Page 161
OIL PUMP
REMOVAL
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.
3, Remove the two bolts in the oil pump flange and the
retaining screw for the oil pump suction line. Remove
the oil pump and its drive shaft.
REMOVAL OF OIL PUMP
INSTALLATION
1. Pass the drive shaft into the engine block with the
pointed end facing the distributor. '
NOTE! The holding ring must be located on the drive
shaft.
Pees ; 25.8 .
S 1240
DRIVE SHAFT WITH HOLDER RING
Febr 1977
2. Push the oil pump onto the drive shaft and install it.
Tighten the actual pump bolts first and then the suc-
tion line bolt,
3. 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 bearing
cap rubber seal.
4. Install and secure the oil pan. Position the two bolts
with the rubber washers at the rear balance shaft bear-
ing.
L
FITTING THE TWO BOLTS WITH RUBBER WASHERS
NOTE
The gasket between the oil pump and the engine
removing and installing the pump.
block has been left out and need not be fitted when
221-1
Page 162
OVERHAULING WITH A REPAIR KIT
Disassembly
1. Unscrew the suction line from the oil pump.
2. Unscrew the oil pump cover. Remove the inner and
outer rotor from the oil pump housing.
3. Make a hole in the relief valve cover plate with a drift.
Pull out the cover plate with a suitably sized selftap-
ping screw.
REMOVAL OF RELIEF VALVE COVER PLATE
4. Remove the spring and the oil relief valve.
CHECKING AXIAL CL
Correct clear
2. Check the clearance betw
EARANCE OF ROTOR
ance 0.004 in. (0.1 mm)
een the outer rotor and the
p housing with a feeler gage. If the maximum
oil pum
a new pump hous-
permissible clearance is exceeded,
ing must be used.
CHECKING RADIAL CLEARANCE OF ROTOR
Correct clearance 0.012 in. (0.3 mm)
NOTE
Take great pains to remove all grinding dust from
the parts before assembling. The inner rotor and
the drive shaft constitute one spare part.
OIL PUMP, DISMANTLED
1. Housing 5. Spring 3
2. inner and outer rotor 6. Cover plate
3. Cover 7. Gasket ‘
4, Relief valve 8. Suction line *
5
Reassembly
1. Insert a new outer and inner rotor in the pump hous- 6
ing. Check the clearance between the sealing surface
of the pump housing and the front sides of the outer
and inner rotor with a ruler and a feeler gage. If neces- 5
sary, grind the sealing surface of the oil pump housing
or the rotor sides with a fine emery cloth on a face
plate.
221-2 SAAB
. Install the relief valve and spring and coat them lightly
with engine oil.
Install a new cover plate with the flat side pointing
outwards. Press it in until it bo i
ere ttoms out against the
. Using a blunt, round-tipped drift with a diameter of
about 0.48 in. (12 mm), tap the middle of the cover
plate in order to press it home.
. In
stall the rotors and coat them with engine oil. Put
th
or ni on the pump housing and tighten the bolts
rotor paving torque. Insert the drive shaft in the
aft and check that the pump runs easily.
. In : a
stall the suction line with a new gasket to the oil
pump housing.
Febr 1977
Page 163
OIL FILTER
CHANGING OF FILTER CARTRIDGE
Use tool 78 62 014 to remove the oil filter Cartridge. Un-
screw the cartridge. The cartridge cannot be cleaned and
should therefore be renewed at the Prescribed intervals
(every 6,000 miles or 10,000 km). Apply a little oil to
the rubber gasket on the new cartridge. Screw in the
cartridge until the gasket makes contact with the
block and then tighten half a turn.
qt!
t!
tee
al
—
engine
goer eres
NOTE
| Excessive tightening of the cartridge involves a risk
of leakage, as the rubber seal may then tilt in its
groove.
ll ecaioome
VT ELERE BEE
REMOVAL OF OIL FILTER CARTRIDGE
Tool 78 62014
Oo)
SAAB
Febr 1977
222-1
Page 165
CARBURETOR
Carburetor, make Solex, mode|
' s
1967 and 1968
REMOVAL
1, Drain off some of the cooling water
2, Remove the air cleaner.
