Page 141
TRANSMISSION
TRANSMISSION COVER
Removal
Engine removed (can also be done in the car)
1p
2.
>
Install the engine on a work stand.
Remove the alternator and its bracket. (Removed in
connection with lifting out the engine.)
. Remove the fan and fan belt pulley.
. To prevent oil sludge and impurities from entering the
engine, the oil pan must always be removed down-
wards with the engine in the normal position.
. Disconnect the water hoses from the water pump.
. Remove the balance shaft pulley.
. Remove the transmission cover.
NOTE
The oil pan cannot be removed with the engine in-
stalled in the car. Instead, back off and remove the
seven front bolts in the oil pan. If this procedure is
adopted, however, there is a great risk that the front
part of the pan gasket will be damaged.
Installation
. If this job is done in the car, it is nearly always neces-
sary to renew the part of the pan gasket that rests
against the transmission cover. The corresponding
part of a new gasket must then be cut off with a sharp
knife, carefully fitted, and glued to the rest of the
gasket.
. Apply a thin coat of sealing compound to the mount-
ing surfaces of the transmission cover. Put the gasket
in place. Put on the cover and center it with tool
78 62 147 until all the bolts have been tightened.
Febr 1977
INSTALLATION OF TRANSMISSION COVER
1. Transmission cover
2. Centering arbor 78 62 147
3. Lightly oil the pulley shaft. Put on the pulley and
tighten it with a bolt and washer.
4. Apply a coat of sealing compound to the two cor-
ner joints where the transmission cover, the interme-
diate plate and the edges of the oil pan meet. Posi-
tion the oil pan gasket on the block and insert the
two tabs on the cork gasket under the recesses in the
rear bearing cap rubber seal.
5. Install and secure the oil pan. Position the two bolts
with the rubber washers at the rear balance shaft bear-
FITTING THE TWO BOLTS WITH RUBBER WASHERS
Install the fan and fan belt pulley.
Reconnect the water hoses to the water pump. To be
: installed after reassembly together with the gear box.
Install the alternator and tighten the fan belt. To be
A installed after reassembly together with the gear box.
215-1
Page 142
196. Place a support under the short
mp tool 78 62
ran flange onto the new shaft to the
REPLACEMENT OF BALANCE SHAFT SEAL acs the
shaft end and press D Keane ti fi
wn in the figure. Do not refi € sealing
Transmission cover removed dimension show"
washer.
Drive out the seal, using tool 78 62 147.
REMOVAL OF SEAL, TRANSMISSION COVER
Too! 78 62 147 REMOVAL OF FAN BEARING
Tool 78 62 436 and drift
Drive in the new seal in the transmission cover, using
tool 78 62 154, until it bottoms out.
ior INSTALLATION OF FAN BEARING
Tool 78 62 196
INSTALLATION OF OIL SEAL, TRANSMISSION COVER
Too! 78 62 154
REPLACEMENT OF FAN BEARING
Transmission cover removed
To press out the fan bearing, use water pump tool
78 62 436 to hold up the transmission cover.
Press the bearing together with the shaft out from the
transmission cover with an arbor. The sealing washer on
engines up to No. 40 399 will be pressed out downwards
at the same time, and the flange will remain loose on the
transmission cover. Commence reassembly by pressing
the new shaft and bearing into the transmission cover.
Next, place the cover on the length of piping again and
press the new bearing in until it bottoms out, using water
INSTALLATION POSITION FOR FAN PULLEY FLANGE
215-2 SAAB
Nov 1977
Page 143
Transmission Cover mounted in _
1. Remove the radiator and,
panel.
2. Clean the transmission cover.
3. Rapidly heat the part of the transmission cover Sur-
rounding the bearing using a gas torch,
CAUTION
There is a considerable risk of fire when open flames
are used in the engine compartment. Take all the
necessary precautions to prevent fire,
if necessary, the front body
4, Remove the bearing and driver.
5, Press the bearing out of the driver.
7A5
7,15
$6172
PRESSING THE FLANGE ONTO THE NEW BEARING
1. Spacer for flange
6. Press the flange onto the new bearing. Use a spacer as
shown in illustration.
7. Coat the new bearing with Loctite.
. Heat the transmission cover.
co
9. Press the bearing and flange into the transmission cov-
er, and position the bearing against the stop.
2,6
$6173
PRESSING THE BEARING INTO THE TRANS
|. Stop for positioning of fan bearing
2. Transmission cover
Nov 1977
MISSION COVER
TRANSMISSION GEAR
NOTE
The transmission gears can be replaced separately.
