Page 581
As from model 1976
The shells of the bumpers consist of U-shaped aluminium
bars to which the bumper brackets are mounted. There
are shock absorbant cellular blocks of polyethylene in the
bars. Outside the blocks there are polyethylene braces and
the bumpers are coated with a layer of rubber. This layer
is provided with anchorage bars on the inside and with a
bracing strip on the outside. Up to and incl. model 1976,
the bracing strip is of stainless steel and, as from model
1977, of rubber with 4 plastic strip with a acai in-
sert. Provision has been made on the front bunert or
the attachment of license plates and additional em = am
The rear bumper of the Saab 95 is equipped wit Be
parate outer parts consisting of steel covered wit ; pate
ber. The outer parts are bolted directly to the body. ‘
bumper brackets are masked with filler plates fastene'
with special clips.
FRONT BUMPER
REAR BUMPER
860—2
Febr 1977
Page 582
REMOVAL AND INSTALLATION
Front bumper and rear bumper, Saab 96
Remove the filler plates and loosen the two bumper brack-
ets.
installation is made in the reverse order.
Rear bumper, Saab 95
Remove the filler plates, loosen the cable harness from
the bumper clamp and the two bumper brackets.
The outer parts are removed by removing the two fasten-
ing nuts inside the fender.
Installation is made in the reverse order.
CHANGING THE CELLULAR BLOCKS
1. Remove the bumper.
2, Remove the bracing strip. Note the spacing sleeves un-
der the filling plates at each end of the bracing strip.
3, Remove the anchorage bars on the side of the bumper
where the cellular block is to be changed. (If the cen-
ter block on the front bumper has to be changed, both
the longer anchorage bars must be removed.)
4, Pull off the rubber layer, after which the cellular blocks
are accessible and can be removed.
CHANGING THE CELLULAR BLOCKS
5. Refit the rubber layer and bracing strip.
FITTING THE BRACING STRIP, UP TO AND INCL. MODEL
1976
FITTING THE BRACING STRIP, AS FROM MODEL 1977
6. Mount the filling plates and their spacing sleeves to-
gether with the anchorage bars. Remount the bumper.
SAAB 860-3
Febr 1977
Page 583
gODY FINISHING
As from model 1971
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890—1
Page 584
TECHNICAL DATA
Primer
Mode of application
Hardening
Manufacturer
Skin thickness after stoving
Intermediate coat
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness
Top coat
Spraying viscosity
Mode of application
Curing
Supplier
Skin thickness
Total skin thickness after stoving
(primer, intermediate coat, top coat)
Electro-immersion
20 min. at 3479°F (175°C)
AB Wilhelm Beckers
Dr Kurt Herberts
appr. 25,um
35—45 sec. (Saab standard 860 at 68°F /20°C)
Hot spraying. Paint temperature approx.
122°F (50°C)
20 min. at 320—338°F (160—170°C)
AB Wilhelms Beckers
appr. 25,um
35-40 sec. (Saab standard 860 at 68°F/20°C)
Hot spraying at approx. 122°F (50°C)
20 min. at 320—338°F (160—170°C)
AB Wilhelm Beckers
Dr Kurt Herberts
appr. 35—40,um
70—100,1m (0.07—0.10 mm)
Touch up enamel (factory paint with added hardener and enamel)
Spraying viscosity
Mode of application
Curing
Supplier
890—2
18—22 sec. (Saab standard 860 at 68°F/20°C)
Cold spraying
60 min. at 212°F (100°C)
AB Wilhelm Beckers
Dr Kurt Herberts
Du Pont
Febr 1977
Page 585
TOUCH-UP AND REFINISH INSTRUCTIONS
General
For all touch-up oF refinish jobs, use synthetic stoving or
airdrying enamel of the same quality type as that for the
original paintwork.
For perfect results, it is essential that the premises iri
which the work is to be done, i.e. the paintshop, be kept
absolutely free of dust. It should also be free of drafts
and must naturally not be used as a means of access to
other departments. The floor should be kept thoroughly
damp while spraying. A paint job ruined by dust cannot
be restored by polishing — flatting and respraying will be
necessary.
Body finishing
Before undertaking any partial refinishing, always spray
a test area to check that the shade used is identical with
the color of the parts that are not to be refinished. Any
deviations must be corrected by toning the paint. The
painting job involves the following operations:
Removal of rust and old paint
Rubbing down
Cleaning with a solvent
Priming of bare metal surfaces, for instance with wash
primer
Filling, if necessary
Flatting
Application of intermediate coat, for instance Surfacer
or Non Sanding, if necessary
Flatting, if necessary
Finishing
Air-drying, stoving with infra-red radiant heat or ina
drying oven, depending on the type of enamel used.
Cleaning
If the old paintwork shows defects such as cracking, pit-
ting due to the impact of flying stones, etc., apply a paint
remover or flatten down to the bare metal. After removal
of the old paintwork by one or the other of these methods,
degrease the metal with spirit, thimmer or some other suit-
able solvent. In principle, the same procedure should be
used even if the old paintwork has merely been rubbed
down instead of being removed. Realign any distorted
Panels and grind, for instance with a disc grinder, if neces-
sary, before flattening with wet abrasive paper P 400.