Febr 1977
CARBURETOR, SOLEX, PRINCIPLES
A Float chamber
B Float chamber cover
C Throttle body assembly
D Housing, automatic choke
1. Main jet
2. Emulsion jet
3. Idling jet, fuel
4, Float
5. Choke tube
6. Float valve
7. Connection, fuel hose
8. Connection, vacuum hose, distributor
9. Air-regulating screw, idling mixture
10. Adjusting screw, idling
um line,
i Disconnect the fuel line.
Remove the carburetor.
. Carburetor 32 PDSIT—4:
. Disco
Bsn on the hoses from the automatic choke.
nect the throttle control linkage and the vacu-
Disco
nnect the hose from the valve cover. Then it is
ssi ‘
Possible to remove the intermediate flange.
8. Ca
refully cover the opening in the induction pipe.
11, Throttle valve
12. Choke valve
13. Ascending pipe, additional system (econostat)
14. Diaphragm, acceleration pump
15. Bimetal spring for automatic choke
16. Coolant connections
17. Diaphragm for vacuum contro} of automatic choke
18. Regulating device, float chamber ventilation
(only on carburetor 32 PDSIT-4)
19. Idling air jet (drilling)
20. Acceleration pump
21, Inlet valve, acceleration pump
22. Outlet valve, acceleration pump
23. Intermediate flange
231-1
Hite
seeteee
ee
Page 166
DISASSEMBLY
1. Remove the retaining ring from the control rod be-
ai the automatic choke and the throttle viave.
3 etach the link from the throttle valve arm.
- Unscrew and lift off the float chamber cover. Re-
move the gasket.
3. Screw out the needle valve.
4. Take the float out of the float chamber
5. Remove the plug from the float chamber and remove
the jet.
6. Pull off the acceleration pump jet (over the accelera-
tion pump).
7. Screw off the idling jet and the emulsion tube jet.
8. Screw off the acceleration pump cover and check
the diaphragm.
9. Screw off the idling mixture air-requlating screw.
10. Carburetor 32 PDSIT-4:
Remove the intermediate flange valve.
REASSEMBLY
NOTE! Clean all passages and jets with a blast of com-
pressed air. Change all parts included in the gasket and
repair kit.
1.
wo
10.
11.
Install the spring, diaphragm and cover for the ac-
celeration pump.
Insert the acceleration pump jet.
Screw in the idling jet and the emulsion tube jet.
Advance the idling mixture air-regulating screw
carefully until it bottoms out then back it off one
complete turn.
Insert the float.
Screw the needle valve with original gasket into the
float chamber cover.
Install a new cover gasket.
Put on the float chamber cover and replace the re-
taining screws.
Pass the rod between the automatic choke and the
throttle valve into the throttle valve arm and secure
with the retaining ring.
Set the valve arm in the semi-open position and at
the same time fully close the choke valve with the
fingers. Meanwhile, hold the valve arm firmly and
make sure that the throttle valve is ajar. The clear-
ance between the valve and the flange must be
0.032 in. (0.8 mm). This can be checked with a
wire or drill bit of the same diameter. To adjust
the clearance, slacken the nuts on the linkage rod
for the fastidling system and then adjust the rod so
that the valve takes up the correct position. Then re-
en the rod and lock it in the correct position.
ight
os ” Adjustment of
For final adjustment, see under
automatic choke”.
Carburetor 32 PDSIT-4:
Fit the intermediate flange valve.
231-2
INSTALLATION
1. Carburetor 32 PDSIT—4:
Fit the intermediate flange, with new gaskets.
2. Install a new gasket, put on the carburetor and tighten
it up evenly.
Reconnect the fuel and vacuum lines.
Reconnect the throttle control.
5. Reconnect the coolant hoses and tighten the hose
Pw
clamps.
6. Refill the cooling system and bleed the system.
7. Install the air cleaner.
CHECKING AND ADJUSTMENT OF FLOAT LEVEL
The fuel level in the float chamber should be measured
while the engine is idling and should be nominally 0.59
in. + 0.04 in. (15 + 1 mm).
The level is decided by the thickness of the float valve
sealing washer. If the level is too high, a thicker washer
should be fitted and conversely a thinner washer must
be fitted to adjust too low a level. The float level is mea-
sured from the top of the float chamber cover to the fuel
level. Measuring can appropriately be carried out with tool
78 60 984 which is connected at the site of the jet plug
in the float chamber.
