Page 121
ENGINE BODY
8. Take out the spark plugs.
— — 9. Remove the Oil pressure gauge.
10. Remove the valve covers, Release the rocker arm
Install the engine on a work stand assembly by slackening the two bolts alternately
Drain the engine oil. and remove the rocker assembling and the oil return
plates.
SA Nie
Remove the distributor CaP and ignition
Remove the distributor vacuum Haw ena eae
let line by applying pressure with a screwd © fuel in-
hind the washers at the flexible connecti river be-
_ Remove the carburetor. PHenS:
6. Remove the distributor clamping screw a
and then remove the distributor.
7. Remove the fuel pump,
nd clamp
PUMP push rod and gasket.
Ts
[ NOTE
| Mark the end of the pump push rod which rests
| against the camshaft as a guide for reassembly
REMOVAL OF ROCKER ASSEMBLY
1. Rocker shaft with rocker arms
2. Oil return plate
11. Remove the push rods and keep them in the correct
order.
12. Remove the thermostat housing cap, the thermostat
and the gasket.
REMOVAL OF THERMOSTAT
REMOVAL OF FUEL PUMP 1. Thermostat housing cover
1, Pump push rod 2. Thermostat
2. Gasket 3. Gasket
3, Fuel pump
Febr 1977
Page 122
|ts
jing bO
' anifold retal! :
13. Remove the induction raat iderside of
he ul
nuts. It may be necessary to tapt
astic OF le
the front and rear ends with 2 Ds not prize
mallet in order to break ahie #08 nd the €
a screwdriver between the manifold 4
: z Id.
head. Remove the induction manifo
J stay:
14. Remove the bracket for the engine side
15. Back off and remove the cylinder head mee
the heads off the cylinder block. Inspect the Y
der head gaskets for any signs of leakage-
16. Remove the tappets with the aid of a bent
keep them in the correct order.
REMOVAL OF TAPPETS
17. Remove the oil pan retaining screws, the oil pan
and the gaskets.
18. Remove the balance shaft pulley.
19. Back off and remove the transmission cover retain-
ing bolts.
20,
Tap the rear of the water pump with a plastic or
leather mallet to loosen the transmission cover from
the intermediate plate.
21.
Disconnect the water pump from the transmission
cover.
210-2
athe
wire and
and
with
ylindel
REMOVAL OF WATER PUMP
22. Take the oil seal for the balance shaft out of the
: transmission cover with tool 78 62 147.
REMOVAL OF TRANSMISSION COVER OIL SEAL
Tool 78 62 147
23. Remove the oil filter with tool 78 62 014.
gid!
-
—
—
=
~
-_
ee
—
ae
er
—_
_
—
oa
_
=:
-
-—
-
_
REMOVAL OF OIL FILTER
Tool 78 62 014
SAAB
repr 1977
Page 123
«4, Remove the oil pump and its dr
© rive shaft
28. :
Back off and remove the camshaft thrust plate, re-
Move the key and the spacer and pull the camshaft
carefully out of the bearings to the front.
NOTE
As the bearings have different diameters, the cam-
shaft can only be removed to the front, even if the
| Tear cover plate has been taken off. |
29. Remove any redges or carbon deposits from the
upper end of the cylinder bores.
30. Make sure that all connecting rods and caps are
marked so that they can be reinstalled in their origi-
nal positions. Remove the nuts and caps, and push
the pistons with connecting rods out of the cylin-
der bores. Protect the crankshaft bearing necks
from contact with the connecting rod cap screws.
REMOVAL OF OIL PUMP
NOTE
In changing pistons, the connecting rod and con-
necting rod cap must be marked as indicated in the
figure.
95. Remove the bolt and washer for the camshaft drive
gear. Take out the camshaft gear by hand.
26. Pull off the balance shaft gear.
27, Remove the two intermediate plate retaining bolts
and remove the plate and gasket.
MARKING OF CONNECTING RODS
ENGINE: BLOG RON TEE 31. Remove the bearing inserts and caps from the con-
a ieneceaatiate. Fass necting rods and mark them so that they can be
2: taining bolts, Inserigiaciiee 2 reinstalled in their original positions. Install the
caps loosely on the connecting rods from which
they were removed.
