Page 151
15. Install the oil pump. Tighten the actual pump bolts
first and then the suction line bolt.
16. Insert the rubber seal in the groove in the rear main
bearing cap,
17. Apply a coat of sealing compound to the two cor-
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 in-
sert the two tabs on the cork gasket under the re-
cesses in the rear bearing cap rubber seal.
18. Install and secure the oil pan. Position the two ni
bolts with the rubber washers at the rear balance Ay
shaft bearing. in
MOUNTING POSITION OF THE CRANKSHAFT SEAL
12, Coat the two wedge-shaped seals with sealing com-
pound and press them into the rear main bearing
cap with a blunt screwdriver.
'
enn
NOTE
The domed side of the seal must be turned to face
the main bearing cap.
POSITIONING OF BOLTS WITH RUBBER WASHERS
19. Puton the pulley and secure it with the bolt.
Replacement of crankshaft seal
(Engine removed)
INSTALLATION OF SEALING KEYS jsRonspuedthe Glitch:
2. Remove the flywheel.
3. Remove the rear crankshaft seal by means of a screw-
driver.
|, Install 4. Lubricate the inner diameter of the new crankshaft
13. Clean the crankshaft flange and the flywhee seal with engine oil and push the seal onto the tool
ia we flywheel, using new oe 78 62 170. Drive the seal onto the main bearing until
- Install the clutch disc and p it has a distance of 0.36—0.38 in. (9.2—9.7 mm) from
disc with tool 78 40 648. the rear plane of the cylinder block.
5. Clean the crankshaft flange and the flywheel. instal!
the flywheel, using new bolts.
6. Install the disc and the pressure plate. Center the disc
with tool 78 40 648.
ure plate. Center the
Febr 1977
Page 152
Ret
Replacement of disc-shaft bushing
1. Fill the bushing with grease.
2. Introduce centering too! 78 40 648 into bushing and
tap gently with a plastic mallet in order to drive out
the bushing. If necessary, gradually add more grease
as the bushing is being driven out.
REMOVING THE DISC SHAFT BUSHING
Too! 78 40 648
3. Remove all grease from the crankshaft and from the
tool. Take care so that no grease adheres to the fric-
tion surface of the flywheel.
4. Fit a new bushing, using centering tool 78 40 648.
Replacement of ring gear
(Flywheel removed)
1. Make center pops in the ring gear and drill two holes
with a diameter of 0.28 or 0.32 in. (7 or 8 mm) as
shown in the illustration. As a rule, the ring gear splits
off during drilling, but otherwise it can easily be
knocked off with the aid of a chisel.
SPLITTING OF RING GEAR BY DRILLING
= _— | NOTE
ke sure that the drill passes through the ring gear
a
is o the flywheel.
only and not int |
———s ee
a
9. Place the new ring gear on a plate witha thickness of
: 0.08-0.12 in. (2-3 mm) and heat it evenly with a
welding flame from below. Test frequently by placing
the ring gear on the flywheel with pliers until it drops
down onto the flywheel lug.
NOTE es
The ring gear is induction-hardened and loses its
hardness if heated to temperatures above 5549°F
(290°C).
PISTON WITH CONNECTING ROD
Disassembly
1. Install the engine on a work stand.
2. Drain the engine oil, if this has not already been
done.
3. Remove the air filter.
Disconnect the distributor vacuum line.
Remove the distributor, distributor cap and igni-
tion cables.
Remove the valve covers.
Disconnect the fuel line.
Remove the carburetor.
Disconnect the induction manifold bolts and nuts.
Separate the induction manifold from the gasket
and remove it.
10. Remove the rocker arm assembly by alternate slac-
kening of the two bolts and remove the oil return
plate.
11. Remove the push rods and keep them in the correct
sequence.
12. Remove the cylinder head,
13. Take away the cylinder head gasket.
14. Remove the tappets with the aid of a bent wire and
keep them in the correct order.
Carefully remove any ridges or carbon deposits from
the upper end of the cylinder bore.
To prevent oil sludge and impurities from entering
the engine, the oil pan must be removed with the
engine in the normal position. The engine must
not be turned over until this has been done.
Remove the oil pump.
