Page 211
SUNDRIES
SERVICE ENGINE
Service engines supplied as a spare part will consist of a
cylinder block with pistons and axles. These engines will
be delivered with a provisional plastic plug in the hole in
the cylinder block where the hose for the air filter is con-
nected in the case of semi-enclosed crankcase ventilation.
This hole should either be sealed with a cover or else a
connection pipe must be fitted, depending on the type of
crankcase ventilation with which the exchanged engine
was equipped.
If the exchanged engine had totally enclosed crankcase
ventilation, the hole in the cylinder block must be sealed
with a cover instead of with the plastic plug. See the
Spare parts catalogue. The cover must be mounted with
its cupped side facing downwards. Press the cover in
about 0.049—0,089 in. (1.25—2.25 mm) under the face
of the cylinder block, Use sealing compound when fitting
the cover.
If the exchange engine had semi-enclosed crankcase ven-
tilation, a connection pipe must be installed in place of
the plastic plug. See the Spare parts catalogue. Use sealing
compound.
EXCHANGE ENGINE
For all models with V4-engine, there is a new exchange
engine. The engine is factory-new, thus both cylinder
bore and crankshaft are of standard dimensions.
With the exchange engine go the following parts: cylinder
head, oil pan, oil pump, induction manifold, water pump,
oil filter, and transmission cover, but not: carburetor,
fuel pump, flywheel, clutch, thermostat housing, fan and
electrical equipment.
Febr 1977
pyeete
seneey
Page 212
Febr 1977
CONTENTS
300
311
321
331
341
342
351
361
362
363
364
371
GENERAL
BATTERY
GENERATOR
STARTER
IGNITION COIL
DISTRIBUTOR
SPARK PLUGS
SUPPRESSION OF INTERFERENCE
LIGHTING
DIRECTION INDICATORS
HORNS, SIGNALING DEVICE
WINDSHIELD WIPERS AND -WASHERS, HEADLIGHT WIPERS AND -WASHERS
ELECTRICAL CONTROLS AND SWITCHES
WIRING AND FUSES
Page 213
GENERAL
The electrical system works on 12 volts and comprises
the following units:
Battery, aise Generator, voltage regulator, ignition dis-
tributor, ignition coil, spark plugs, road lights and interior
lighting, clock (model 1967), warning lamps, temperature
transmitter, fuel gauge and -transmitter, manoeuvre relay
for headlights, oil pressure switch, direction indicators,
flasher unit, windshield wipers, horns, fan motor, stop
light switch, cable harnesses, wiring, switches and fuses,
As from model 1967 all USA versions have a warning
flasher system. As from model 1969 are all versions
equipped with this system.
As from model 1968, all cars are equipped with electric
windshield washer and a brake warning contact.
As from model 1971, headlight wipers and -washers are
provided for certain markets.
As from model 1972, the cars are fitted with electric
heating of the drivers seat.
As from model 1976 all L.H.D. Saab 96 cars are equipped
with electrically heated rear window.
As from model 1977 all Saab 95 L and R.H.D. Saab 96 L
are equipped with electrically heated rear window.
BATTERY
The 12-volt, 6-cell lead battery has a capacity of 44 amp-
hours (Ah). It is placed on a shelf on the right hand wheel
house. The negative cable is grounded to the body.
L.H.D. cars as from model 1971 has 60 Ah batteries.
GENERATOR
The generator is of the AC type. An indicator light shows
whether the generator is charging or not.
STARTER
The starter up to and incl. model 1968 has a rated output
of 0.6 kW (0.8 h.p.). The pinion is engaged by means of a
solenoid switch that is turned on with the ignition key.
As from model 1969 the starter has 4 rated output of
0.7 kW (1.0 h.p.).
IGNITION SYSTEM
The engine is equipped with a battery ignition system
which, apart from the battery, comprises an ignition coil
and a distributor equipped with a centrifugal governor in
combination with a vacuum governor,
The ignition is switched on with the ignition key.
The suppressors which eliminate radio interference are
mounted in the rotor and in the ignition cable terminals.
For further suppression see section 346 “Interference
suppression”.
LIGHTING
The road lights comprise the headlights, front direction
indicators and parking lights, the number plate light, stop
lights, rear direction indicators, and tail lights.
The headlight inserts can easily be adjusted both vertical-
ly and laterally. Lights on/off by means of a switch on
the steering column stand. As from model 1963 the switch
is placed on the instrument panel. Up to and incl. model
1968 the headlights are dimmed with a footoperated
switch.
