Page 231
STARTER
REMOVAL
1, Disconnect negative cable from battery.
9. Disconnect supply cable from the solenoid switch.
3, Disconnect positive cable from starter.
4. Unscrew the two retaining screws and remove starter
INSTALLATION
IMPORTANT
Before installing starter, check for wear on ring gear
and starter pinion. Clean all mating surfaces.
|
|
=
1, Secure starter with the two retaining screws.
2, Connect cables to starter.
CABLE CONNECTIONS AND CABLE COLOURS, STARTER
1, Red from battery
2. 85 grey
3. 84 yellow
3. Connect negative battery cable.
Febr 1977
DISASSEMBLY
(See fig. overleaf)
Pe: NS =
10,
11,
12.
13:
14,
Disconnect the solenoid feeder cable.
Remove the solenoid retaining screws.
Unhook and remove the solenoid.
Undo the two retaining screws from the capsule
bracket.
Remove the capsule bracket,
rubber gasket (pos. 5—8).
Undo the screws from the commutator bear
ing (1).
Remove the commutator bearing housing (10).
Lift the brush springs off their retainers with a wire
hook and remove the brushes.
Remove the brush plate, fiber washer and steel
washer (11—13).
Pull the starter assembly off the drive and bracket
U-washer, spacers and
assembly.
Undo the engaging lever arm locating screw.
Remove the rubber and steel washers from the drive
and bracket housing (17—18).
Remove the rotor and engaging lever arm.
Press the stop ring towards the cog with a piece of
tubing.
S 1338
PRESSING DOWN THE STOP RING
331-1
ing hous-
Page 232
STARTER, DISASSEMBLED
1. Screws, commutator end frame
. Solenoid switch
. Pinion housing
. Bearing bushing, drive side
Protective cap
U-shaped washer
Shims
. Rubber gasket
. Bearing bushing, commutator side
10. Commutator end frame
. Brush plate assembly
12. Fiber washer
OMNAOS WN
15.
Remove the lock ring with lock ring pliers.
Remove the pinion and the gasket ring.
17.
16.
24 20 21 22 23
S 3481
Steel washer
Field winding
Starter housing
Armature
Rubber washer
Stee! washer
Engaging lever
Starter pinion
Bearing, bushing, starter pinion
Stop ring
Retaining ring
Gasket ring
13.
14,
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Inspect the spiral splines on the rotor shaft for burrs.
If there are any, file them off.
Check the gear ring, starter drive cog and the bush-
ings.
NOTE
Check all components and exchange or repair any
that are damaged. Soak the bearing bushings in
warm oil before reassembling.
REMOVAL OF LOCKING RING
331-2
ASSEMBLY
Place the gasket ring on the rotor shaft.
Lubricate the spiral splines and the drive cog engag-
ing ring with silicone grease.
Mount the pinion, stop ring and lock ring on the
rotor shaft.
Use pliers to seat the lock ring in its groove in the
rotor shaft,
Push up the stop ring using a press or claw puller.
Febr 1977
Page 233
PRESSING UP THE STOP RING
5. Fit the engaging lever arm to the Cog engaging ring
and insert the assembly, together with the rotor
into the drive housing,
6. Secure the engaging lever arm with its locating screw.
7. Place the washers in the drive housing, first the steel
washer and then the rubber washer. The lips must
be turned towards the rotor.
8. Fit the starter housing with the notches above the
guide pin and the lip of the rubber washer,
9. Slip the steel washer and fiber washer over the rotor
shaft.
10. Fit the brush plate. Lift the brush springs with a
wire hook and insert the brushes.
11. Mount the commutator bearing housing with the
notches above the feed cable’s rubber insulation,
12. Fit the rubber gasket, shims and U-washer.
13. Locate the capsule bracket and secure it with the
two screws.
14. Insert and tighten the bearing housing screws.
15. Check the axial play of the shaft 0.002—0.012 in.
(0.05—0.30 mm) and correct with shims if neces-
sary.
16. Hook the solenoid to the engaging lever arm and
secure with the two screws.
17. Connect the feeder cable.
18. Test the starter (see group 9 for specifications and
test values).