32. Remove the crankshaft gear retaining bolt and re-
move the gear with tool 78 62 188.
210-3
Febr 1977
Page 124
REASSEMBLY OF ENGINE
ring inserts in position after having
ea
‘ , b
4 ’ ; if Place all th engine oil.
coated them lightly W!
Sa
REMOVAL OF CRANKSHAFT GEAR -
Tool 78 62 188
x
INSTALLATION OF c
33. Remove the flywheel.
RANKSHAFT
NOTE
Before removing the flywheel, this item and the
crankshaft flange must be marked up in relation
to each other.
2. Place the crankshaft carefully in the bearing seats.
|
34. Using a plastic or leather mallet, drive the balance
shaft rearwards until the sealing washer is out. Care-
fully remove the balance shaft from the rear of the
block.
INSTALLATION OF MAIN BEARING
REMOVAL OF BALANCE SHAFT
3. Install th i i
bear; Ne main bearing caps with inserted and oiled
faring inserts. Apply a thin coat of seali wid
35. Remove the bolts from the main bearing caps. Re- Pound to the rear part of th nile al .
move the main bearing caps together with the bear- i eating = ae
ing inserts.
36. Lift the crankshaft carefully out of the block.
37. Slide the oil seal off the crankshaft.
38. Remove the main bearing inserts and caps from the
block and keep them in the correct order,
Febr 1977
Page 125
NOTE i
The arrows on the center and front main bearing |
caps must point to the front,
4, Tighten the front and rear bearing caps to a torque
of 98 Nm (72 ft.lb., 10.0 kpm). Finger-tighten the
bolts for the center bearing cap.
| NOTE
Do not confuse the screws for cylinder heads and
main bearings. These have the same diameter, but
| the screws for the main bearings are approx. 0.4
in. (10 mm) longer than those for the cylinder
heads.
As from engine No. 74900, the cylinder head screws
have been lengthened approx. 0.4 in. (10 mm) and
consequently there is no danger of confusion.
5, Press the crankshaft forwards and pry the axial (cen-
ter) bearing cap to the rear. Then, tighten the cap
bolts to a torque of 98 Nm (72 ft.lb., 10 kpm)
while holding the crankshaft forward. (This is nec-
essary to make both halves of the bearing insert
equally ready to bear axially.)
TORQUING THE CENTER MAIN BEARING CAP
kshaft
6. Lubricate the inner diameter of the 8 oe
seal with engine oil and push the oe a to a dis-
78 62 170. Drive it into the main bearing
he rear
tance of 0.36—0.38 in. (9.2-9.7 mm) from the
plane of the engine block.
MOUNTING POSITION OF THE CRANKCASE SEAL
REAR CRAN
Pal 9,2—9,7 mm
786217
$2415
KSHAFT SEAL ASSEMBLY
Tool 78 62 170
7. Fit new connecting rod bolts.
shaft has been disassembled.
NOTE
Fit new connecting rod bolts every time the crank-
8. Coat the pistons, rings and cylinder bores with en-
gine oil. Place the piston rings in the following man-
ner:
The oi
| control ring center spring gap 180° from
the mark on the top of the piston; the oil segments
with the gaps staggered 1 in. (25 mm) on either
side of the center spring gap; the lower compres-
sion ring gap 150° from one side of the center
spring
gap and the upper compression ring gap
150° from the other side of the center spring gap.
Installation of the piston rings as above is essential
for optimum sealing and low oil consumption.
Segment ring
et
1 in. (25 mm)
Oil control 11g,
nter spring
ee Compression ring
ge |
[ a)
The mark faces
forward
ce’
rin, (25 mm}
Segment ning
Compression ring
$ 2921
FITTING PISTON RING GAP
SAAB
Febr 1977
210-5
Page 126
coat of sealing compound to the new
sealing washer and drive it into the
t. Install the washer with
13, Apply a thin
9. Install the piston together with connecting rod balance shaft
using tool 78 62 287 by carefully pressing the pis- siexcke itl ¢ bottoms OU
ton with the handle of a hammer. Make sure
the mark on the top of the piston faces forwards.
that
the flat side out.