Finally, reclean the parts with spirit or cellulose thinner.
Thoroughness in this respect is vital to good adhesion.
Febr 1977
Priming
Coat all bared metal surfaces with primer. The drying
time and temperature for oven-drying or air-drying should
be as prescribed by the paint suppliers. An infra-red radia-
tion lamp may also be used for drying, but care must be
taken to keep it at a distance of not less than 16 in. (40
cm) from the metal. After drying, fill as necessary, apply-
ing the putty in thin layers and allowing the stipulated
drying time for each layer before the next application.
Rubbing down
Rub down the primed and filled surface with wet abra-
sive paper P 400 and then with grade P 600. After remov-
ing all water, rewash the surfaces with spirit or cellulose
and wipe with a piece of gauze drenched in slow drying
varnish (tack-ragging).
Equipment and procedure for refinishing
A. Stoving touch-up enamel
Oven:
A convection oven with an air temperature of 194—212°F
(90—100°C) is needed. A radiation oven can be used, and
in this case the metal temperature should be about 176°F
(80°C). It is important for the air temperature to be even
throughout the oven and for the temperature to be conti-
nuously checked. For this purpose, it is appropriate to
use, for example, a calibrated max. and min. thermome-
ter or a thermo-element with a compensator. Only this
latter measuring method can be used to check the plate
temperature.
Enamel:
Hardener must be added to the touch-up paint used in
the amount stipulated by the paint supplier. The enamel
can be sprayed either hot or cold, and the viscosity
should be adjusted accordingly with the thinner recom-
mended by the paint supplier to the following:
Hot spraying — viscosity approx. 35 sec.
Cold spraying — viscosity approx. 21 sec.
Measure the viscosity with a beaker according to the
method described in the Saab standard 860 at a tempe-
rature of approx. 68°F (20°C).
SS
Page 586
a
MEASURING VISCOSITY WITH AN SIS BEAKER
Procedure:
First of all, clean the body and chassis of the car tho-
roughly, thus ensuring that dust will not spread in the
spraying booth or drying oven. The glasses for the tail
lights, brake lights and back-up light, as well as the con-
trol relay for the Eberspacher BL2 ZW parking heater,
must be removed to prevent them from being damaged
by the heat,
The air inlets and air outlets from the passenger compart-
ment must be masked.
Cover the insides of all glass windows with sheefs of
board or the like to prevent the temperature from be-
coming too high.
On account of fire risk the battery cable must always be
disconnected and the fuel filler cap removed. The tank
should contain only a very small quantity of fuel.
lf the luggage compartment lid, the hood, or one of the
doors has to remain open, the opening must be masked
to prevent the air temperature inside the car from rising
above 167°F (75°C).
When the car is being pretreated and painted it should be
at normal room temperature. When the car is placed in
the oven, the latter should have reached the prescribed
temperature of 194—212°F (90—100°C).
Leave the car there for one hour.
B. Air-drying touch-up enamel (68—176°F/20—80°C)
When air-drying enamel is used, no special arrangements
are necessary other than a well heated, dustless booth.
The drying time can, however, be speeded up consider-
ably by stoving the enamel with an infra-red radiation
lamp or in an oven with an air temperature of not more
than 176°F (80°C).
890—4 SAAB
USE OF RADIATION LAMP TO DRY REFINISHED PART
The enamel can be sprayed either hot or cold, and the
viscosity should be adjusted accordingly with the thinner
recommended by the paint supplier to the following:
Hot spraying — viscosity approx. 35 sec.
Cold spraying — viscosity approx. 21 sec.
Measure the viscosity with a beaker according to the
method described in the Saab standard 860 at a tempera-
ture of approx. 68°F (20°C).
The metal must have adapted normal room temperature
prior to pretreatment and painting.
NOTE
Under the chassis sign is a sign indicating by means
of a code the original body color. Always quote
this code when placing orders for touch-up enamel.
This is particularly important as enamel conforming
to the same color specification may be supplied by
several different manufacturers.
GENERAL MAINTENANCE WORK
Proper care and maintenance of the care is necessary to
retain the gloss and durability of the enamel finish and
the protective properties of the underbody sealing. Re-
commendations in these respects are given in Group 1.
Febr 1977
_
Page 587
CONTENTS
900 GENERAL
Page 588
GENERAL
viodel 1967
CONTROLS
|
17 13
CONTROLS, MODEL 1967
1. Switch for extra equipment. (USA, warning flasher
switch).
2. Heating and ventilation controls.
Ventilator fan switch.
4. Switch for windshield wipers, 2 speeds, and wind-
shield washer pump. To start the wipers, turn the
knob clockwise. The first position is for low speed,
and the second position for high speed. To wash
the windshield, first pull the knob out, than let it
go.
5. Switch for headlights and instrument panel lights.
When the knob is pulled out to the first stop, the
side and rear lights as well as the number plate
light are lighted. Pulling the knob all the way out
lights the headlights as well. When the knob Is
pulled in either position, the intensity of the in-
strument panel lights may be adjusted by turning
the knob.