In the Monte Carlo’), the R.H.D. Saab 95/96 cars and as
from model 1969 also the L.H.D. cars, there is a device
that provides headlight flashing and dimming via relays
operated by moving the direction indicator switch lever
toward the wheel.
Up to and incl. model 1968, all cars of the USA version
have foot operated dimmer and no device for headlight
flashing. As from model 1969 all cars have a handoper-
ated device for dimming and for headlight flashing.
A warning lamp on the instrument panel glows when the
headlights are in high beam.
The parking lights are always on together with the head-
lights, regardless of whether these are dimmed or not.
The headlight/parking light switch knob can be turned to
regulate the intensity of the instrument lighting.
As from model 1968 the intensity of the instrument pan-
el lighting is regulated by means of a rheostat placed to
the left of the light switch.
As from model 1970 the Saab 96 is fitted with trunk light.
The switch is placed at the left hinge of the trunk lid.
As from chassis Nos. 95753001200 and 96752010045
(Scandinavian market) the cars are equipped with a new
headlight function, town light.
The town lights, together with the rear lights and license
plate light, are switched on automatically when the en-
gine is started.
Full headlight power at both high and low beam will be
obtained when the headlights are switched on by means
of the normal switch.
SAAB 300—1
Febr 1977
Page 214
MISCELLANEOUS ELECTRICAL EQUIPMENT
The interior lighting consists of a dome lamp operated
ey a switch on the lamp itself and by door switches.
e direction indicators are operated by means of an au-
tomatically re-set switch located under the steering wheel.
A green warning lamp on the instrument panel indicates
when the flashers are operating.
The horns emit a dual-tone signal, composed of harmoni-
zed high and low tone (up to and incl. model 1971 ). As
from model 1972 there is only one horn mounted.
In the model 1967 the horns are operated with a signal
ring at the steering wheel, in models 1968—69 with the
same lever as the windshield wipers and as from the 1970
model with a signal contact in the steering wheel uphol-
stery.
The two windshield wipers are driven, at two speeds, by
@ motor via twin linkages. They are turned on and off
with a switch on the instrument panel. (As from model
1968, with a switch beneath the steering wheel.) This
switch is combined with the windshield washer control.
The same switch is also used te operate the headlamp
wipers and -washers on cars which, as from model 1971,
are provided with this equipment.
As from model 1976 all L.H.D. Saab 96 (as from model
1977 even Saab 95 L and R.H.D. Saab 96 L) are equipped
with electrically heated rear window. The switch for
which is placed in the instrument panel. A control lamp
in the switch lights with green light when the current is
on.
1) Excl. the USA version.
WIRING AND FUSES
attery or generator to the
umers are gathered into a
ed in groups. The indivi-
asy identification
The various wires from the b
different electric power cons
harness network that is arrang
dual wires are color-marked for e
throughout the network.
The wiring connections consist of solderless AMP connec
tors. Fuses are provided to protect wiring etc. from ab-
normally high current intensities (due to short circuits,
for instance) and to reduce fire hazards. The fuses are
grouped ina fuse box located to the right on the instru-
ment panel in the engine compartment. A spare fuse is
provided for extra equipment.
BRAKE WARNING SYSTEM
Faults in the brake system in the form of leakage or ne-
glected adjustment of the rear brakes, are indicated by
the brake warning light located in the speedometer. The
lamp is lighted by a contact placed above the brake pedal.
WARNING FLASHER
As from model 1969 all cars are equipped with a warning
flasher. The switch is located on the steering column
stand (up to and incl. model 1969). When the knob is
pulled out, all the direction indicator lights and connected
indicators are flashing. As from model 1970 the switch is
placed on the instrument panel.
300-2 SAAB
Febr 1977
Page 215
BATTERY
GENERAL
rhe battery is a 12-volt lead accumulator with gix Cells
the working voltage per cell being roughly 2 volts The
electrolyte is diluted sulfuric acid with a Spec, gravity of
1.28 at G8PF (20°C) when the battery is fully charged
All cars up to and incl, model 1970 are equipped with:
44 Ab batteries. As from model 1971 L.H.b cars are
equipped with GO Ah batteries and R.H.D, cars with
44 Ah. The positive pole of the battery is connected to
the starter and other consumer units, while the negative
pole is earthed through the chassis,
REMOVAL AND INSTALLATION
To remove the battery from the car, first disconnect the
negative cable, in order to prevent shorting, and then the
positive cable. Note! Engine with an alternator must be
stopped before detachment of cable.
Having done this, back off the two wing nuts on the hold-
er and lift the battery out.
Before reinstalling, make sure that the outside of the bat-
tery is clean and that posts and terminals are also clean,
thus ensuring good contact. When the battery is in place
again, coat the posts and terminals with acidfree vaseline.
