
Metallic noise from charge
pressure regulator
Play in regu lator valve
Overhaul the charge pressure regulator
Spring insufficiently
sure regulator
Adjust position of spring (replace as
necessary)
Engine knocking (pinking)
offset in charge pres-
Excessive charging pressure
Adjust charging pressure
Unsuitable fuel (octane too low)
Change fuel
Ignition setting too far advanced
Adjust timing
Poor return flow from turbo:
Clogged return line
- Excessive crankcase pressure
Check return line
Check crankcase ventilation
Turbo unit seals damaged
Exchange turbo compressor
'I,
Oil leakage at turbo shaft
seals (oil fumes in exhaust)
,,
291-21
Nov. 1977
",
Page 38
',-
Electrical system, general
Battery
Turbo cars are equipped with a service-free battery.
In common with conventional batteries, this battery contains highly corrosive electrolyte and also produces an
explosive gas which is emitted into the atmosphere.
The battery must therefore be handled with the same
care as conventional batteries.
BATTERY
The battery is located in a specially removable shelf.
Cooling air is supplied to the battery shelf by means of
a hose running from a special duct in the right-hand side
of the spoiler.
Starter motor
The starter motor cables are equipped with special insulation (silicone rubber) to protect them against high temperature.
300-1
Nov. 1977
.,.
Page 39
.LTERNATOR
The alternator otherwise corresponds to earlier Bosch
alternators of this type.
For dismantling, assembly and testing, refer to the service
manual, M 69-74, section 321. The following altered
test specifications apply:
A. Testing the rotor.
Resistance in rotor winding: 2.8 ohm ± 10 % (measured
across slip rings).
B. Testing the stator.
Resistance in stator winding: 0.10 ohm ± 10 % (rectifiers disconnected).
C. Testing at 2/3 maximum current.
At 2100 rev/min the alternator should deliver 44 A.
irhe alternator has a maximum charging capacity of 65 A
and is equipped with charging regulator which forms an
integral unit with the brush housing.
1
S5839
~LTERNATOR
1. Charging
regulator
Charging
current
A
70
J.,.o
60
~
•...I-
I"'"
~
1/
~
/
50
r
,
J
40
I1
J
I
30
I
I1
11
,
20
,
1
10
,
I
o
o
1000
2000
3000
4000
5000
Aternator
6000
rev/min
55883
AMPERAGE OUTPUT DIAGRAM
14 V constant
321-1
voltage
Nov. 1977
Page 40
------
-
-----
--
-
ALTERNATOR
-~-
----
The alternator otherwise corresponds to earlier Bosch
alternators of this type.
For dismantling, assembly and testinq, refer to the service
manual, M 69-74, section 321. The following altered
test specifications apply:
A. Testing the rotor.
Resistance in rotor winding: 2.8 ohm ± 10 % (measured
across slip rings).
B. Testing the stator.
Resistance in stator winding: 0.10 ohm ± 10 % (rectifiers disconnected).
C. Testing at 2/3 maximum current.
At 2100 rev/min the alternator should deliver'44 A.
The alternator has a maximum charging capacity of 65 A
and is equipped with charging regulator which forms an
integral unit with the brush housing.
1i--:-n~
ALTERNATOR
1. Charging regulator
Charging current
A
70
j,..o loo-'
t.,.. ••••
60
~
~
,/
1..1
~
50
r
J
IJ
40
IT
11
30
I
I1
11
20
I
I
I
10
11
o
o
1000
2000
3000
4000
5000
6000
Aternator rev/min
S 5883
AMPERAGE OUTPUT DI,AGRAM
14 V constant voltage
321-1
-
SA~
Nov. 1977