Page 551
26
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VIEW B-B
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BASIC BODY MEASUREMENTS, SAAB 96
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810—9
Page 552
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Body measurements, Saab 96
Item in. mm Remarks
0 - = Underside of sill
1 84.17 +0.08 2138 +2
2 13.66 +0.04 347 +1
3 1.50 +0.02 38 +0.5
4 3.33 + 0.06 84.54+1.5
5 8.27 + 0.04 210 +1
6 3.90 + 0.02 99 +0.5
7 9.82 + 0.06 249.5 +1.5
8 3.94 +0.02 100 +0.5
9 19.09 + 0.06 485 +1.5
10 90.31 £0.12 2294+3
11 30.87 +0.12 784+3
12 28.74 +0.08 730 +2
13 12.87 0.12 327+3 To leading edge of pil-
lar reinforcement tube
14 14.37 +0.12 365 +3
15 5.47 +0.12 139 +3
16 9.33 +0.04 237 +1 To middle of center
bearing
17 2.09 +0.12 53+3 To middle of center
bearing
18 1.18 £0.02 30 +0.5
19 45.71 +0.16 1161+4
20 7.99 +0.16 203 +4
21 27.80 +0.12 7O6+3
22 41.34+0.12 1050 +3 To leading edge of pil-
lar reinforcement tube
23 47.52 +0.16 120744
24 40.28 +0.16 1023 +4
25 | 90° 90°
26 54.21 +0.20 1377+5 Tongue of cowl plate
view A and C—C
27 49.45 +0.12 1256 +3 Measured parallel to
wheelhouse, See C—C
28 16.54 +0.08 420+2
29 0.98 + 0.08 25242
30 42.68 +0.08 1084 +2 See view A, view C—C
and view G—G
31 28.74 + 0.08 730 +2 See view C—C and
view H—H
33 10.67 + 0.12 271 +3
34 29.92 + 0.08 760 £2
35 25.31 +0.12 643 +3
36 26.10 + 0.08 66342
37 39.61 +0.12 1006 +3 To upper edge of pil-
lar
38 59.21 +0.16 150444
39 26.24 +0.08 | 666.5+2 Holes for engine sus-
pension pads
40 17.71 +0.04 450 +1
810—10
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Febr 1977
Page 553
HOOD, FRONT PANEL AND FENDERS
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HOOD WITH ATTACHMENT COMPONENTS
Removal
1, Open the hood with the control mechanism under the
instrument panel. The hood then opens half-way. To
open the hood wide, move the latch at its rear edge
forwards and lift the hood forwards.
REMOVAL OF HOOD
Installation
1. Lift up the hood and hold it upright beneath the front
; panel.
2. Press the hinge stays inwards and slide the pins into
HOOD CATCH the bearings. :
Fit locking needles, if the pins already had such ones.
4. Close the hood.
~
2. Remove the locking needles of the pivot pins, then
Press one of the hinge stays slightly inwards to dee
the pin. The assistant holding the hood on the other
side helps to lift it off.
Page 554
Hood lock
The hood is fitted with a locking pin, longitudinally ad-
justable by means of two nuts. This adjustment can be
used to obtain the wanted amount of tension on the hood
The lock can be
tion to the pin in the hood by slackenin
Ng screws in the front panel,
If the hood contro} should be dama
cannot be opened from inside the
Pass a screwdriver through the gril
the lock and press the control arm
can now be opened,
As from model 1976, a stay is introdu
hood be kept in the open position.
in the locked position. centered in rela-
g the two retain-
ged so that the hood
Car, proceed as follows,
le immediately under
to the right. The hood
ced, by which the
FRONT PLATE, UP TO AND INCL. MODEL 1968
To remove the front panel, back off and remove the two
screws On either side and the screws for the radiator sup-
ports and wheel housing brackets.
REMOVAL OF SCREWS, FRONT PANEL
Disconnect the hood control and the cable connections
for the headlights and direction indicators/and parking
lights.
REMOVAL OF FRONT PANEL
Headlight shells
The headlight shells are incorporated in the front panel
which is pressed in a special fashion in order to accom-
modate them. When replacing the front panel or shells,
the parts must be drilled and riveted to each other.
Grille
The grille is attached to the front panel by means of six
bolts which are screwed directly into the grille panel and
are accessible from inside the front panel.
820—2
Febr 1977
Page 555
FRONT PLATE, MODEL 1969—1979
Decor frames, headlights
The decor frame is attached to the front plate as follows:
Two pins in the lateral part of the decor frame are orice
jnto the rubber bushings in the outer ends of the front
plate, and a selftapping screw is inserted through the op-
posite side of the decor frame.
At removal, loosen the self tapping screw, then pull the
frame out.