BATTERY MAINTENANCE
The condition of the battery determines the ease of start-
ing, and regular testing and attention is therefore essen-
tial. Negligence in this respect may cause starting diffi-
culties, particularly in the winter, when starting loads are
higher and battery capacity lower because of the low
temperature. An insufficiently charged battery is liable to
freeze.
ELECTROLYTE LEVEL
Evaporation and decomposition of electrolyte water will
cause the level to decrease gradually. Top UP, using distil-
led water only, until the electrolyte level is approx. 0.4 in.
(10 mm) above the plates. k
age or to refill the battery if it has been emptied. eet
cific gravity must be checked whenever sulfuric acid has
been refilled.
Febr 1977
s . ‘sf
SPECIFIC GRAVITY OF ELECTROLYTE
The spociti gravity of the electrolyte can be cheeked
with a syringe-type hydrometer, The result of the test in
dioates the charging condition of the battery
Charging condition Spec, gravity of electrolyte
]
Fully charged approx, 1.28
Half charged approx, 1.21
Discharged | approx, 1.12
CHECKING THE BATTERY WITH A SYRINGE
311-1
Page 216
CELL VOLTAGE
A mo
= ssl accurate test of the state of the battery is made
ing é i
hati a cell tester, which consists of a voltmeter and a
ce, connected in parallel, givi
iit Pp , giving a load of 80—100
Each i indivi
a cell is tested individually by placing the tips of the
: tester against the cell terminals
a Zao voltage should not fall below 1.6 V after
oe sec. discharge. A bigger voltage drop is a sign of a
efective or discharged cell.
Th
‘iy normal no-load cell voltage is 2 volts, and the differ-
e in voltage between any two cells should not exceed
0.2 volts.
CHECKING THE BATTERY WITH A CELL TESTER
Batteries of more recent design have covered cell termi-
nals which makes it impossible to test separate cells. The
rest voltage of the battery can, however, be measured by
connecting a voltmeter between the positive and nega-
tive terminals.
311-2 SAAB
CHARGING
The charging rate must be adapted to the capacity of the
battery.
The bat
to 2.5—2.7 volts witho
for the last three hours
Decomposition of water caus
and in view of this the plugs $
the battery is being charged.
tery is fully charged when the cell voltage amounts
ut load and has remained constant
of charging.
es the electrolyte to boil,
hould be unscrewed while
CAUTIO
onnect the battery. Reversing the pole
omentarily, will damage the al-
ternator rectifier. Connect the positive cable to the
positive pole of the battery (both marked +) and
the negative cable (ground lead) to the negative pole
(both marked _), If an external battery is temporar-
ected to the car battery, connect the poles
nd negative-to-negative. The
connected to or disconnected
Do not misc
connections, even ™
ily conn
positive-to-positive a
battery must not be
from the electrical system of the car while the en-
gine is running. When quick-charging the battery,
first disconnect the positive cable.
Febr 1977
Page 217
GENERATOR
Up to and incl. chassis No. 47.295
443.386 ay
GENERAL
The car is equipped with an alternator, The Most j
tant advantages of the alternator compared lost impor-
generator are the following. with the D.c,
The charging current commences earlier in anal
and feeds current to battery and consumers al ternator,
gine idling speed, ready at en-
Return current relay and current regulator are missj
Only a voltage regulator is needed. Missing.
———
IMPORTANT
The battery must always be connected, when th
alternator is running. i :
Do not mix up the battery connections, confusion
leads to serious damage to the alternator
ALTERNATOR
1. Alternator assy.
2. Bearing, gear side
3. Stator
4. Slip ring end bracket
5, Protective ring
6. Rotor
7. Voltage regulator
——————
The al
Gitbon Eciatig very little maintenance, because
Output current. In commutators are not needed for the
Not prescribed ry loos ome periodical attention is
alternator should ? is type of generator. Repair of the
a8 it is most nie made bya specialized service garage,
made in the hob nt that disassembly and testing is
may resiilein a se wey: for even a minor inadequacy
rious damage.
tetas NOTE
shale sig of the alternator, use the charge in-
r light. This must be of minimum 2 watts.
ae WARNING
“caine €ctrowelding on a car equipped with an al-
Or, the ground connection shall be discon-
nected before. Otherwi F
sed
the rectifiers. amage will be caused to
SAAB 321-1
Febr 1977
iii
2 22>
===>
===:
r>3
==
-=
Page 218
INTERNAL WIRING
The alternator is for 12 V and internally air-cooled, has a
12-pole, fork-type rotor and is equipped with sex silicon
diodes for rectification. To each of the three winding loops
's connected an exciter diode, Their common junction
constitutes the terminal D+/61.