Remove the crankshaft bearing cap nuts. Take off
the caps and bearing inserts and press the piston
Out with the handle of a hammer. Protect the crank-
shaft bearing necks from coming into contact with
€ connecting rod bearing cap screws.
o>
© 2ND
15.
16.
17,
18,
th
NOTE
Note the marks on Piston, connecting rod and bear-
ing cap.
216-4 SAAB
Fer 1977
Page 153
Reassembly
1. lfn
€cessary, clean the piston ring grooves (using a
a a worn piston ring). Lubricate pistons,
: nd cylinder bores with engine oil. Place the
Piston rings in the following manner:
ae oil control ring center spring gap 180° from
eee on the top of the piston; the oil segments
hace on Staggered 1 in. (25 mm) on either
ion € center spring gap; the lower compres- sss
A ring gap 150° from one side of the center aig
Spring gap and the upper compression ring gap 150° wet
f = oeeeee
ee the other side of the center spring gap. |n- we
' : 3 tHe
cies $1233 ; aliation of the piston rings as above is essential my
MARKING OF NS AND CONNECTING RODS or optimum sealing and low oil consumption. ON,
yyy.
YY
ring can be removed by hand, 1 in. (25 mm)
19, The two upper piston rings can now be removed Segment ring Compression ring
from the piston with piston-ring pliers. The center aa Ta
spring and segment in the tripartite oil control /?
Oil control ring, The mark faces
center spring forward
1 in, (25 mm)
Compression ring
Segment ring
S$ 2921
LOCATION OF PISTON RING GAP
2. Fit new connecting rod bolts.
NOTE
Fit new connecting rod bolts every time the crank-
shaft has been disassembled.
PISTON WITH CONNECTING ROD
3. Lubricate the piston and cylinder with a thin coat
of engine oil.
4. Install the piston together with the connecting rod
NOTE z :
: i using tool 78 62 287 by carefully pressing the pis-
As from about engine No. 274 900, the connecting :
rode hein th ded with strengthened big-end ton with the handle of a hammer. Make sure that
: i In this connection, the mark on the top of the piston faces forwards.
bearing caps and longer ae pis cai Concerning piston- and piston ring clearance, see
the following modifications have section 210.
A. The crankshaft counter-weights have been mo-
dified to compensate for the increase in the
weight of the connecting rods. ‘We
B. The oil pump has been slightly modified to tig
greater clearance between the connecting '
and the oil pump.
Old and new type connecting rods
n-
mixed in the same engine. However, the new co
é : ided
necting rods may be fitted in old engines, aoe
that all connecting rods are changed. The stig
e tolerated.
resulting unbalance and play can b
————
must not be
SAAB 216-5
Febr 1977
Page 154
10
FITTING THE T
PISTON ASSEMBLY
Too! 78 62 287
11.
5. _1f new bearings are installed check that the correct
clearance is obtained. The measuring procedure is
described in this section.
6. Install the bearing inserts dry in the connecting rods
and then coat them with engine oil. Put on the bear-
ing caps and tighten to the prescribed torque.
7. Slide the oil pump onto its drive shaft and install it
with the gasket. Tighten the actual pump bolts first
and then the suction line bolt.
8. Insert the rubber seal in the groove in the rear main
bearing cap.
12.
INSTALLATION OF OIL PAN GASKET
9. Apply a coat of sealing compound to the two cor-
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 insert
the two tabs on the cork gasket under the recesses
in the rear bearing cap rubber seal.
216—6
13.
To ensure effectiy
ened in three Stages to th
sequence indicated.
Position the two bolts
he oil pan
stall and secur’ !
In washers at the reat balance shaft
with the rubber
bearing.
WO BOLTS WITH RUBBER WASHERS
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”.
INSTALLATION OF CYLINDER HEAD GASKET
“et the complete cylinder heads, insert the bolts
and tighten them in the sequence indicated in three
s
Stages to the correct torque according to the follow-
ing table:
Nm kpm —ftilb.
ielline ake
2. 69 7.0 50
3. 93 9.5 68
IMPORTANT
@ sealing, the bolts must be tight:
€ prescribed torque in the
Febr 1977
Page 155
$4132
INSTALLATION OF INDUCTION MANIFOLD GASKET
NOTE
The outer, rear bolt for the righthand cylinder
head is specially adapted for the engine earth cable.
