Page 201
Febr 1977
—- Water
ow c Warmair
9
mp Cold air
COOLING AND HEATING SYSTEM, UP TO AND INCL. MODEL 1968
15. Cold-air intake
1. Water pump 8. Water jacket, automatic choke
2. Radiator 9. Heat exchanger 16. Defroster hose
3. Fan 10. Bleeding nipple 17. Fan wheel
4. Water distribution pipe 11, Fan motor 18. Air distributor
5. Temperature transmitter 12. Side defroster hose 19. Thermostat valve
6. Thermostat 13. Defroster jet 20. Drain plugs (one on each side)
7. By-pass 14. Collector box
<> Warmair
=> Cold air
COOLING AND HEATING SYSTEM, MODEL 1969
9. By-pass
10. Water jacket, automatic choke
17. Cold-air intake
1. Water pump
18. Defroster pipe
2. Radiator
3. Radiator cap
4. Expansion tank
5. Pressure cap
6. Fan
7. Temperature transmitter
8. Thermostat
11, Heat exchanger
12. Bleeding nipple
13, Fan motor
14. Side defroster hose
15. Defroster jet
16. Collector box
19. Fan wheel
20. Air distributor
21. Thermostat valve
22. Drain valve
23. Drain plugs (one on each side)
261-1
Page 202
Sera ee es
261-2
COOLING AND HEATING SYSTEM, MODEL 1970-1975
1. Water pump
2. Radiator
3. Radiator cap
4. Expansion tank
5. Pressure cap
6. Fan
7. Temperature transmitter
8. Thermostat
—_— Water
— Warmair
==> Cold air
9. By-pass 17. Cold-air intake
10. Water jacket, automatic choke 18. Defroster pipe
11. Heat exchanger 19. Fan wheel
12. Bleeding nipple 20. Air distributor
13. Fan motor 21. Thermostat valve
14. Side defroster hose 22. Drain valve
15. Defroster jet 23. Drain plugs (one on each side)
16. Collector box
—
7 — Water
Pa Warm air
™™> Cold air
COOLING AND HEATING SYSTEM, AS FRom MODEL 1976
1. Water pump
2. Radiator
3. Radiator cap
4. Ecpansion tank
5. Pressure cap
6. Radiator fan
7. Thermostat
8. Heat exchanger
9. Bleeding nipple
10, Fan
11. Thermostatical!
12. Drain cock
13. Drain Plugs (one on ®ach side)
SOAR,
Y regulated water valve
Febr 1977
Page 203
COOLING SYSTEM
Draining
1. Remove the filler cap of the radiator, As from the
1969 model, remove also the pressure cap of the ex-
pansion tank.
2. The coolant is first drained off through the drain valve
in the lower part of the radiator. If the system is to be
drained completely, loosen also the two hexagon plugs
one on each side of the lower part of the cylinder
block.
Empty the expansion tank by loosening it and then
holding it so high that the fluid Pours into the radia-
tor.
3. The heat control of the fresh-air heater should point
to maximum heat, otherwise the system cannot be
fully drained.
Refilling
Coolant is filled through the radiator opening. When
doing this, make the heat control point to maximum
heat and open the bieeding nipple of the heat exchanger,
in order to have the system filled completely. As from
mode! 1969, fill the expansion tank up to the maximum
mark or, at the most 0.79 in. (20 mm) above it.
Once the cooling system is completely full, start the en-
gine und run it at a varying speed for approx. a minute
or until coolant escapes through the open bleeding nipple
of the heat exchanger. Now, shut the bleeding nipple.
Pour additional coolant into the radiator, as required,
then put both the caps on.
Only clean coolant is permissible. Never fill much of cold
water, if the engine is hot, or the cylinder block may
crack,
Check the level in the expansion tank after driving for a
few days, as a complete bleeding is achieved only when
the system has been warmed up and cooled off a few
times.
Top up once the level is at the minimum mark again.
Use a recommended coolant only.
Febr 1977
Cleaning
1, Drain off the water.
2. Flush the system with clean water.
3. Fill the system with clean water to which a suitable
commercial solvent has been added, Follow the sol-
vent manufacture’s instruction.
4. Shield the radiator and run the engine until warm.
5. Stop the engine and, after waiting a few minutes,
drain off the water.
6. Flush the system again with clean water, treating the
engine jacket and radiator separately. This time, flush
against the normal direction of coolant flow, i.e. flush
the engine jacket from the cylinder head and down-
wards, and the radiator through the lower connection
pipe and upwards.
Before flushing the system this time, back off the up-
per water neck and remove the thermostat.
7. Flush the heat exchanger also against the normal di-
rection of circulation.
8. Check the function of the tap in the line to the heat
exchanger.
9. Refit the thermostat, water neck and hoses. Test the
system, also check that the radiator overflow pipe is
not choked up with foreign matter. If the cleaning
method described does not suffice to clear all deposits
from the radiator, take the radiator out of the car and
send it to a specialist.
261-3
Page 204
Pressure testing
It is often difficult to discover leakage in the cooling sys-
tem, as the pressure in the system reaches its full value
only while the car is being driven. One good method is
to put the system under pressure with the aid of a pres-
sure tester, whereupon the radiator, hoses and seals can
be checked. The maximum permissible pressure is 1 bar
(kp/cm2, 14 psi).
TESTING THE COOLING SYSTEM FOR LEAKS
The opening pressure of the pressure cap can also be
checked with the pressure tester. Concerning opening
pressures, see specifications in group 0.
CHECKING THE OPENING PRESSURE OF THE PRESSURE
CAP
RADIATOR
Removal
i i jator in order
ke care when working with the radiato
Always ta
to avoid damage and leaks.