Front plate
The front plate has, at its lower part, three pins which
are attached to brackets on the front member. Between
pins and brackets, there are rubber spacers. Inside each
decor frame, there is a screw and a clamp, which retain
the front plate to the wheel housing.
At its upper edge, the front plate is attached to each fend-
er and wheel housing stay with a screw, At removal, first
joosen the decor frames, and the screws retaining the
front plate. Then loosen the hood lock control from the
dash panel and the wheel housing stay. Loosen the con-
nectors from the headlights. Move the front plate for-
ward, and lift it out of the brackets.
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REMOVAL OF SCREWS, FRONT PANEL
Febr 1977
REMOVAL OF FRONT PANEL
Installation is made in the corresponding way.
Grille
The grille consists of three parts, attached to the front
plate with self tapping screws. All the screws are within
easy reach from the front.
820—3
Page 556
FRONT PLATE WITH HEADLIGHT WIPERS, AS FROM
MODEL 1971
$4217
FRONT PLATE WITH GRILL
1. Decor frame, up to and inci, model 1973 6. Fixing screw, fender
2. Rubber bushings 7. Fixing screw, wheel housing stay
3. Self tapping screw, decor frame 8. Self tapping screws for grille plate
4. Fixing screw for front plate 9. Grille, up to and incl. model 1973
5. Clamp 10. Grille, as from model 1974
Disassembly and installation Grille
1. To remove the front plate first loosen the decor frames. The grille consists of three parts, attached to the front.
Loose the headlight washer hoses from the jets and the On cars up to and incl. model 1973, the grille is divided
cable connections from the headlights. Unscrew the into three parts. As from model 1974, the grille is
front plate retaining screws. Loosen the radiator stays moulded in plastic in one piece which also encloses the
from the body, the radiator suspension straps and the headlights. The grille is fixed to the front sheet by means
hood lock control wire. of self tapping screws, all of which are easily accessible
2. Unscrew the lower screw for the expansion tank brack- from the front.
et a few turns and fold the bracket rearwards so that
the wiper motor goes free. Remove the cables from the
wiper motor. Note the cable connections.
3. Move the front plate forwards and lift it out of the
brackets.
Installation is made in the reverse order. See to it that
the rubber strips in the ends of the front plate are fitted
and that the plate is correctly positioned in the guides.
REMOVING THE GRILLE
820—4 SAAB
Febr 1977
Page 557
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FENDERS
After considerable mileage, especially on gravel roads,
the underbody coating may be worn away at exposed
ints, and should therefore be examined at regular in-
tervals and touched up as required. The rear fenders are
particularly exposed to the effects of flying gravel and
stones.
Removal
When removing the rear left fender, plug the fuel filler
pipe with a piece of clean linen rag to prevent dirt from
entering the fuel tank during the course of the work,
when the cap is removed,
1, Take off the wheel.
2. Back off and remove the fender retaining screws, start-
ing at C and D.
3, Disconnect the electrical cables as necessary, and then
back off and remove the screws at B.
4. Release and remove the fender, collecting the tad-
pole sealing bead.
DISASSEMBLY AND REASSEMBLY OF FENDERS
Installation
After having treated the fender with underbody coating
and refitted the moldings, lights and possible rubber
grommet (left rear fender), reinstall as follows:
1, Locate the fender and tadpole sealing bead in posi-
tion and insert screws B and Cc.
- Align corner A and tighten screws B and C enough to
retain the fender firmly while permitting further align-
ment if necessary.
. Insert the remaining screws.
- Check the fender alignment and tighten all the screws
finally, but not so hard as to buckle the fender panel
at the tadpole sealing bead.
5. Reconnect cables, as applicable, and refit the cable
sleeves, Pass the filler pipe through the rubber grom-
met and screw on the filler cap after removing the
linen rag or similar plugging material. Tighten the
clamps, if previously slackened.
6. Cut off surplus sealing bead below the fender and re-
fit the wheel.
The clearance between the front fender and the door can
be adjusted by removing the fender and hammering the
vertical panel to which the fender is attached forwards
Or rearwards as necessary.
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Page 558
Left rear fender
As from model 1970 the fuel filler tube opening in the
left rear fender is located lower down than in earlier
models. Only the new type of rear fender is available for
replacements. A new filler tube has therefore been pro-
duced for Saab 95 UP to and incl. chassis No. 95.010.115,
while for other cars up to and incl. model 1969 an adapt-
er set has been made Up containing parts for the new filler
tube that are needed to be able to fit fenders of the new
type to older cars. Where replacements for the old type
of fender are needed, you should order the new fender
plus the appropriate adapter set. For Saab 95 up to and
incl. chassis No. 95.010.115 order only the new filler tube.