SOLENOID SWITCH
Starter removed
Removal
1. Disconnect supply cable.
2. Remove the two retaining screws
noid switch.
and then the sole-
Installation
1. Hook solenoid switch in engaging lever and secure
With the two retaining screws.
2. Connect supply cable.
3. Test starter. See group 0, Specifications.
CARBON BRUSHES
Starter removed
Removal
—
. Remove the two screws from the capsule bracket.
2. Remove the capsule bracket, U-washer, shims and rub-
ber gasket (pos. 5—8).
3. Remove the screws from the commutator bearing hous-
ing (1).
4, Remove the commutator bearing housing (10).
5. Lift the brush springs from the holders with a wire
hook and take out the brushes.
6. Remove the brush plate.
7. Unsolder the brush wiring connections from the brush
plate and field winding.
BRUSH HOLDER PLATE AND FIELD WINDING
1, Brush holder plate
2. Brush
3. Brush, negative
4. Brush spring
5. Starter housing
6. Brush, positive with field winding
7. Field winding lead
SAAB 331-3
Febr 1977
Page 234
Installation
1. Wire the new brushes to the brush plate and field
Winding by soldering,
2. Fit the brush plate in position. Lift the springs with a
wire hook and insert the brushes.
3. Mount the commutator bearing housing with the not-
ches above the feed cables rubber insulation.
4. Fit the rubber gasket, shims and U-washer,
5. Locate the capsule bracket and secure it with the two
screws.
6. Insert and tighten the bearing housing screws.
7. Check the operation of the starter (see group 0).
STARTER PINION
Starter removed
Disassembly
Disconnect the feeder cable from the solenoid.
Undo the solenoid retaining screws.
Unhook the solenoid and remove it.
Undo the engaging lever arm locating screw.
Og PWN =
Pull off the drive housing. Save the rubber and steel
washer (17—18).
7. Push down the stop ring towards the pinion,
8. Remove the lock ring with lock ring pliers.
9. Remove the stop ring and the pinion.
10. Check the spiral splines on the rotor shaft for burrs.
If there are any, file them off.
331-4
Remove the commutator bearing housing screws (1).
Assembly
11.
12.
Lubricate the spiral splines on the rotor shaft and
the pinion engaging ring with silicone grease.
Mount the pinion, stop ring and lock ring on the
rotor shaft.
Use pliers to seat the loc
rotor shaft.
Push up the stop ring using a claw puller.
Fit the engaging lever arm to te pinion engaging
ring and put on the drive housing.
Secure the engaging lever arm with its locating screw.
Place the washers in the drive housing, first the steel
washer and then the rubber washer. The lips must
be turned towards the rotor.
Mount the drive housing so that the notches on the
starter housing are above the guide pin and the lip
of the rubber washer.
Insert and tighten the bearing housing screws.
Hook the solenoid to the engaging lever arm and
secure it with the two screws.
Connect the feeder cable.
Check the operation of the starter.
k ring in its groove in the
Febr 1977
Page 235
IGNITION COIL
REMOVAL
1, Disconnect leads from coil.
9, Back off retaining screws and remove coil,
INSTALLATION
1. Secure coil with the retaining screw.
2. Connect leads.
IGNITION COIL
Febr 1977
TEST
. Disconnect leads.
. Connect test equipment
and proceed as follows:
i ter-
a. Measure resistance of primary winding between
minals 1 and 15.
b. Measure coil perfor add
of spark length. See group 0, Specifications.
NOTE! Check that distributor gap and dwell angle are
correct.
mance in volts or millimeters
Faults otten pecome evident only after the coil has
heated up. If in doubt, connect coil to test stand
load half an hour prior to testing — after which it
shall function perfectly.
— 7
Page 236
DISTRIBUTOR
REMOVAL
GENERAL
1. Remove ignition cables from spark plugs.
The distributor, make Bosch, is mounted at the rear of ; pt a oe micriaanihel
the engine block. ; :
. ‘ 4. Remove vacuum hose
The distributor rotates clockwise and is driven b :
; y the cam- 5. i j d the mark
shaft via an angle drive. The firing order is 1 Crank engine until the mark on the rotor an
a . . k —3-4~—2, The
distributor is equipped with a centrifugal governor in com-
bination with a vacuum governor. The centrifugal governor 6
regulates the ignition setting relative to the engine speed.