———
14.
Apply sealing compound to the surfaces of the cyl-
15;
Install the induction manifold. Tighten the screws
and nuts with the tightening torque specified in
group 0.
inder heads as shown in the figure, Install the induc-
tion manifold gasket, and make sure that the pro-
truding part of the righthand cylinder head gasket
enters the aperture in the induction manifold gas-
ket.
IMPORTANT
To ensure effective sealing, the bolts must be tight-
ened in two stages to the prescribed torque in the
sequence indicated.
ASSEMBLED CYLINDER HEAD WITH MARKED SURFACES
FOR APPLICATION OF SEALING COMPOUND
16.
17;
18.
19.
Febr 1977
TORQUING THE INDUCTION MANIFOLD
Dip the push rod ends in engine oil and install the
push rods in their original positions in the tappets.
Lubricate the ends of the rocker arms with engine
oil and install the oil return plate and the rocker
arm assembly. In so doing, align the push rods
under the rocker arms. Check that the oil return
plates are not in contact with the valve springs. Se-
cure the rocker arm assembly by alternately tight-
ening the two screws.
Adjust the valve play. See the section “Valve ad-
justment”’.
Install the distributor and secure it with the clamp.
Adjust the ignition setting.
Insert a new gasket in the valve cover. Press the
clamp ends of the gasket into the notches in the
cover.
216—7
Page 156
§ 1241
INSTALLATION OF NEW GASKET IN VALVE 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.
21. Reinstall the distributor cap and attach the ignition
cables.
22. Reinstall the carburetor, together with its gasket.
23. Reconnect the fuel and vacuum lines.
NOTE
Retighten the cylinder head bolts and adjust the
valves when the car has been driven for about
1,200 miles (2,000 km).
Piston pins
The piston and piston pin comprises a complete unit and
the two must be replaced together. The piston pin bore
and the piston pin are colour coded according to class
and must agree. The colour marking is located at the bot-
tom of the piston and on the outer edge of the piston
pin.
The piston pin is shrunk into the small end of the con-
necting rod. It is therefore of utmost importance to in-
stall the piston pin swiftly and correctly in the small end
of the connecting rod while it is still hot since the posi-
tion of the piston pin cannot be altered once the con-
necting rod has cooled.
Removal ;
1. Using a press, press the piston pin out of the piston
(use a drift with a diameter a few millimeters smaller).
Scrap the piston and piston pin.
2. Measure the connecting rod by means of a gauge and
a surface plate.
216-8 SAAB
_ 7
|
——
~o-o10mmtT
ee
p> ea
~ {J0-015m
CHECKING THE CONNECTING ROD S 5284
Installation
1. Place the piston on a flat surface (3/4—1 in./20—25
mm wide) so that the outer surface in the rectangular
recess at the piston pin end rests on the surface (see
the markings in the illustration).
OOO eG
SORT
r OS
Ko Osa
%%
HH S$ 5285
RECTANGULAR RECESS AT THE PISTON PIN END
§ 5286
POSITION FOR DOLLY
Febr 1977
Page 157
2. On installation, ensure that the mar
the piston and the lubricating hole j
rod are aligned as shown in the illus
K On the front of
n the connecting
tration,
UL
CONNECTING ROD posit T INST T
ON AT INSTA | wn
¢ z STALLATION OF Hie
MOUNTING POSITION OF THE PISTON
3. Heat the small end of the connecting rod to a tempera-
ture of between 500 and 570°F (260—300°C). Before Any
heating, coat the small end of the connecting rod with
pyrometric paint (e.g. Faber Castell 2815) to facilitate
temperature checking. When the correct temperature
has been reached, the paint will change colour in ac-
cordance with the tone of colour given on the package
for the paint.
4. Once the correct temperature has been obtained, in-
sert the connecting rod as swiftly as possible in the l i i
piston so that it butts against the lower piston pin
bearing in the piston. Using a drift, fully insert the
piston pin through the connecting rod, again, as S 5289
quickly as possible.
N.B. Ensure that the connecting rod is correctly aligned
in the piston (see point 2).
INSERTING THE PISTON PIN
5. Keep the connecting rod in this position until it has
cooled.