1. Remove the hood.
2. Drain off the water.
3. Disconnect the water hoses.
diator retaining screws.
er and lower ra
4. Back off the upp
REMOVAL OF RADIATOR
5. Lift out the radiator,
Installation
. Replace the radiator in position and screw in the up-
per and lower retaining screws.
. Reconnect the hoses. Be sure to stretch them properly
in order to avoid kinks. Refit the clamps.
3. Refill the radiator with water.
4. Remount the hood.
Testing
If the radiator is removed it can be tested for leaks by
sealing the Pipe connections, submerging it in water and
— with compressed air at max. 1 bar (kp/em2, 14
psi),
A leaky radiator can be re
Paired by soldering. al
ers which are added ie s/ ering. Patent se
261—4 SAaB
Febr 1977
Page 205
WATER DISTRIBUTION PIPE AND WATER HOSES
Removal
1. Drain the coolant through the tap in the lower part of
the radiator.
2. Slacken the three hose clamps so that the hoses re-
main on the water distribution tube.
3, Slacken the clamp which holds the water Pipes togeth-
er.
4. Remove the water distribution tube from the engine
together with the hoses.
WATER DISTRIBUTION PIPE
Installation
1. Moisten the hoses and pass them onto the water distri-
bution pipe.
2. Hold the distribution pipe over the engine connection
tail-pieces and slide on the hoses.
3. Tighten all hose clamps and pipe clamps.
4. Fill the system with coolant and bleed the system.
Febr 1977
261—5
————
Page 207
WATER PUMP
REMOVAL
1. Drain the coolant through the tap at the bottom of
the radiator.
2. Remove the alternator and its bracket and take off
the belt.
3. Slacken the water pump bolts, but allow them to re-
main in the transmission cover. Remove the water
pump.
INSTALLATION
1. Remove all residual gasket fragments from the gasket
surfaces.
2. Install the water pump with a new gasket. Refit the
bolts.
3. Install the alternator and its bracket.
4. Put on the belt and tighten it with the alternator.
Tighten the alternator brackets,
5. Fill the cooling system. Check for water leaks.
OVERHAULING WITH A REPAIR KIT
Roel
REPAIR KIT, WATER PUMP
1. Tool 78 62 204
2. Tool 78 62 196
Disassembly
Using a drift, press the pump shaft with bearing and im-
peller simultaneously out of the pulley and pump hous-
ing. Use tool 78 62 436 as pressure base. Reject all parts
except the pulley and the pump housing.
Febr 1977
“a
REMOVAL OF PUMP BEARING
Reassembly
1.
Place the pump housing on tool 78 62 204 and press
the long end of the shaft into the upper pump housing
face with the aid of tool 78 62 196 (short hole).
To secure the new pump bearing in the old pump
housing, the outer bearing race should be coated with
Loctite prior to installation. Loctite is available as
spare part, No. 78 60 513.
786219
INSERTION OF PUMP BEARING
Tools 78 62 196 and 78 62 204
262-1
Page 208
4. Install the pulley in tool 78 62
aid of a mandrel the p '
that it protrudes 0.03—0.08 in.
2. Place the housing with tool 78 62 196 and 78 62 204
respectively in the reverse position on the pressing
table. Position the seal and press it in firmly with the
small edge of tool 78 62 204. a
gainst the pump shaft an
Press ai
peller.
786220
786219
INSTALLATION OF PULLEY
Tool 78 62 196
INSERTION OF PUMP SEAL
Tools 78 62 196 and 78 62 204
Concerning replacement of fan bearing see Transmission”
section 215.
3. In the same position, mount the impeller on the pump
shaft and press it in with tool 78 62 204 in the same
way until it bottoms out.
FITTING OF IMPELLER
Too:s 78 62 196 and 78 62 204
262-2 SAAB
196 and press with the
ump shaft into the pulley so
(0.8—2.0 mm).
d not against the im- |
S 2424
Febr 1977
Page 209
=
FAN
REPLACING AND TENSIONING THE FAN BELT
Back off the alternator retaining bolts and remove the
belt. Fit the new belt and tension it with the alternator.
Secure the alternator firmly. The belt should be so ten-
sioned that it can be pressed down approx. 0.28 in. (7
mm) at a load of 15 N (3.3 Ib./1.5 kp).
ADJUSTMENT OF BELT TENSION
1, Adjusting bolt
2. Retaining bolt
THERMOSTAT
REMOVAL
1. Drain the coolant through the tap at the bottom of
the radiator.
. Remove the air filter and the carburetor.
. Disconnect the water hoses.
4. Back off and remove the bolts and lift the upper part
of the thermostat housing. Remove the thermostat.
WN
REASSEMBLY
1. Clean the thermostat housing gasket surface to re-
move all residual gasket fragments.
Febr 1977
[ _ NOTE
The thermostat retaining bracket must be perpendi-
cular to the longitudinal axis of the car, as other-
wise the bracket will be squeezed by the water out-
let tailpiece.
INSTALLATION POSITION, THERMOSTAT
2. Insert the thermostat, position a new gasket and
screw on the upper part.
. Reconnect the water hoses.
. Reinstall the air filter and the carburetor.
5. Fill the system with coolant and bleed the system.
> w
INSPECTION OF REMOVED THERMOSTAT
Place the thermostat together with a thermometer ina
vessel full of water. Heat the water to the temperature
specified for opening (see group 0). Check that the ther-
mostat closes in cold water. A faulty thermostat cannot
be repaired and must be replaced.
262-3