The vacuum governor regulates the ignition setting rela-
tive to the load.
See instructions in group 1, Maintenenace, for informa-
tion about distributor lubrication,
Different distributors occur, see group 0.
(line) on the distributor housing are directly opposite
each other. This is the firing position for cylinder 1.
» Unscrew retaining clamp screw and remove clamp.
manent
$ 1335
REMOVING DISTRIBUTOR
7. Remove distributor from engine.
DISTRIBUTOR
‘isoueeaee 7 16 15 14 13 12 11 10 867
2. Contact DISTRIBUTOR
: ent ne 1, Vacuum chamber 9, Capacitor
P 2. Adjustment mark 10. Primary cable
5. Rotor 3. Adjustment rod 11, Fiber peg
6. Vacuum hose connection 4. Ground lead 12. Adjuster for fixed breaker point
7, Vacuum chamber 5. Lubricating felt 13, Breaker points
8. Primary cable 6. Assembly mark 14. Locking screw
9, Retaining spring 7. Retaining spring 15, Fixed breaker point
10. Capacitor 8. Bearing 16. Movable breaker point
11, Gear
SAAB 342-1
Febr 1977
Page 237
DISASSEMBLY, UP To AND INC
L.
49.092 RESP. 453.129 CHASSIS No. elas
- With the aid of two screwdrivers, press away the
cam from i hts.
1. Remove the rotor the centrifugal governor weights
13. Remove the lubricating felt, the lock ring and wear-
Remove th : B:tSNe,
2. R = Ke breaker arm connection. ‘ng washer from the breaker cam.
3. emove € Capacitor retaining screw and remove 14. Remove the lock ring and the washers from the
i“ aa together with the connection breaker arm pivots. Valid for distributor
4, Remove the lock ring from the pi 0 231 146 044
€ piv and 0 231 146 024.
chamber control rod. PIVOE of the vacuum 1. Press leaf spring out of hole in contact support and
5. Remove the two screws from the va remove breaker arm. Collect any shims (applies to
and remove same, suum chamber distributors 0 231 146 044 and 0 231 146 024).
6. Remove the two cap retaining pring screws 16. Remove retaining screw that secures fixed breaker
7. Lift up the breaker plate . point.
i i : — 17. Remove th i it distri
8. bie with the es of 20.16 in. (4 mm) mandrel out 0 231 ia Hs ea ‘sii Sia aes acta
the tension pin from th ‘
9. Remove the gear with ee he a sui 18. If necessary, remove bearing bushing by the aid of
suitable puller. a mandrel. During this operation, the distributor
housing should be turned upside down.
19. Check all parts. Clean and replace as required.
ASSEMBLY, UP TO AND INCL. CHASSIS NO. 49.092
RESP. 453.129
1. Soak bearing bushing in warm oil prior to mounting.
Then use mandrel 78 62 154 to press it into same
plane as edge of distributor housing.
2. Smear distributor shaft with oil, fit breaker cam
and hook the two coil springs in place.
3. Insert wear washer and retaining ring in breaker
cam. Press retaining ring into place using a tubular
REMOVALOF DIST RIRUIOG Grima drift; inside diameter 0.25 in. (6 mm), outside dia-
meter 0.32 in. (8 mm), length approx. 2 in. (50 mm).
Insert lubricating felt and soak with oil.
5. Fit distributor shaft in distributor housing after
10. Lift up the entire distributor shaft. smearing it with oil.
11. Remove the two coil springs from the governor. 6. Fit a new gear to the shaft so that the holes in the
gear and the shaft correspond. If the shaft must be
turned to align the holes, use a 0.24 in. (6 mm) in-
hexagonal key in the hole in the shaft end.
7. Place the distributor in a suitable dolly and drill up
the hole through gear and shaft, using a 0.20 in. (5
mm) drill. Clean thoroughly and drive in a new ten-
sion pin so deep that its end is level with the gear.