SAAB 216-9
Febr 1977
Page 158
CRANKSHAFT BEARINGS
Disassembly
1. Install the engine on a work stand,
2. To prevent oil sludge and impurities from entering the
engine, the oil pan must be removed downwards with
the engine in the normal position.
. Remove the oil pump with its drive shaft.
4. Remove the crankshaft bearing cap nuts and take off
the bearing caps and bearing inserts.
5. Press the connecting rod away from the crankshaft
and remove the bearing insert.
Ww
Reassembly
1. Fit new connecting rod bolts.
NOTE
Fit new connecting rod bolts every time the crank-
shaft has been disassembled.
2. To ensure that the fitting clearance is correct, the
clearance should be measured.
3. Install the bearing inserts dry in the connecting rods
and then coat them with engine oil.
4. Pull the connecting rod against the crank pin and put
on the bearing cap. Make sure that the marks on con-
necting rod and bearing cap coincide. Tighten the nuts
to the prescribed torque.
MARKING OF PISTONS AND CONNECTING RODS
Slide the oil pump onto its drive shaft and install it
5. ‘ oecaatknt Tighten the two bolts for the actual
Fr ;
p first and then the suction line bolt.
um
p | in the groove in the rear main
6. Insert the rubber sea
bearing Cap. 2s
if a new crankshaft or new bearing inserts have been
installed, check that the correct fitting clearance js
obtained.
MEASURING THE CLEARANCE, CRANKSHAFT AND
CONNECTING ROD BEARINGS
The clearance is measured with Plastigage. Plastigage is
available under spare part number 78 60 505.
Plastigage is supplied in three different thicknesses. Type
PG-1 (green) must be used, since this type allows measu-
rement of clearances from 0.00098 to 0.00299 in. (0.025—
0.076 mm).
Instructions for the use of Plastigage
1. Position the engine with the cylinder head facing
downwards to prevent the weight of the crankshaft
from influencing the measurement of main bearing
clearance.
The weight of the crankshaft does not influence the
measurement of the connecting rod bearing clearance.
2. Make sure that the parts to be measured are free of
oil and dirt. Install a dry bearing insert in the bearing
cap and position a strip of Plastigage in the insert
about 0.236 in. (6 mm) off center.
MEASURING PLACE FOR PLASTIGAGE
216-10 SAAB
Febr 1977
Page 159
3, Make sure that the crankshaft is shor
. lower dead center (about 30°). With
in this position, install the bearing ca
and Plastigage and tighten the bearin
prescribed torque.
NOTE
Do not turn the crankshaft durin
procedure. When measuring the
tly behind the
the crankshaft
P with insert
§ Cap nuts to the
g the measuring
connecting rod
bearing clearance, also make sure that the connec-
ting rod is not moved.
|__|
Remove the bearing cap. The Plastigage strip will be
. found pressed in the bearing cap or on the crankshaft
ieanire the width of the flat pressed Plastigage strip
5. by means of the scale printed on the Plastigage packing
nd read off the clearance. One side of the packing
oe the reading in mm and the other side in thousand
g
f an inch. :
le the Plastigage at its widest point but do not
touch it with the fingers.
E STRIP
MEASURING OF FLAT PRESSED PLASTIGAG
Febr 1977
Conicity of a crankshaft journal
ists j of the
Conicity of a crankshaft journal exists if one site
flat pressed Plastigage strip is wider than the other.
Ovality of a crankshaft journal
er mea-
Having completed the above Roeasurament, mae ep
surement must be undertaken after having turne ee
crankshaft through 90°. The difference between
i aft
Measurements indicates the ovality of the cranksh
journal.
216-11
Page 160
OIL PAN
REMOVAL
1. Install the engine on a work stand.
2. To prevent oil sludge and impurities from
the engine, the oil pan must be removed d
with the engine in the normal position,
entering
Ownwards
INSTALLATION
1, Insert the rubber seal in the groove in the rear main
bearing cap.
INSTALLATION OF OIL PAN GASKET
Febr 1977
2. Apply a coat of sealing compound to the two 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 bear-
ing cap rubber seal.
» Install and secure the oil pan. Position the two bolts
with the rubber washers at the rear balance shaft
bearing.
FITTING THE TWO BOLTS WITH RUBBER WASHERS
217—1
ST)
nner