The backlashes (side play) valid for the transmission gears
are specified below:
Balance shaft gear |
Camshaft
New gears |0.0020—0.0079 in.| 0.0020—-0.0055 in. |
(0.05—0.20 mm) | (0.05—0.14 mm)
Max. back-
lash (wear- | 0.0157 in. 0.0157 in.
ing limit) | (0.4 mm) (0.4 mm)
A side play of 0.0157 in. (0.40 mm) in the balance shaft
gear is equivalent to 0.022 in. (0.56 mm) on the outside
diameter of the balance shaft pulley.
Changing of the camshaft gear only can be carried out
with the engine in the car after removal of the front panel
and radiator.
See also removal of transmission cover, points 2, 3, 5—7
and for installation points 1 and 2.
When changing the crankshaft gear and balance shaft
gear, the engine must be removed.
Removal
Secure the engine in a work stand.
To prevent oil sludge and impurities from dropping
down into the engine, the oil pan must be removed
downwards with the engine in the normal position.
Remove the balance shaft pulley.
Disconnect the hoses from the water pump.
Remove the transmission cover.
Back off the screws for the camshaft gear and
crankshaft gear.
7. Turn the crankshaft round until the marks on the
gears coincide.
8. Remove the screw and washer for the camshaft
gear. Pull off the gear by hand.
9. Remove the balance shaft gear.
10. Pull the crankshaft gear off the crankshaft, using
tool 78 62 188.
NO —
SAM al
215—3
Page 144
215-4
786218
$2414
REMOVAL OF CRANKSHAFT GEAR
Tool 78 62 188
Installation
1. Insert the key in the crankshaft. Tighten the gear on
the shaft with a bolt and washer to a torque of 49 Nm
(36 ft.lb., 5.0 kpm). Avoid tapping the gear, as this in-
volves a risk of damage to the crankshaft axial bearing.
INSTALLATION OF CRANKSHAFT GEAR
2. Turn the crankshaft until the mark on the crankshaft
gear faces the camshaft.
3, Pass the camshaft gear onto the camshaft so that the
mark coincides with the mark on the crankshaft gear
and secure it with a bolt and washer.
4. Install the balance shaft gear so that the mark coin-
cides with the mark on the crankshaft gear.
S 1142
INSTALLATION MARKS, TRANSMISSION GEAR
5. Apply sealing compound to the mounting surfaces of
the transmission cover. Position the gasket. Put on the
transmission cover and center it with tool 78 62 147
until all the bolts have been tightened.
6. Lightly oil the pulley shaft. Put on the pulley and
tighten it with a bolt and washer.
7. Apply a coat of sealing compound to the corner joints
where the transmission cover, the intermediate plate
and the edges of the oil pan meet. Position the oil pan
gasket on the block and insert the two tabs on the
cork gasket under the recesses in the rear bearing cap
rubber seal,
8. Install and secure the oil pan. Position the two bolts
with the rubber washers at the rear balance shaft bear-
ing.
CAMSHAFT
Removal
(Can also be done with the engine in the car)
Install the engine on a work stand.
Remove the air filter.
Disconnect the vacuum line from the distributor.
Remove the distributor, distributor cap and igni-
tion cables.
Remove the valve covers.
Disconnect the fuel line.
Remove the Carburetor.
Remove the fuel pump and the push rod.
N=
Pnon
NOTE
Mark t
he end of the Pump push rod that rests against
th '
© camshaft for identification at reassembly.
9. Re . ¥
Move the induction Manifold bolts and nuts.
Separate the i i
Nduction i ket
and remove it Manifold from the gas
Nov 1977
Page 145
10. Remove the rocker arm assemblies by alternat
slackening of the two bolts and remove the a
turn plates. =
Remove th 5
11. ae € push rods and keep them in the correct
12. Remove the cylinder heads,
13, Take away the cylinder head gaskets,
14, Remove the tappets with the aid of a bent wire and
keep them in the correct order.
REMOVAL OF TAPPETS BY MEANS OF A BENT WIRE
15. To prevent oil sludge and impurities from entering
the engine, the oil pan must be removed down-
wards with the engine in the normal position. (En-
gine removed.)
NOTE on
The oil pan cannot be removed with the engine in
the car. Instead, back off and remove the seven
front bolts in the oil pan. If this procedure !s adopt-
ed, however, there is a great risk that the front part
of the pan gasket will be damaged.
a
16. Remove the balance shaft pulley. oe
17. Disconnect the water hoses from the water pump.
18. Remove the transmission cover.
ar.