=
NOTE
The gear must not be driven or pressed on to the
shaft because this can spoil the ignition advance
device.
IGNITION GOVERNOR
1. Lubricating felt 6. Coil spring
2. Retaining ring 7, Retaining ring
3. Wear washer 8. Governor weights
4. Breaker cam 9, Distributor shaft
5. Spacer ring
SAAB 342-3
Febr 1977
Page 238
10.
11.
13.
14.
15.
16.
17,
18.
19.
20.
21.
Fit breaker plate in distributor housing (turn spring
with ball toward. Primary terminal.)
Screw on retaining spring with lug (that determines
Cap position) on primary terminal side.
Screw on retaining spring on other side.
Fit the fixed breaker point or breaker unit and in-
sert retaining screw without tightening it firmly.
Lubricate pivot and bearing bushing on breaker arm
with Bosch Ft 1 v 22 grease.
Insert breaker arm leaf spring in hole in contact sup-
port (applies to distributors 0 231 146 044 and
0 231 146 024). The faces of the points must be
parallel to each other. Correct any misalignment
with shims or by aligning the fixed breaker point.
Fit shims and clip on the pivot (applies to distri-
butors 0 231 146 044 and 0 231 146 024).
Smear the breaker cam and fiber peg with Bosch
Ft 1 v 4 grease.
Turn distributor shaft until breaker arm is lifted all
the way from the fixed breaker point. Insert a
screwdriver between the two adjusting lugs and
slot. Turn screwdriver to set gap. Tighten retaining
screw and re-check gap.
Hook vacuum chamber adjusting rod to pivot and
secure with locking ring.
Secure vacuum chamber with the two retaining
screws.
Fit capacitor terminal to distributor housing and
screw capacitor in place.
Connect breaker arm lead.
Fit rotor.
DISASSEMBLY/OF DISTRIBUTOR, AS FROM CHASSIS
NO. 49.093 RESP. 453.130
As
from chassis No. 49.093 resp. 453.130, the design of
the distributors has been modified. The breaker plate is
not removable. Repair kits have not been prepared.
1.
2
3.
342-4
Remove the rotor.
Remove the breaker arm connection cable.
Back off the capacitor retaining screw and remove the
capacitor together with the connection,
. Remove the lock ring from the pivot for the vacuum
regulator control rod.
Back off the two retaining screws for the vacuum regu-
lator and remove the regulator.
Back off the retaining screw for the fixed breaker point.
Remove the breaker point — point unit.
Using an 0.16 in. (4 mm) mandrel, drive the tension
pin out of the gear.
Remove the gear with the aid of a suitable puller.
RE
OVAL OF DISTRIBUTOR GEAR
M
LY, AS FROM CHASSIS NO. 49.093 RESP.
ASSEMB
453.130
1. Fit anew gear to the shaft so that the holes in the
; gear and the shaft correspond. If the shaft must be
turned to align the holes, use a 0.24 in. (6 mm) in-
hexagonal key in the hole in the shaft end.
2. Place the distributor in a suitable dolly and drill up
the hole through gear and shaft, using a 0.20 in. (5
mm) drill. Clean thoroughly and drive in a new ten-
sion pin so deep that its end is level with the gear.
NOTE
The gear must not be driven or pressed on to the
shaft because this can spoil the ignition advance de-
vice.
3. Fit the fixed breaker point or the breaker unit and
insert the retaining screw without tightening it
firmly.
4. Smear the breaker cam and fiber block with Bosch
grease Ft 1 v 4,
5. Turn the distributor shaft until the breaker arm is
lifted completely from the fixed breaker point. Ap-
ply a screwdriver between the two adjusting lugs
and the slot. Turn the screwdriwer to adjust the gap.
Tighten the retaining screw and recheck the gap.
6. Hook the vacuum regulator control rod onto the
pivot and secure with the lock ring.
7. Secure the vacuum regulator with the screw.
8. Pass the capacitor terminal into the distributor hous-
ing and screw the Capacitor in place.
9, Reconnect the breaker arm connection cable.