E
INSTALLATION OF BALANCE SHAFT COVER PLATE
14. Coat the two wedge-shaped seals with sealing com-
PISTON ASSEMBLY pound and press them into the rear main bearing
Tool 78 62 287 cap with a blunt screwdriver.
10. 1f new bearings are installed, check that the correct
fitting clearance is obtained, The measuring proce-
dure is described in section 216.
11. Install the bearing inserts dry in the connecting
rods and then coat them with engine oil. Put on
the bearing caps and tighten the nuts to the pre-
scribed torque.
12. Coat the balance shaft journals and bearings with
engine oil and install the balance shaft from the
rear end of the block.
INSTALLATIO
CAP N OF SEALING KEYS, REAR MAIN BEARING
NOTE
Thed i
Omed side of the seal must be turned to face
15,
Clea
n the crankshaft flange and the flywheel. |
st
INSTALLATION OF BALANCE SHAFT eine flywheel, using new bolts
210-6
Page 127
AXIAL CAMSHAFT BEARING
INSTALLATION OF FLYWHEEL NOTE
The spacer is a little thicker than the camshaft |
thrust plate. The difference in measurement corre-
sponds to the axial play in the camshaft. To indi-
cate the size group, the spacers have red or blue
on the shaft with a bolt and washer, tightening to markings. When fitting new parts, choose a spacer |
giving the correct axial play. A red spacer gives a |
a torque of 49 Nm (36 ft.lb., 5.0 kpm).
- : . || clearance and a blue one a larger clearance.
Avoid tapping the gear, as this may damage the sma
sei ne ae nh Byte Axial play 0.00098—-0.003 in. (0.025—0.076 mm).
16. Locate the key in the crankshaft. Secure the gear
20. Apply a thin coat of sealing compound to the
mounting surface of the intermediate plate on the
front of the block and to the block. Position the
gasket on the block and install the plate loosely
with the two retaining bolts. Temporarily install
the two lower bolts as guide dowels and tighten
the two retaining bolts. Also make sure that the
lower edge of the plate is in line with the level of
the pan. Then remove the guide bolts.
INSTALLATION OF CRANKSHAFT GEAR
: ; iJ and in-
17. Coat the camshaft bearings with Oe ck
stall the camshaft carefully '" the eng
18. Install the spacer with t :
wards the camshaft. Insert the + of the cam- | | |
19. Position the thrust plate over the fron . re,
shaft so that it covers the main ©
INSTALLATION OF INTERMEDIATE PLATE
210-7
SAA
Febr 1975
erpeeee
Page 128
21. Turn the crankshaft until the ma! k on the cran
shaft gear faces the camshaft.
22. Pass the camshaft gear onto the camsh
the mark coincides with the mark on the ¢
gear. Secure the camshaft gear with a reta!
and washer.
23. Install the balance shaft gear so that the mark ¢
cides with the mark on the crankshaft gear.
aft so that
he crankshaft
ning bolt
oin-
S 1142
INSTALLATION MARKS, TRANSMISSION GEAR
24. Install a new balance shaft pulley seal in the trans-
mission cover, using tool 78 62 154.
“ 786215
INSTALLATION OF TRANSMISSION COVER OIL SEAL
Tool 78 62 154
25. Apply a thin coat of sealing compound to the gas-
ket mounting surfaces on the intermediate Plate
and transmission cover. Position the transmissio
cover gasket against the intermediate plate. Con
the transmission cover with the special Silo: ete
210-8
nd secure It with the nine retaining
jitate installation of the water pump,
be secured to the transmission
installed on the engine.
78 62 147 a
bolts. TO faci
the latter should
cover befor
e this is
INSTALLATION OF TRANSMISSION COVER
1. Transmission cover
2. Centering arbor 78 62 147
26.
27.