IDLING ADJUSTMENT
NOTE! The idling speed must be adjusted when the en-
gine has reached the normal working temperature and
the headlights switched on. Depending on the mileage,
the adjustment should be preceded by a check of the
spark plug electrode gap, the ignition setting and the
valve play.
1. Reduce the engine speed so that the engine runs as
slowly as possible or at max. 500 rev/min.
2. Adjust the volume contro! screw until the engine runs
as smoothly as possible.
3. Switch on the headlights (high beam) and increase
the speed to 800—900 rev/min with the idle adjusting
screw.
Febr 1977
Page 167
ADJUSTMENT OF AUTOMATIC CHOKE
Adjustment of the automatic choke involy
tions, viz. setting of the choke lights and ¢
justment. These two tasks are described b
&s tWo opera-
ast-idling ad-
elow.
Adjustment of choke flap
Temperature setting
The automatic choke is set for the choke valve to open
wide at a temperature of GO—65°C (140—1499F).
The setting mark on the rotatable thermostat housing
must coincide with the middle one of the five fixed set-
ting marks comprising the adjustment range,
Turning clockwise makes the choke open later.
ADJUSTMENT OF THERMOSTAT HOUSING
Adjustment of thermostat housing after removal T
1. Hook the bimetal spring onto the driver cam. !urn
the thermostat housing the sh
ting marks coincide.
2. Check that the choke valve stretches to
Closed position.
wards the
Febr 1977
Fast-idling adjustment
1. Remove the air cleaner.
2. Operate the engine until it reaches normal! working
temperature, Then switch on the headlights.
3. Connect a tachometer to the engine.
4. Adjust the engine to the correct idling speed, i.e.
800—900 rev/min.
5. Close the choke valve a little, in order to make it
contact the ratchet wheel in the starting automat-
ics, Hold the choke valve in this position, and keep
pressing it towards the ratchet wheel.
6. Open the throttle valve cautiously, enough to allow
the choke valve to move to the next position. First
release the throttle valve cautiosly, and then the
choke valve. The step which serves to increase the
idling speed, is now in the first position (first step)
of the ratchet wheel.
7, The throttle contro! must not be touched at this
stage, as the ratchet wheel would then revert to the
neutral position. For safety’s sake, the control rod
should be pushed up hard with the fingers.
8. When the throttle valve is in this position, the en-
gine speed should be between 1 200—1 300 rev/min.
Adjust the length of the control rod.
To increase the speed = lengthen the rod
To reduce the speed = shorten the rod
NOTE
After having performed this adjustment, check that
the control rod does not jam in the throttle contro!
lever owing to twisting during tightening of the two
adjusting nuts.
ortest way until the set-
9. Inorder to check the good functioning of all stages
of the fast-idling (see page 200—7), check the numb-
er of revolutions of the third step. Same shall be
2 600—3 000 rev/min.
10. Recheck the idling speed and adjust if necessary.
11. Disconnect the tachometer and install the air clean-
er. In principle, the above adjustments shall be per-
formed only if the engine is difficult to start at low
temperatures and when a check has shown that
there are not other faults in the system.
Page 168
Carburetor, make FoMoCo,
models 1969—1975 |
REMOVAL
Remove the air cleaner.
Detach the coolant hoses from the automatic choke.
Remove the throttle control.
Detach fuel- and vacuum hoses.
Remove the carburetor.
Cover the orifice of the suction pipe.
OAfWNnN>
\
REMOVAL OF THERMOSTATIC SPRING HOUSING BOLTS
DISASSEMBLY
1. Remove the three bolts and detach the thermosta-
tic spring housing.
a)
Unscrew the step cam from the throttle body.
3. Unscrew the bolts retaining the float chamber cover,
and lift the cover off. Collect the spring of the float
chamber cover. Remove gasket. By holding the
float chamber upside down, remove the ball and
the weight from the accelerating fuel channel.
$4196
CARBURETOR, FOMOCO, PRINCIPLES
A Thermostatic spring housing 6. Throttle valve
B Choke flap housing 7, Choke valve
C Float chamber cover 8. Step cam
D Float chamber 9. Acceleration pump
1. Main jet 10. Ball and weight, accelerating pump fuel channel
2. Volume screw, idling mixture 11, Float chamber ventilation, alternative designations
3. Idling screw 12, Coolant connections
4. Float 13. Fuel connection
5. Float valve 14, Vacuum connection, distributor
1977
231-4 Febr
Page 169
BALL AND WEIGHT, ACCELERATING PUMP FUEL
CHANNEL
Unscrew the bolts in the accelerating pump cover.