10. Refit the rotor.
Febr 1977
Page 239
CHANGING OF BREAKER POINTS, REMOVED
pISTRIBUTOR
Disassembly
. Disconnect breaker arm lead.
_ Remove clip and washers from breaker pivot (applies
to distributors 0 231 146 044 and 0 231 146 024).
_ Press leaf spring out of hole contact support and re-
move breaker arm. Collect any shims (applies to distri-
butors 0 231 146 044 and 0 231 146 024).
_ Remove retaining screw that secures fixed breaker
point.
_ Remove breaker point (breaker unit on distributor
0 231 146 033).
Assembly
NOTE
Do not get any oil or grease on contact surfaces
(may cause oxidation).
Febr 1977
. Insert the fixed breaker point or breaker unit and in-
sert retaining screw without tightening it.
. Lubricate pivot and bearing bushing on breaker arm
with Bosch Ft 1 v 22 grease.
. Insert breaker arm leaf spring in hole in contact sup-
port (applies to distributor 0 231 146 044 and
0 231 146 024). The faces of the points must be par-
allel to each other. Correct any misalignment with
shims or by aligning the fixed breaker point.
. Fit shims and clip on the pivot (applies to distributors
0 231 146 044 and 0 231 146 024),
= . 4
5. Smear the breaker cam and fiber peg with Bosch Ft 1 v
grease.
6. Turn distributor shaft until breaker
way from the fixed breaker point. Insert 4 screwdriver
between the two adjusting lugs and slot. Turn screw-
driver to set gap. Tighten retaining screw and re-check
gap.
7. Connect breaker arm lead.
arm is lifted all the
7 16 15 14 13 12, 1110 867
DISTRIBUTOR
10. Primary terminal
12. Adjuster for fixed breaker point
14. Locking screw
342-5
Page 240
CHANGING BREAKER POINTS, INSTALLED DISTRI-
BUTOR
DisassembI+
Release retaining springs and remove cap.
Remove rotor.
Disconnect breaker arm lead,
Remove clip and washers from breaker pivot (app-
lies) to distributors 0 231 146 044 and 0 231 146 024).
Press leaf spring out of hole in contact support and re-
move breaker arm. Collect any shims (applies to distri-
butors 0 231 146 044 and 0 231 146 024).
PN: =
6. Remove retaining screw that secures fixed breaker point.
7. Remove breaker point (breaker unit on distributor
0 231 146 033).
Assembly
NOTE
Do not get any oil or grease on contact surfaces
(may cause oxidation).
1. Insert the fixed breaker point or breaker unit and in-
sert retaining screw without tightening it firmly.
2. Lubricate pivot and bearing bushing on breaker arm
with Bosch Ft 1 v 22 grease.
3. Insert breaker arm leaf spring in hole in contact sup-
port (applies to distributors 0 231 146 044 and
0 231 146 024). The faces of the points must be par-
allel to each other. Correct any misalignment with
shims or by aligning the fixed breaker point.
4. Fit shims and clip on the pivot (applies to distri-
butors 0 231 146 044 and 0 231 146 024).
5. Smear the breaker cam and fiber peg with Bosch
Ft 1 v 22 grease.
6. Connect breaker arm lead.
7. Adjust gap and dwell angle.
a. Breaker point gap.
Crank engine until breaker arm is lifted all the
way from the fixed breaker point. Insert a screw-
driver between the two adjusting lugs and slot,
turn screwdriver to set gap. Tighten retaining
screw and re-check gap.
342-6
i
7 16 15 141312 11 10
DISTRIBUTOR
10. Primary cable '
12. Adjuster for fixed breaker point
14, Locking screw
b. Dwell angle.
Connect a dwell angle tester. Turn on ignition
and crank engine with starter. Compare indicated
value with specified value. See Group 0, Specifi-
cations. Correct if necessary by adjusting the
fixed breaker point. Tighten retaining screw and
re-check gap.
IMPORTANT
When the breaker points are new they should be set
for the narrower dwell angle since the dwell angle in-
crease as the points wear.
The three drawings shown below illustrate the relation-
ship between gap A and dwell angle S.
The cross-hatched point illustrates the gap at the highest
position of the cam.
Febr 1977