The six rectification diodes are arranged as an A.C. bridge-
coupling, i.e. three diodes are connected for normal po-
larity (anode on supply terminal), and three diodes for re-
versed polarity (anode on housing).
According to polarity, the diode carrier is fitted insulated
i To consumers
~ ground or direct connectec to 4 ground contact, re-
ng
fror s
se two carriers IS located insulated
spectively. Between the
iter diode.
the carrier of the exciter
The stator windings are star-coupled (see wiring diagram).
The rotor carries the ring-shaped exciter coil and is of the
e execution, one fork having north polarity (six
outh polarity (six poles). The twu
embled rotor alternately a south
fork typ
poles) and the other s
forks then give the ass
and a north pole. 2a
The exciter coil ends are connected to the slip rings to re-
ceive the exciter current.
AD1 14V
ADN1 14V
eas
Voltage Regulator
——
i
t
Battery 12 V Charge
I ¥ - 1 & indicator |!
tit light
' i
RS
exis 1
it
D: Li ‘yy OF
8 —
“ + D+/61 H _ D : ;
i hacia
Ww
; '
' Stator \
winding
Exciter
winding
; Alternator
£2 K1 ———m14V 35A 20
[| L_ 4% 4
Rectifier
rN
321-2
WIRING DIAGRAM FOR A.C, ALTERNATOR
Febr 1977
Page 219
DESIGNATION
The Bosch designation of the alternator js
14 V 35 A 20
The meaning of the type designation is
K 1 ——
x 100 = 2000 r/min
_ (r/min for 2/3 of
Max. Current out-
put)
~ Maximum current
Kf = = 14V 35A 20
|
————— Maximum voltage
_ Direction of rota-
tion
Design: 1 ... fork or
claw type rotor,
,______________ 2... single pole
rotor, 3... brush-
less
| Pole housing dia-
meter @
TERMINALS
D+/61: Output of exciter diodes, connection of regula-
tor D+ and of charge indicator light.
DF: Input of exciter coil, connection of regulator DF
Bt: Battery connection
D-: Ground, connection to regulator D—.
LOURS, ALTERNATOR
CABL ABLE CO
E CONNECTIONS AND C RESP. 443.386
UP TO AND INCL. CHASSIS NO. 47.295
5. 61 red to D+/61
6. 49 black to D—
7, 47 black to D-
1. 85 grey to B+
2. 74 grey to B+
3.72 red to D+/6I
4, 73 yellow to DF
Febr 1977
DISASSEMBLY
1. Hold the belt pulley with a suitable tool, and loosen
the nut with a 0.87 in. (22 mm) open end wrench.
Loosen the belt pulley,
- On the drive end plate, mark out the location of the
attachment ear. Remove the cover ring, and the brush
holder plate — the carbon brushes are going with it.
REMOVAL OF BRUSH HOLDER PLATE
3. Loosen the fixing screws of the drive end plate, and
take out of the stator the rotor together with the drive
end plate.
REMOVAL OF DRIVE END PLATE AND ROTOR
4. Place the drive end plate on a suitable support, and
press out the rotor — gently. Now it is possible to re-
move the bearing. Take care that the rotor — when
same comes loose from the drive end plate — not fall
down and be damaged.
5. Remove the ball bearing at the slip ring end, by means
of a suitable puller.
321-3
Page 220
REASSEMBLY
RENEWAL OF CARBON BRUSHES
1. Fill the ball be
the ball serail jie iid Bosch grease Ft:1 v 34. Press Remove the brush holder plate, see fig,, the carbon
aring into the drive end plate, the enclosed
5 , : : he cable connections
side facing the drive sid brushes are going with it. Detach t ,
2. Ease the drive end plate onto tt by heating, then it is possible to remove the carbon
eon e ro ;
3. By pressing, fast esha brushes. When soldering the carbon brush connections on,
Se ONDE Gases ng one: it is necessary to make sure that the tin does not flow
into the cable. Minimum length of the carbon brushes to
be approx. 0.34 in, (9 mm).
SOLDERING THE CARBON BRUSH CONNECTION
PRESSING IN THE SLIP RING END BEARINGS
4. Put the rotor in, and assemble the alternator by screw-
ing. When doing this, make sure that the drive end
plate gets correctly positioned as regards the slip ring
end plate. Fit the brush holder plate and the cover
ring. Fasten the belt pulley by screwing, torque 34—39
Nm (25—29 ft.-Ib., 3.5—4.0 kpm).
SAAB
Febr 1977
321-4