19. Remove the bolt and washer for the camshaft ge
Remove the gear by hand.
20. Remove the camshaft thrust pla
21. Pull the camshaft carefully out ©
te.
f the engine.
NOTE
As the bearings have different diameters,
shaft can only be removed to the front,
rear cover plate is removed.
a
ha plastic
22. Drive the key out of the camshaft wit
mallet and remove the spacer.
Nov 1977
Installation
Lubricate the camshaft bearings with engine oil and
Pass the camshaft carefully into the engine block
Pass on the spacer with the countersunk side facing
the camshaft. Insert the key.
Position the thrust plate over the front of the cam-
shaft so that it covers the main oil galley hole.
AXIAL CAMSHAFT BEARING
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. The spacer
is available in two different thicknesses. To indicate
the size group, the spacers have red or blue markings.
When fitting new parts, choose a spacer giving the
correct axial play. A red spacer gives a small clear-
ance, and a blue one a larger clearance. Axial play
0.00098—0.0030 in. (0.025—0.076 mm).
EASUREMENT OF THRUST PLATE
215-5
Page 146
4, Turn the crankshaft until the mark on the crank-
shaft gear faces the camshaft.
5. Pass the camshaft gear onto the camshaf
the mark coincides with the mark on the crank-
shaft gear. Secure the camshaft gear with a re-
taining bolt and washer.
t so that
§ 1142
INSTALLATION MARKS, TRANSMISSION GEAR
6. If this job is done in the car, it is nearly always
necessary to renew the part of the oil pan gasket
that rests against the transmission cover. The cor-
responding part of a new gasket must then be cut
off with a sharp knife, carefully fitted, and glued
to the rest of the gasket.
7. Apply a thin coat of sealing compound to the moun-
ting surfaces of the transmission cover. Position
the gasket. Put on the cover and center it with tool
78 62 147 until all the bolts have been tightened.
TION OF TRANSMISSION COVER
INSTALLA
1. Transmission cover
2. Centering arbor 78 62 147
10.
11.
12.
oses to the water pump
ect the water h
ft. Put on the pulley and
pulley sha
bolt and washer.
in the groove in the rear main
Conne
Lightly oil the
tighten it with a
Insert the rubber seal
bearing Cap-
Apply a coat of sealing compound to the two cor-
ner joints wt transmission cover, the inter-
mediate plat
Position the oil pan gasket ont
the two tabs on the cork gasket under the recesses
in the rear bearing cap rubber seal.
here the
e and the edges of the oil pan meet.
he block and insert
ure the oil pan. Position the two
Install and sec
bolt
shaft bearing.
s with the rubber washers at the rear balance
FITTING THE TWO BOLTS WITH RUBBER WASHERS
13.
14.
Lubricate the tappets and their bores with engine
oil and install the tappets in the same sequence as
they were originally fitted.
Install the cylinder head gaskets. The gaskets are
marked “Front” and “Top”.
2
°°
-
-
5
=
“
=
th
oO
z
: J
>
aE
INSTA
LLATION OF CYLINDER HEAD GASKET
215-6 Sp
Nov 1977
Page 147
15, Install the complete cylinder heads insert the b
and tighten them in the sequence indi ol
Cated in
stages to the correct torque as per the oir
eaisia’ following
Nm kpm _ft.lb.
1. 54 5.5 40
2. 69 7.0 50
3. 93 9.5 68
IMPORTANT
To ensure effective sealing, the bolts must be tigh-
tened in three stages to the prescribed torque in
| the sequence indicated.
|
ts
ee
17.
Install the induction manifold. Tighten the screws
and nuts with the tightening torque specified in
group 0.
IMPORTANT
To ensure effective sealing, the bolts must be tight- |
ened in two stages to the prescribed torque in the
sequence indicated. |
TIGHTENING SEQUENCE’ INDUCTION MANIFOLD BOLTS
18. Dip the push rod ends in engine oil and install the
push rods in their original positions in the tappets.
19. Lubricate the ends of the rocker arms with engine
TIGHTENING SEQUENCE, CYLINDER HEAD BOLTS oil and install the oil return plates and rocker arm
assemblies. In so doing, align the push rods under
the rocker arms and check that the oil return plates
are not in contact with the valve springs. Secure
NOTE the rocker arm assemblies by alternately tightening
The outer, rear bolt for the righthand cylinder head the two screws. a.
is specially adapted for the engine earth cable. 20. Adjust Siae valve play. See the section “Valve ad-
justment”’.
21. Install the distributor in the engine block. See group
p f the cyl- 3, section 342.
