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TROUBLE SHOOTING
GENERAL
The localization of faults is often the most difficult part
of the work, and no written instruction can replace know-
ledge about the car and its construction. The information
contained in this section has been prepared with the object
of facilitating systematic diagnosis, but does not claim to
be exhaustive. Under each heading, the most likely sources
of trouble are listed in order of probability, together with
the appropriate corrective measures. Since a number of
different auxiliary apparatuses may be used to facilitate
trouble shooting, the instructions given for each indivi-
dual problem should be followed.
ENGINE
Starting difficult, cold engine
Source of trouble
Faulty spark plugs. Gaps too wide.
The distributor is faulty.
The battery is poorly charged.
The capacitor is faulty.
The ignition coil is weak.
The interference suppressors on the spark plugs are faulty.
No fuel in the carburetor.
Clogged jets and passages in the carburetor.
No primary current to ignition coil and distributor.
No secondary current.
Febr 1977
Remedy
Adjust or replace.
Check, adjust.
Check condition of battery. Recharge when necessary.
Test the capacitor.
Test the ignition coil.
Replace.
Check that the pump is feeding fuel by loosening hose
at carburetor and running with starter motor. If no
fuel is supplied, check pump filter, pipes, hoses and
fuel filter for leaks and clogging. If fuel supply still fails
after a new test, running with starter motor for about
12—15 sec., the pump itself is probably defective. Re-
move the pump for examination, and repair if necessary.
Blow jets and passages clean with air.
Check cable connections, and especially the starter
switch, to confirm that current is supplied to ignition
system when starter motor is on. The cable may be
ruptured at the ignition switch.
030-1
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Choke Strangler flap fails to close.
Faulty Carburetor gaskets.
Incorrect fast-idle adjustment.
Oil to viscous or dirty.
Poor compression Caused b
Piston rings. Piston rin
valves.
y worn cylinders, pistons or
gs stuck in ring grooves. Leaking
The cylinder head gasket is leaking.
Starting difficult, warm engine
Source of trouble
ee OUIIS
The float level is incorrect, Damaged float or leaking
needle valve.
No primary current to ignition coil and distributor.
No secondary current.
Dirt in jets or Passages of the carburetor.
The carburetor is flooding.
Engine does not idle
Source of trouble
The float level is incorrect. Leaking needle valve.
Idling fuel jet clogged with dirt.
Improperly adjusted idling screw and/or air-regulating
screw.
Faulty gasket between induction manifold and carburetor.
Leakage at vacuum connection.
030—2 SAAB
Remove air cleaner. Check that choke spindle runs
asily. If spindle binds, clean its bearing surfaces with
e :
gasoline or trichloroethylene.
Replace gaskets.
Check adjustment. See section headed “’Fast-idle ad-
justment”’ in group 2.
Change oil.
Measure compression pressure in all cylinders.
Replace gasket.
Remedy
Check, adjust if necessary. Replace any faulty parts.
Check, correct as instructed above.
Blow jets and passages clean with air.
Check needle valve and float. Clean or replace.
Remedy
Check, adjust if necessary.
Clean.
Check, adjust
Replace gasket.
Check, repair,
Febr 1977
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Page 43
Pinging
Source of trouble
Ignition wrongly timed
Wrong jets in carburetor. (Mixture too lean.)
Automatic ignition advance in distributor sticks at earliest
timing.
Heavy deposits of carbon in compression chambers due
to excessive city driving.
Octane number of fuel is too low.
Ignition by incandescence
Source of trouble
Spark plugs faulty.
Heavy deposits of carbon in compression chambers.
Engine idles too fast.
Excessive fuel consumption
It should be borne in mind that apparently excessive fuel
consumption may result from extraneous causes such as
a car top carrier, snow tires, predominately city driving,
etc. A small tank installed in the engine compartment
may be used to check fuel consumption. Connect up the
small tank ahead of the fuel tank so that the same pump
pressure is obtained. A test based merely on consump-
tion between two fill-ups cannot be regarded as reliable.
Source of trouble
Fuel tank damaged.
Fuel line damaged.
Nipples or fittings leaking.
Ignition improperly adjusted.
Distributor faulty.
Ignition coil faulty.
Capacitor faulty.
Febr 1977
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Remedy
Adjust ignition timing. See group 3, Electrical System.