Installation
1. Remove the old fender. Clean the wheel housing to
prevent dirt from entering the fuel tank.
2. Remove the filler tube and connecting hose. Leave
the vent tube connecting hose in place on the vent
tube of the tank.
3. Fit a plastic plug into the small vent tube of the new
filler tube. Connect the filler hose between the fuel
tank and filler tube, using the existing hose clamps.
Fit the vent tube and connecting tube.
CONNECTING FILLER TUBE TO FUEL TANK
1, Plastic plug
2. Hose clamp
3. Vent hose
4. Connecting tube
5. Hose clamp
6. Connecting hose
7. Hose clamp
4. Mount the fender. Spread a string of sealant between
the filler tube flange and the fender, and tighten the
flange and holder with the four self tapping screws.
Fit the filler cap.
NOTE! Use only the old type of filler cap (with venti-
lation).
CONNECTING FILLER TUBE TO REAR FENDER
1, Sealing collar
2. Fender
3. Holder
4. Philips screw
5. Plastic plug
6. Hose clamp
7. Vent hose
820-6 SAAB
Febr 1977
Page 559
4
poORS AND LIDS
poors
Removal
1, Remove the interior door trim.
2. Release the door stop by driving out the pin at the up.
per hinge.
3, Let the door rest On a suitable SUpport Or suspend it
; in a suitable way in order to relieve the hinges of its
weight.
4. Bend back the locking tabs for the externally sited
nuts.
5, back off the two nuts, accessible from inside the door,
and remove the door.
NOTE
Be careful not to damage the outside of the door
with the tools used to release the nuts.
REMOVAL OF DOOR
6. Remove the hinges from the body.
Installation and adjustment
1. Refit the hinges to the body, of previously removed.
Also fit the inner locking nuts on the hinge pROE pins,
2. Block UP or suspend the door in the correct position
and pass it onto the hinge pivot pins.
4. Refit the washers and hinge nuts inside the door.
4: Check carefully to see if the door fits properly into
the Opening,
NOTE
Be Careful not to damage the front fender when
Opening the door without the door stop being
fitted,
5. Adjust the door in the longitudinal direction of the
car by advancing or backing off the nuts a little at a
time. To adjust the vertical position of the door, move
it Up or down in the elongated holes after loosening
the nuts slightly.
6. When the door is correctly positioned and fits snugly
against the weather Strips, tighten the nuts and secure
with the locking tabs,
7. Refit the door stop pin and the interior trim.
Window regulator
Removal and installation
1. Remove, the door trim.
2. Back off the four nuts accessible through the hole in
the toothed segment of the window regulator, holding
the window pane in position meanwhile. The screws
can than be removed.
3. Release the control arm pin from the retainer groove
and remove the window regulator.
REMOVAL OF WINDOW REGULATOR
To reinstall the window regulator, proceed in the reverse
order to that given above.
830-1
Page 560
Door lock
Replacement
1. Close the door window.
2. Remove the interior door trim,
Ss i
Unscrew the inner door handle remote control retain-
er, Note the return spring on cars as from model 1969.
Back off and remove door lock retaining screws, and
unscrew the button used to lock the door.
5. Release and remove the lock. Note that locks as from
model 1968 must be in ‘‘closed’’ position when re-
moved.
REMOVAL OF DOOR LOCK
6. If necessary, the outside door handle can be removed
by backing off and removing the two retaining screws,
one inside and one on the back of the door.
To reinstall the door handle and door lock, proceed in
the reverse order to that given above. Before refitting,
check that the moving parts of the lock, and the lock
springs, are well jubricated with Saab Special Chassis
Grease.
Check with the button of the outside handle pushed in
that there is a play of about 0.04’ (1 mm) when the door
is closed. If the play is less than this, adjust as follows:
a. Cars up to and incl. model 1971: File down the part
of the push button arm that actuates the door lock.
b. Cars as from model 1972: Bend the outer part of the
push button arm.
After refitting the door, adjust the striker plate so that
the door opens and closes easily.
830-2
Door striker plate
Adjustment
The striker plate is adjustable and can be moved if the
screws are slackened. Adjust the striker plate so that the
door opens and closes easily without being forced up or
down by the location of the plate.
ADJUSTMENT OF DOOR STRIKER PLATE
Lock cylinder
Removal
After removing the interior door trim, take off the out-
side door handle by removing the two retaining screws,
one inside and one on the rear edge of the door.
Disassembly, up to and incl. chassis No. 95773000541
and 96773000960
1. Up to and incl. model 1971:
Depress the push button (7) and drive out the pin (2)
with a driver (max. 0.12 in/3 mm). Remove the arm
(1) and the washers (3 and 4).
Nov 1977