Lubricate the inner diameter of the balance shaft
pulley seal with engine oil. Align the pulley key
way with the balance shaft key and install the pul-
ley, the flat washer and the retaining bolt.
Insert the oil pump drive shaft in the block with
the pointed end first.
- NOTE
he stop plate on the shaft must be positioned 5.02
in. (127.5 mm) from the blunt end.
wl
Page 129
28.
29.
30.
Install the oil pump. Tighten the actual pu
first and then the suction line bolt PUMP bolts
Insert the rubber seal in tt .
1€ groove in tt
Ve rear main
bearing cap.
Apply a coat of sealing compound to the two c
ner joints where the transmission cover, the inter.
mediate plate and the edges of the oil pan meet
Position the oil pan gasket on the block, and ae
the two tabs on the cork gasket under the recesses
in the rear bearing cap rubber seal.
INSTALLATION OF OIL PAN GASKET
Install and secure the oil pan. Position the two
bolts with the rubber washers at the rear balance
shaft bearing.
31.
nnn
q
=]
—~
i
=
=
\-—-
—
=
—
a
=:
=
ate o
——
—
=
=
H RUBBER WASHERS
FITTING THE TWO BOLTS WIT
bores with engine
32. Lubricate the tappets and site same sequence as
oil and install the tappets in
they were originally fitted.
33. Install the cylinder head gaske
marked ‘Front’ and “Top”:
«. The gaskets ar©
=e
wo
or
se
ao
oc
a
\
INSTALLATION OF CYLINDER HEAD GASKET
34. Install the complete cylinder heads, insert the bolts
and tighten them in the sequence indicated to the
correct torque, tightening in three stages as per the
following table:
Nm kpm
54 5.5 40
69 7.0 50
3: 93 9.5 68
No —
IMPORTANT
To ensure effective sealing, the bolts must be tight-
ened in three stages to the prescribed torque in the
|
|
|
|
sequence indicated.
L__—
——
NOTE |
The outer, rear bolt for the righthand cylinder head
is specially adapted for the engine earth cable.
S|
ae
NG OF CYLINDER HEAD BOLTS
TORQU!
eorent el
210—9
Page 130
———— jmpORTANT
ctive sealing, the bolts must be tight-
effe ; :
To ensure prescribed torque in the
35. Install the bracket for the engine side stay. :
, two stages to the
36. Dip the push rod ends in engine oil and install the |
push rods in their original positions in the tappets.
37. Lubricate the ends of the rocker arms with engine
oil and instal! the oil return plate and rocker arm =
assembly. In so doing, align the push rods under
the rocker arms. Secure the rocker arm assembly
by alternately tightening the two screws.
ened If
sequence indicated.
NOTE
Check that the oil return plate is not in contact with
the valve springs.
TORQUING OF INDUCTION MANIFOLD
40. Install the thermostat, the gasket and the thermo-
stat housing cover in the front part of the induction
manifold, placing the thermostat holder at right
angles to the longitudinal direction of the engine.
41. Adjust the valve play. See the section ’’Valve adjust-
ment’.
INSTALLATION OF ROCKER ASSEMBLY 42. Install a new oil filter. Tighten it by hand until the
1. Rocker shaft with rocker arms oiled rubber seal makes contact with the cylinder
2. Oil return plate block and then tighten it another half turn.
43. Install the fuel pump push rod, the gasket and the
pump. Fit the push rod with the same end on the
cam as originally.
44. Apply sealing compound to the threads of the oil
pressure gauge and install the gauge in the block.
38. Apply sealing compound to the surfaces of the cyl-
inder heads as shown in the illustration. Install the
induction manifold gasket and make sure that the
protruding part of the righthand cylinder head gas-
ket enters the aperture in the induction manifold
gasket. See fig. page 211—2.
ASSEMBLED CYLINDER HEAD WITH MARKED SURFACES
FOR APPLICATION OF SEALING COMPOUND
INSTALLATIO
i ; N OF
39. Fit the induction manifold. Tighten the screws and nit PRESSURE GAUGE
nuts with the tightening torque specified in group 0
210—10
SAAR
cabr 1977