Page 51
GENERAL HINTS
GENERAL
A neat and tidy workshop is essential for the proper ser-
vicing of vehicles. Some parts of the car need to be treat-
ed with special care and effectively protected against dirt
and contamination while work is in progress. For the me-
chanic who may be new to the job the following points
may be of help:
1. Protect fenders and other paintwork with suitable cov-
erings.
2. Lay protective coverings over the seats and upholstery
to save them from spots of oil and dirt.
3. Clean the insides of fenders and the space round the
rear axle thoroughly before starting to work on wheel
hubs and axles. This makes the job easier and prevents
grit and dirt from getting into bearings and other sus-
ceptible parts.
4. Before unscrewing spark plugs, clean the recess round
the plug thoroughly.
5. Every job must have its proper place. It is bad practice,
for example, to disassemble an engine or transmission
on a bench which is also used for filing, etc. or where
filing is done in the immediate neighbourhood.
Febr 1977
THREAD SYSTEM AND WRENCH SIZES
The thread system mainly used in the Saab car is the UNC,
i.e. UNIFIED COARSE THREADS, in which inches are
the unit of measurement.
Wrench sizes for nuts and bolts are expressed in inches and
the dimensions are the same as the designations of the
tools. In a few cases, UNF, i.e. UNIFIED FINE, threads
are used.
An important exception is the engine, which has the metric
thread system.
Exceptions to the thread system will also be encountered
in the case of components supplied by sub-suppliers, such
as Bosch, where metric threads will be found.
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Page 52
-_——
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100-2
INSTRUCTIONS FOR JACKING-UP THE CAR
The construction of the car, with its self-supporting body,
offers no natural lifting points at which to apply a jack,
as on cars with a conventional chassis, Two special fittings
are provided one on each side, to take the jack included
in the tools for the car, They are intended for use when
changing wheels, etc. Under the front of the engine com-
partment floor, immediately behind the front muffler, a
reinforcement provides a support for a shop jack. This is
the best point at which to lift the front of the car in order
to lubricate the ball joints. A similar jacking point is pro-
SUPPORTING THE FRONT END
fan
vided under the rear part of the car, where the floor is re.
inforced. This point is located on the center line of the
car, immediately in front of the rear axle tunnel. Most
shop jacks feature a lifting head shaped like a low fork,
and it is therefore advisable to place a wooden block of
suitable size on this in order to avoid damaging the floor,
For certain jobs it is necessary to support the front or
rear part of the car on trestles, Make sure that the weight
of the car is borne up on the jacking points, or in the
immediate vicinity of the wheel houses.
JACKING UP THE REAR END
SUPPORTING THE REAR END
Febr 1977
Page 53
SPECIAL TOOLS
GENERAL
The seven figure number quoted in the following list of
special tools is the part number. The number which is
also marked on the tools only includeds the first six fi-
gures.
The special tools in the list are classified as follows:
Tools for engine, transmission and chassis work
Class AOQ-1 = Tools used very frequently in service
work (e.g. adjustment of timing)
AO-—2 = Tools used frequently in maintenance
work (e.g. replacement of brake pads)
Al = Tools necessary for simple repairs (e.g.
replacing the clutch or valves)
A2 = Tools necessary for qualified repairs
(e.g. reconditioning the gearbox)
A3 = Tools which are mainly recommended
for reasons of operational efficiency
Tools for body work
Class B1 = Tools necessary for simple body work
(e.g. replacement of front fenders)
B2 = Tools necessary for qualified body work
(e.g. alignment work)
B3 = Tools which are mainly recommended for
reasons of operational efficiency
TOOL RACKS
It is most important that special tools be kept in a suit-
able place, where they will be readily accessible and easi-
ly found.