Remove cover, diaphragm and spring.
5. Remove accelerating pump rod from the lever of
the throttle valve shaft. Remove the lever.
6. Remove idle mixture control screw, and idle ad-
justing screw as well. Collect the springs.
7. Remove throttle valve.
8. Remove (by using a contact file) the possible burrs
from the threaded bores in the throttle valve shaft.
Only then pull out the shaft.
9. Remove the float. Unscrew float needle valve.
10. Unscrew main jet.
11. Unscrew the automatic choke housing from the car-
buretor.
12. Pull out the pins of the air cleaner mounting yoke.
Remove yoke.
13. Remove choke plate.
14. Remove (by using a contact file) the possible burrs
from the threaded bores in the choke plate shaft.
Only then pull out the shaft.
REASSEMBLY
Clean the carburetor. Clean with compressed air all chan-
nels, passages and jets. Renew gaskets and possibly de
fec-
tive parts.
Us
Mount the throttle valve shaft in the throttle body.
Fit the accelerating pump lever on the throttle
valve shaft, turn the side marked “O” upward ve
Fit the throttle valve so, that the face atin
two punched marks faces downward when f of.
throttle is kept closed. Prior to tightening ee ’
see to it that the valve centers in closed position.
Check that the shaft moves easily.
Nov 1977
LOCATION OF FITTED THROTTLE VALVE
11.
Fit the following screws of the idle device: mixture
control, and idle adjusting. Fit the springs too.
Fit the accelerating pump rod, between the levers
of the accelerating pump and the throttle valve.
Fit the accelerating pump diaphragm, and its spring.
NOTE! The small end of the spring shall face the
diaphragm. Fit the cover.
Fit the choke plate shaft. Prior to tightening the
bolts, see to it that the choke plate centers in
closed position, Check that the shaft moves easily.
Fit the air cleaner mounting yoke, and drive the
pins in.
Fit the automatic choke housing, with its gasket,
and connect accelerating pump rod to choke plate
shaft.
Screw the main jet on.
Screw needle valve on and fit float. Regarding
checking and adjustment of float level, see page
231-6.
Insert ball and weight in the accelerating pump
channel,
231-5
Page 170
CHECKING AND ADJUSTMENT OF FLOAT LEVEL
1. When checking the measurement A, which shall be
. 1.08 in. (27.5 mm), hold the float chamber cover per-
pendicularly, with a view not to press in the spring-
loaded ball of the float valve. When adjusting, bend
the stop gently at the arrow.
2. The lower end position of the float is checked by
measuring the measurement B, which shall be 1.34
in. (34 mm), When adjusting, bend the stop gently at
the arrow.
BALL AND WEIGHT, ACCELERATING PUMP FUEL CHANNEL
12. Fit the float chamber valve spring into the carbu-
retor cover. Fit the cover, and insert the float
chamber valve push-rod into the cover. Tighten
cover,
13. Screw step cam on.
14. Fit the thermostatic spring housing.
CHECK MEASUREMENT, FLOAT
INSTALLATION A = 1.08 in. (27.5 mm)
B = 1,34 in. (34 mm)
1. Fit new gaskets beneath the intermediate flange and
carburetor.
NOTE! Turn the face marked ’'Oben”’ upward.
ADJUSTMENT OF ACCELERATING PUMP
1. Fill the float chamber with fuel, using a funnel and a
hose connected to the inlet pipe.
2. Slacken the idle adjusting screw completely so that
full pump strokes are obtained. Open the throttle
valve a few times in order to fill the fuel ducts.
3. Hold the carburetor over a glass measuring cylinder
with a funnel as shown in the illustration. Open the
throttle valve ten times with smooth movements.
Compare the measured amount of fuel with the spe-
cifikations in group 0.
LOCATION OF FITTED GASKET
NOTE
A special gasket is required for this carburetor and
must not be mixed up with the gasket for the Solex
carburetor.
Refit fuel- and vacuum hoses,
Refit the throttle control.
Refit the coolant hoses.
Refit the air cleaner.
oP Oh
CHE
CKING THE ACCELERATING PUMP SETTING
231-6 SAAR
Febr 1977