—— s
Change jets. See group 0.
Test distributor on test rig. if available. Clean and
lubricate all parts. Replace any worn parts.
Decarbonize cylinder head.
Change fuel next time tank is refilled.
Remedy
Make certain that correct type of plug is fitted. See
group 3, Electrical System.
Decarbonize cylinder head.
Adjust idling speed.
Remedy
Check, repair if necessary.
Check, replace if necessary.
Tighten or replace.
Check, adjust.
Test, adjust.
Test, replace if necessary.
Test, replace if necessary.
Page 44
Carburetor improperly adjusted. Float level too high,
wrong type of jets fitted, or air-regulating screw impro-
perly adjusted.
Automatic choke improperly adjusted.
Air cleaner clogged
Brakes dragging.
Lack of power
Source of trouble
Engine not firing on all cylinders.
Carburetor adjusted improperly.
Icing in carburetor.
Unsatisfactory fuel.
Leaking valves in fuel pump.
Fuel pump filter clogged with dirt.
Air cleaner clogged.
Dirt in jets.
Poor compression caused by worn cylinders, pistons or
piston rings.
Leaking valves.
030-4
Check carburetor settings and adjust if necessary. See
group 2.
Check, adjust.
Blow air cleaner clean with-air. Replace if necessary.
Check brake adjustment and free rolling of wheels.
Note! Make sure that handbrake wire returns properly.
Remedy
Check spark plugs and connections at plug terminals
and distributor cover. Check radio interference sup-
pressors if fitted. Set air preheater device to winter
position.
Check carburetor jet sizes, float level and richness ad-
justment.
Set air preheater device to winter position.
Empty and clean tank.
Replace.
Remove and clean.
Remove and clean.
Clean.
Measure compression pressure in all cylinders.
Decarbonize and grind valves.
Febr 1977
Page 45
Overheating
Source of trouble
Coolant level too low.
Fan belt slipping.
Pump impeller damaged.
Thermostat faulty.
Radiator clogged.
Hoses and passages clogged by dirt and sludge.
Water distribution pipe clogged.
Ignition improperly adjusted.
Air/fuel mixture too lean.
Source of trouble
Unsatisfactory fuel. Water in fuel.
Fuel line partially clogged.
Fuel pump faulty.
Poor contact at ignition coil connection.
Open contacts at primary circuit connections.
Primary circuit open or shorted.
Ignition cables faulty.
Breaker contact points burnt.
Breaker contact points incorrectly gapped.
Febr 1977
Remedy
Replenish coolant.
Adjust belt tension.
Replace.
Test, replace if necessary.
Clean.
Clean.
Remove, clean.
Check, adjust if necessary.
Clean, adjust carburetor.
Remedy
Empty tank, then remove and clean.
Check, flush clean.
Check, repair if necessary.
Check, test and repair.
Check, correct.
Check, correct.
Clean connections. Replace cables if insulation is
damaged.
Replace.
Check, adjust.
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Page 46
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Escessive oil consumption
Remember that it is advisable to ascertain the conditions
under which the car is driven before examining the engine
or taking corrective measures when oil consumption is
high. If possible, ask the driver about his driving habits and
the type of driving for which the car is used. It’s a good idea
to let the driver take the car out for a spin and watch how
he operates it. Abrupt acceleration, racing the engine and
high speed driving lead to excessive oil consumption. Ex-
cessive oil consumption may be caused by keeping the oil
level too high. It is not necessary to add oil until the level
has dropped to (or just above) the lower mark on the dip-
stick. However, the level must never be permitted to drop
beneath the lower mark.
Source of trouble
Leakage at oil pan gasket.
Gasket between fuel pump and cylinder block faulty.
Gasket in transmission cover damaged.
Crankshaft seal damaged.
Leakage at valve cover.
Oil filter seal faulty.
Worn cylinders, pistons or piston rings.
Piston rings stuck in grooves or broken.
Valve stem seals damaged.
Valve guides worn.
Low oil pressure
Source of trouble
Oil pressure gauge faulty.
Wiring to oil pressure gauge damaged.
Relief valve stuck in open position.
Relief valve spring broken or too weak.
Relief valve plunger worn.
Oil pump strainer clogged with dirt.
Worn rotor in pump.
Main and/or connecting rod bearings damaged or worn.
Overflow vaive in oil filter faulty.