16. Seely ee ee oe pines 25, 22. Install the fuel pump push rod, the gasket and the
duction manifold gasket and make sure that the pump. Install the push rod with the same end against
: 2 linder head gas- the cam as originally.
protruding part of the righthand cy 23. Insert a new gasket in the valve cover. Press the
ket enters the aperture in the induction manifold
gasket.
. ACES
ASSEMBLED CYLINDER HEAD WITH MARKED SURF
OR APPLICATION OF SEALING COMPOUND
Nov 1977
clamp ends of the gasket into the notches in the
cover.
NOTE
Before the valve covers of the cylinder heads are re-
fitted, the lubrication of the rocker shaft must be
checked with the engine running.
215-7
Page 148
$ 124)
INSTALLATION OF NEW GASKET IN VALVE COVER
24.
25.
26.
27.
Install the carburetor and gasket.
Reconnect the fuel and vacuum lines.
Install the distributor cap and attach the ignition
cables.
Install the air filter.
NOTE
Retighten the cylinder head bolts and adjust the
valves when the car has been driven for about 1,200
miles (2,000 km).
215-8
Nov 1977
Page 149
CRANK MECHANISM
CRANKSHAFT
Disassembly
SPN On +
Install the engine on a work stand.
Drain the engine oil, if this h
i as not already been
To prevent oil sludge and impurities from enterin
the engine, the oil pan must be removed down- ,
wards with the engine in the normal position.
Remove the oil pump with its drive shaft.
Remove the balance shaft Pulley.
Disconnect the water hoses from the water
Remove the transmission cover,
Remove the crankshaft gear bolt. Pull the gear off
with tool 78 62 188.
pump.
$2414
REMOVAL OF CRANKSHAFT GEAR
Tool 78 62 188
9. Screw off the clutch thrust plate and remove the
disc.
10. Remove the flywheel.
11. Back off and remove all crankshaft bearing cap
nuts. Remove the bearing caps together with the
bearing inserts.
12. Remove the bolts from the main bearing caps. Re-
move the main bearing caps together with the bear-
ing inserts. ‘
13. Lift the crankshaft carefully out of the engine
block. Slide the oil seal off the crankshaft.
14. Remove the bearing inserts and place them In the
correct sequence for reinstallation.
15. Remove satan gasket fragments from all mount-
ing surfaces.
Reassembly
the
1. Put on the crankshaft gear and secure it to
crankshaft with a bolt and washer.
Febr 1977
INSTALLATION OF CRANKSHAFT GEAR
If a new crankshaft or new bearing inserts are in-
stalled, check that the correct fitting clearance is
obtained, The measuring procedure is described in
this section.
Coat all bearing inserts with engine oil after having
placed them in their bearing positions.
Insert the crankshaft carefully into the engine block
on the bearing inserts and make sure that the mark
on the gear takes up the correct position in relation
to the camshaft gear and the balance shaft gear.
S 1142
INSTALLATION MARKS, TRANSMISSION GEAR
Put on the main bearing caps with inserted and
oiled bearing inserts. Apply a thin coat of sealing
compound to the rear part of the contact surface
of the rear bearing cap.
216-1
Page 150
REAR BEARING CAPS WITH MARKED SURFACES FOR
APPLICATION OF SEALING COMPOUND
NOTE
Fit new connecting rod bolts every time the engine
has been disassembled.
NOTE
The arrows on the center and front main bearing
caps must point to the front.
6. 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 screw 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,
7. Press the crankshaft forwards and pry the axial
(center) 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 inserts
equally ready to bear axially.)
TORQUING THE CENTER MAIN BEARING CAP
216-2
g. Check that the crankshaft runs easily in the bearing
seats. 3
9, Pull the connecting rods up against the crank webs
on the shaft. Put on the bearing caps with inserted
and oiled bearing inserts. Make sure that the marks
coincide. Tighten the new bolts to the prescribed
torque.
10. Apply a thin coat of sealing compound to the trans-
mission cover gasket surface and to the intermedi-
ate plate. Position the gasket. Install the transmis-
sion cover and center it with tool 78 62 148 until
all bolts have been tightened.
INSTALLATION OF TRANSMISSION COVER
1. Transmission cover
2. Centering arbor 78 62 147
11. Coat the inner diameter of the new crankshaft seal
with engine oil and slide the seal onto tool 78 62 170.
Insert the seal so that the distance between the seal
and the rear of the engine block is between 0.36
and 0.38 in. (9.2 and 9.7 mm).
g 241s
Tool 78 62 170
SAAB
Febr 1977