Febr 1977 SAAB
101—1
b
Page 54
Special tools, engine
Part No. Description Class Mlusteation Remarks
7860794 | Floor stand A2 Also Saab 99
7860877 | Bench stand A2
- Part of
7860885 | Vise stand
7860877
Also Saab 99
7861479 | Engine stand A2 Alternative to
7860794
Also Saab 99
8390478 | Shaft A2 Also Saab 99
7860851 | Retainer, engine A2
$4973
7860802 | Oil pan A2 Also Saab 99
101-2 SAAB March 1979
Page 55
Special tools, engine
Part No. Description Class iMustration Remarks
7862022 | Lifting tool, power unit (q)
oY _a|
q
§ 4963
7862014 | Strap tool, oil filter cartridge A0-1 Also Saab 99
2.0 | engine
7862147 | Removing and centering tool, oil seal, A2
balance shaft
7862154 | Installing tool, oil seal, balance shaft A3
and bushing, distributor
7862170 | Installing tool, rear crankshaft seal A2
7862188 | Removing tool, crankshaft gear A3
PY
(a=
CZ
S 4969
7 ing tool, pist
862287 | Installing tool, piston A3 Kies Biualion
2.0 | engine
March 1979 SAAB 101-3
Page 56
ae
ee
~~
ua
———__
(0G ere Special tools, engine
Part No. |
| Description Class Iustration Remarks
———-—____
7862394 F Et
eeler ga ;
eel Measuring valve A3
7862279 | Remoy;
7861230 oauewe tool, valve spring A3
Spare Part
7862402 | Valve retainer me
$4976
8392193 | Valve seat cutter A2 TE
integral parts,
see spare parts
catalogue
7862105 | Reamer, valve guide, over-size 0.2 A2
7862113 | Reamer, valve guide, over-size 0.4 A2
7862121 | Reamer, valve guide, over-size 0.6 A2
7862139 | Reamer, valve guide, over-size 0.8 A2 a
——— ws
; March 1979
101-4
Page 57
CS ee
Special tools, engine
a - — ee
Part No, Dereription Clans Wustration
Nomar
7862196 | Installing tool, water pump shaft A3’
84070
7862204 | Installing tool, water pump impeller A3
a)
Ca
S$ 4971
7862436 | Dolly, water pump A3 0 )
$4972
7843303 | Pliers, hose clamps Al Also Saab 99
8392045 | Adaptor, ignition timing A0-1 cw Cc 0 Also Saab 99
$2363
8392052 | Adaptor, dwell angle setting A 0-1 —= > Also Saab 99
$2364
7860620 | Key, bolts, inlet manifold A 0-1
§ 4970
March 1979 SAAB 101-5
Page 58
Special tools, engine
Part No. Description Class Illustration Remarks
7860984 | Level tube, float level A3
$4975
7860919 | Key, fast idling setting A3
S$ 4977
7860513 | LOCTITE locking liquid Also Saab 99
8343808 | LOCTITE quickset Also Saab 99
7868052 | Atmosit sealing compound, inlet
manifold
TERDSON
Atmosit
S$ 4980
7860505 | Plastigage, for measuring bearing Also Saab 99
clearance
SAAB March 1979
101—6
Page 59
= ES Fo SERS A NTT AGEN SR EE BT ETS ee oer "
Special tools, transmission
Pt RQ, Baseeatian Clan (aateation Remarks
| a —
PRANAB | Centering tool cluteh-cluted dive AN =>
aagar
PAAORDD | _ Dial raloator (ink tea gare points) AQ-2 Alao Saab 00
FAIA | Protective cover, inner universal joints A\ Also Saab 99
madel 1960
PIBW7PTS | Protective cover, bearing, inner drive shaft | At Also Saab 99
model 1969
7841000 | Assembling and disassembling fixture, A2 Concerning
transmission ease integral parts,
gee spare parts
eatalogue
8790305 | Installing and removing tool, freewheel A2 Pp
8790313] Sleeve a) Spare part
8790321 Key S 4084 Spare part
7841158 | Puller, pinion-shaft bearing A2
101-7
IE
Page 60
TVS 0ew tee Special tools, transmission tin
Part No, i
Description Klass Mlustration [un
I a Marks |
7 NNEr ring, pinion-shaft bearing A2
S 4998
7 .
840945 Wrench, intermediate shaft end nut, A2 UP to and
gearbox sy incl, 9@arbox
; No. F 108919
7861321 Wrench, intermediate shaft end nut, A2 sam As from gear.
gearbox box No,
F 108911
7860588 | Arbor, intermediate shaft A2
7841117] Point, short, for 7860588 Spare part
7841125 | Point, medium, for 7860588 o $4994 aL
7841133 | Point, long, for 7860588 Spare part
7841257 | Supporting tool, intermediate shaft A2
7841042 | Driving-out arbor, primary shaft A2
7841091 | Installing tool, bearing A2
$4993
i y. Also Saab 99
41067 | Driving-on sleeve, pinion latin A2 —f\
shi steering knuckle housing inna cH y
on outer drive shaft $ 4990
L SAAB a