Page 1
SAAB V4.
SERVICE MANUAL
M 1967—1979
Page 2
SERVICE
MANUAL
SAAB \Yy
SAAB 95, 96 AND
MONTE CARLO
MODEL 1967—1979
Ordering Number 305631
SAAB-—SCANIA AKTIEBOLAG
Saab Car Division
NYKOPING SWEDEN
Copyright SAAB--SCANIA
Enbart for spridning utomlands
| SPECIFICATIONS,
TROUBLE SHOOTING
TOOLS, SERVICE,
MAINTENANCE
ENGINE
ELECTRICAL SYSTEM
TRANSMISSION
BRAKE SYSTEM
FRONT ASSEMBLY, STEERING,
COLUMN SHIFT GEAR
SUSPENSION, WHEELS
BODY
INSTRUMENTS, ACCESSORIES,
HEATING SYSTEM
Page 3
March 1979
FOREWORD
This Service Manual has been compiled for the use of service shops as an aid to ser-
vice and repair work which, we hope, will enable all concerned to do a thorough and
successful job. The recommendations and directions contained in this Manual are
based on experience gained up to date. As fresh experience becomes available, the
relevant information will be passed on to Saab general agents and authorized service
shops in the form of ‘Service Informations” (SI). Service Informations should be
filed in a special binder.
Like the Spare Parts Catalogue, the Service Manual is arranged in sections according
to the same system as used in the Repair Catalogue issued by the Swedish Automo-
bile Servicing and Retailing Employers’ Association.
Each section begins with a brief design description followed by detailed descriptions
of the service work relevant to that section.
Technical data such as dimensions, tolerances, tightening torques, etc. are listed in
group 0.
SAAB-—SCANIA AKTIEBOLAG
Saab Car Division
NYKGOPING
SWEDEN
Page 4
Febr 1977
CONTENTS
010 GENERAL
020 SPECIFICATIONS
030 TROUBLE SHOOTING
Page 5
SSS SSS SSS 55>5>55=
SS =
SSSSSSSSSSSSSsSSSS=
010-1
EXTERIOR, SAAB 96 GL
Nov 1977
Page 6
GENERAL
CHASSIS AND ENGINE NUMBERS
hassis
The illustrations below show the locations of the c
ers. To ensure correct identification In
the case of a particular car or engine, these numbers, “<
gether with the mileage, must always be quoted in si
ranty claims, etc. If a exchange engine is fitted in co ‘a
the number of the original engine must, without fal :
stamped in the appropriate place. This is of the utmes
importance if customs difficulties are to be avoided in
the event that the car is subsequently used in a country
other than that of registration.
and engine numb
CHASSIS NUMBERS, AS FROM MODEL 1972
As from mode! 1972, the chassis number consists of elev-
en digits. Explanation of the digits is shown in the follow-
ing example:
96 72 2 000 001
Car type i
Year of model
Place of manufacture
2 = Trollhattan
3 = Arlov
6 = Nystad (Finland)
Serial number. Each model
year befins with 000 001.
Cars made in Trollhattan
Saab 95
Model 1967
Model 1968
Model 1969
Model 1970
Model 1971
Model 1972
Model 1973
Model 1974
Model 1975
Saab 96
Model 1967
Model 1968
Model 1969
Model 1970
Model 1971
Mode! 1972
Model 1973
Model 1974
Model 1975
Model 1975B
Model 1976
Model 1977
010-2
42001 — 50197
52001 — 62059
65001 — 74968
80001 — 88371
95095001 — 95102180
95722000001 — 95722008323
95732000001 — 95732007767
95742000001 — 95742006620
95752000001 — 95752002048
420001 — 458526
470001 — 507018
520001 — 552859
560001 — 592844
96600001 — 96627413
96722000001 — 96722021567
96732000001 — 96732023028
96742000001 — 96742017275
96752000001 — 96752015165
96752060001 — 96752064517
96762000001 — 96762011756
96772000001 — 96772000439
Cars made in Arlov
Saab 95
Model 1975
Model 1975B
Model 1976
Model 1977
Model 1977B
Model 1978
Saab 96
Model 1975B
Model 1976
Model 1977
Model 1977B
Model 1978
95753000001 — 95753003018
95753060001 — 95753061838
95763000001 — 95763003838
95773000001 — 95773001668
95773002001 — 95773003140
95783000001 — 95783001474
96753060001 — 96753060550
96763000001 — 96763001222
96773000001 — 96773004539
96773006001 — 96773009922
96783000001 — 96783004536
Cars made in Nystad (Finland)
Saab 95
Model 1970
Model 1971
Model 1972
Model 1973
Model 1974
Model 1975
Model 1976
Saab 96
Model 1970
Model 1971
Model 1972
Model 1973
Model 1974
Model 1975
Model 1976
Model 1977
Model 1977B
Model 1978
Model 1979
50600001 — 50600838
51600001 — 51601165
95726000001 — 95726000119
95736000001 — 95736000185
95746000001 — 95746000165
95756000001 — 95756000281
95766000001 — 95766000080
60600001 — 60601540
61600001 — 61602639
96726000001 — 96726006009
96736000001 — 96736008344
96746000001 — 96746005605
96756000001 — 96756007419
96766000001 — 96766007634
96776000001 — 96776003753
96776006001 — 96776009247
96786000001 — 9€786006137
96796000001 —
Page 7
Engine number
Nov 1977
Gearbox number
CAR MANUFACTURED BY
SAAB-SCANIA
Trollhattan - Sweden
CAR COLOUR Wi
Color code and chassis
number signs
Chassis number imprinted in car body
010-3
Page 8
GENERAL DATA
Model 1967—1968
Overall length, incl. bumpers
Overall width
Overall height (unladen)
Ground clearance (2 people front)
Track, front and rear
Wheelbase
Turning radius
Empty weight, incl. fuel, coolant, tools
and spare wheel
Total weight, incl. permissible passengers
and luggage
Weight distribution:
Empty
Fully laden, incl. Passengers and luggage
Number of seats (incl. driver)
Available load luggage space
Loading area with driver +4 Passengers
Loading area with driver + 1 Passenger
Trunk height
010-4
Saab 95
14 ft. O in.