030-6 SAAB
Remedy
Tighten the bolts. Replace gasket if faulty.
Replace gasket if faulty.
Replace gasket.
Replace seal.
Check that cover is correctly fitted. Replace gasket
if necessary.
Check. Replace oil filter cartridge if necessary.
Measure compression pressure.
Replace piston rings.
Replace seals.
Reaming of valve guides. Installation of oversize valves.
Remedy
Test, replace if necessary.
Replace wiring.
Remove, replace.
Replace.
Replace.
Clean.
Replace.
Replace. Regrind crankshaft if damaged or worn.
Replace oil filter.
Febr 1977
Page 47
Engine jerks and spits on acceleration
Source of trouble
Spark plugs faulty.
Flash-over in ignition cables. Moisture in distributor cover.
Ignition coil faulty.
Acceleration pump inlet valve leaks.
Acceleration pump outlet valve leaks.
Acceleration jet clogged with dirt.
Water in fuel.
Fuel supply unsufficient.
Fuel pump operates improperly or not at all
Source of trouble
Leakage at connections and pump housing cover.
Impurities in fuel.
Condensed water in fuel causes fuel system to freeze up
in winter.
Pump diaphragm and valves leaks.
Febr 1977
Remedy
Test, replace if necessary.
Check and wipe ignition cables and distributor cover.
Replace if necessary.
Test, replace if necessary.
Blow clean with air.
Blow clean with air.
Clean jet.
Look for water in fuel pump filter (at lowest point)
and in float chamber.
Check jets, float level, fuel pump pressure, etc. See
group 2. Check that no air leakage occurs at gasket
between induction manifold and cylinder block or
at carburetor.
Remedy
Check fuel hose connection nipples and cover gaskets.
Check that pump filter and fuel lines between tank and
carburetor are not clogged.
Check for icing in fuel pump filter and fuel lines.
Drain tank and refill with fresh fuel if necessary.
Check pump diaphragm and valves, and replace if nec-
essary. Check pump pressure with manometer. See
group 2.
030-—7
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Page 48
Carburetor floods or leaks fuel
Source of trouble
Dirt in needle valve.
Valve or seat worn.
Float level incorrect.
Fuel pump pressure to high.
Leakage at fuel pipe connections.
Float damaged.
Uneven idling
Source of trouble
Volume control screw adjusted improperly.
Dirt in idling jet.
Idling passage clogged.
Air leakage at carburetor or induction manifold gaskets.
Faulty fuel gauge
Source of trouble
Fuel gauge registers too low or too high.
Fuel gauge works intermittently or not at all.
Low coolant temperature
Source of trouble
Difficulty in maintaining sufficiently high coolant tem-
perature in winter.
030—8
Remedy
Clean valve and seat.
Replace.
Check float level.
Check pressure.
Replace faulty connections.
Replace.
Remove, clean.
Remove carburetor and clean passage.
Tighten screws or replace gaskets. Adjust.
Remedy
Remove tank sender unit and adjust by carefully
bending float arm.
Fit a new gauge or tank sender unit in order to loca-
lize the fault. Faulty part can either be replaced or sent
to local Saab agent for reapir.
Remedy
Check thermostat opening temperature. (One method
is to install a new thermostat for comparison.) It is re-
commended that air flow be screened at the front
panel.
SAAB Febr 1977
Page 49
ELECTRICAL SYSTEM
Battery rundown
Source of trouble
Fan belt slipping.
Battery cells dry.
Battery faulty
Alternator or relay giving insufficient current.
Short circuit in starter switch.
BRAKES
Brake warning light glows
The light glows because of too great pedal travel, but the
braking effect is good.
The light glows because of too great pedal travel. The
braking effect is poor or uneven.
Febr 1977
Remedy
Adjust belt tension. See group 3, Electrical System.
Check fluid level in battery.
Check that specific gravity is same in all cells after
charging.
Carry out charging test. Check cable connections.
Disassemble and inspect switch.
Adjust the rear wheel brake shoes.
Investigate and repair leakage on brake lines, hoses or
cylinders.
030-9
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| CONTENTS ae
101
Dnata
120
110
| TREATMENT =
SPECIALTOOLS ae
_ SERVICE INSPECTIONS :
‘LUBRICATION
_ UNDERBODY AND RUSTPREVENTING -