(4270 mm)
5 ft. 2 in.
(1580 mm
4 ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4 ft. O in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. Sin.
(5.3 m)
2080 Ib.
(945 kg)
3370 Ib.
(1530 kg)
Front 57 %
Front 44%
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in.
(800 mm)
Saab 96
13 ft. 8 in.
(4170 mm)
5 ft. 2 in.
(1580 mm)
4 ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4 ft, 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 5 in.
(5.3 m)
1940 Ib.
(880 kg)
2880 Ib.
(1300 kg)
Front 62 %
Front 52 %
5
13 cu. ft.
(0.37 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
18.1 in.
(460 mm)
Monte Carlo
13 ft. 8 in.
(4170 mm)
5 ft. 2 in.
(1580 mm)
4 ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4 ft. O in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 5 in.
(5.3 m)
2000 Ib.
(910 kg)
2880 Ib.
(1300 kg)
Front 61 %
Front 51%
ate
13 cu. ft.
(0.37 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
18.1 in.
(460 mm)
Febr 1977
Page 9
Model 1969
Overall length, incl. bumpers
Overall width
Overall height (unladen)
Ground clearance (2 people front)
Track, front and rear
Wheelbase
Turning radius
Empty weight, incl. fuel, coolant, tools
and spare wheel
Total weight, incl. permissible passengers
and luggage
Weight distribution:
Empty
Fully laden, incl. passengers and luggage
Number of seats (incl. driver)
Available load luggage space
Loading area with driver + 4 passengers
Loading area with driver + 1 passenger
Trunk height
Febr 1977
Saab 95 Saab 96
14 ft. 1 in. 13 ft. 9 in.
(4300 mm) (4200 mm)
5 ft. 2 in. 5 ft. 2 in.
(1580 mm) (1580 mm)
4 ft. 10 in. 4 ft. 10 in.
(1470 mm) (1470 mm)
5.1 in. 5,1 in,
(130 mm) (130 mm)
4 ft. Oin. 4 ft. 0 in.
(1220 mm) (1220 mm)
8 ft. 2 in. 8 ft. 2 in.
(2498 mm) (2498 mm)
17 ft. 9 in. 17 ft. Qin.
(5.4 m) (5.4 m)
2160 Ib. 2000 Ib.
(980 kg) (910 kg)
3370 Ib. 2880 Ib.
(1530 kg) (1300 kg)
Front 57 % Front 62 %
Front 44 % Front 52 %
7 5
39 cu. ft. 13 cu. ft.
(1.1 m3) (0.37 m3)
39.4 x 37.4 in. 39.4 x 37.4 in.
(1000 x 950 mm) (1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in. 18.1 in.
{800 mm) (460 mm)
SAAB
010-5
Page 10
—————™———™
Model 1970
Overall length, incl. bumpers
Overall width
Overall height (unladen)
Ground clearance (2 people front)
Track, front and rear
Wheelbase
Turning radius
Empty weight, incl. fuel, coolant, tools
and spare wheel
Total weight, incl. permissible passengers
and luggage
Weight distribution:
Curb weight incl. driver
Total weight
Max. roof load
Max. trailer weight
Number of seats (incl. driver)
Available load luggage space
Loading area with driver + 4 passengers
Loading area with driver + 1 passenger
Trunk height
010-6
Saab 96
14 ft. 1 in.
(4300 mm)
5 ft. 2 in.
(1580 mm)
4 ft. 10.5 in.
(1490 mm)
5.1 in.
(130 mm)
4 ft. Oin.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 6 in.
(5.4 m)
2150 Ib.
(975 kg)
3395 Ib.
(1540 kg)
Front 58 %
Front 45 %
220 Ib.
(100 kg)
2000 Ib.
(910 kg)
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in.
(800 mm)
Saab 96
13 ft. 9 in.
(4200 mm)
5 ft. 2 in.
(1580 mm)
4 ft, 10 in.
(1470 mm)
5.1 in.
(130 mm)
4 ft. 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 6 in.
(5.4 m)
2000 Ib.
(905 kg)
2990 Ib.
(1350 kg)
Front 62 %
Front 51 %
220 Ib.
(100 kg)
2000 Ib.
(910 kg)
5
13 cu. ft.
(0.37 m3)
39.4 x 37.4 in,
(1000 x 950 mm)
60.5 x 37.4 in.
(1540 x 950 mm)
18.1 in.
(460 mm)
Febr 1977