6. Hood lock.
The hood hinges upwards and forwards towards
the fromt of the car and is released in the follow-
ing manner:
a. Pull out the knob situated und
panel. This opens the hood to t
Position.
b. Push aside the lock mechanism
at the main lock under the front par
hood.
c. Lift up the hood.
Febr 1977
-
er the instrument
he half-locked
which is situated
t of the
: he button
; shtray, A | i
ie Y- Also provided in rear Passenger compart-
he Gear lever.
OSS |:
oe glove compartment. The door is provided
ha detachable plate for the installation of a
radio if desired
Direction indicator switch and except USA versions
i headlight flasher.
Fr
€€ wheel control, To lock out the free wheel action,
pull the handle ri
ght out. See page 19.
13, Handbrake, :
14. Dimmer switch.
15, j
5. Seat adjustment. When the catch is pressed down,
the seat is released and can be moved forward or
backward as desired.
re Control for adjusting angle of seat backrest,
Armrest. This can be adjusted to three different po-
sitions by means of the fastening screws.
FF FT a
i Ff
=<
er) 1 6 7
INSTRUMENTS, MODEL 1967
INSTRUMENTS
1. Speedometer with odometer. The speedometer is gra-
duated in m.p.h. or km/h. The odometer shows the
distance covered in miles (kilometers).
2. Indicator light, oi! pressure.
The lamp glows when the oil pressure of the engine is
too low. Never race the engine until the lamp is out.
If the lamp begins to glow when driving, the engine
should be stopped immediately and the cause be
traced.
3. Direction indicator repeating lights. Flash green in
time with the indicators.
4. Fuel gauge. The amount of fuel in the tank is shown
when the ignition is switched on. An indicator light
glows red when there is less than 1.5 imp. gals. (7 lit.)
left.
5. High beam indicator light; shows a blue light when
the headlights are on with the beam undimmed.
6. Charge indicator light; glows orange when the alterna-
tor is not charging.
7. Temperature gauge. The green zone indicates normal
operating temperature.
8. Electric clock with setting screw. The regulating screw
is at the back of the clock.
SAAB 900-1
Page 589
Model 1968
CONTROLS
13 42 567 #98 10
13
1211 14 15 16 17 18 19
CONTROLS, MODEL 1968
= ONS
900—2
Heating and ventilation controls.
Switch for extra equipment,
Ventilator fan switch.
Rheostat for instrument illumination, The intensity
of the instrument lights is adjusted by turning the
knob clockwise, (functions only when the lights are
on).
Switch for lighting units. In the first position, when
pulling out the knob, the parking lights are on as
well as the licence plate lights. In the second posi-
tion, the knob pulled all the way out, also the head-
lights are switched on.
Direction indicator switch. Also functioning as
switch for high beam headlight signal when the lever
is moved towards the steering wheel.
Ashtray. Also provided in rear passenger compart-
ment.
Switch for signal horn, windshield wipers/washer.
Operation:
a. The lever moved towards the steering wheel—
signal horn activated. (Pos. 0-3).
b. Position 1. (See symbols)—windshield wipers, low
speed.
c. Position 2. —Windshield wipers, high speed.
d. Position 3. Windshield wipers, high speed, and
windshield washers.
SWITCH FOR SIGNAL HORN AND WINDSHIELD WIPE RS/
WASHER
(Pos. 0-3)
0.
ibe
2.
3.
11,
12,
13.
14,
15.
16.
17.
18.
19.
Windshield wipers — neutral position
Windshield wipers — low speed
Windshield wipers — high speed
Windshield wipers — high speed and washer
Gear lever.
Lockable glove compartment. The lid is provided
with a detachable plate for the installation of a
radio if desired.
Hood lock.
The hood hinges upwards and forwards towards the
front of the car and is released in the following
manner:
a. Pull out the knob situated under the instrument
panel. This opens the hood to the half-locked po-
sition.
b. Push aside the lock mechanism which is situated
at the main lock under the front part of the hood.
c. Lift up the hood.
Dimmer switch.
Armrest. This can be adjusted to three different po-
sitions by means of the fastening screws.
Switch for brake warning light.
Free wheel control. To lock the free wheel action,
pull the handle right out.
Handbrake,
Seat adjustment. When the catch is pressed down
the seat is released and can be moved forward or
backward as desired.
Control for adjusting angle of seat backrest.
Fresh air ventilation lid. The lid may be opened by
pushing the handle of the lid forward.
The interior rear-view mirror has two different positions
of height. To adjust, turn the mirror half a turn
Febr 1977
Page 590
INSTRUMENTS, MODEL 1968
1
Febr 1977
. Speedometer with odometer. The speedometer is grad-
uated in m.p.h. or km/h. The odometer shows the
distance covered in miles (km).
{ndicator light, oil pressure.
The lamp glows when the oil pressure of the engine is
too low. Never race the engine until the lamp is out.
If the lamp begins to glow when driving, the engine
should be stopped immediately and the cause be traced.
. Direction indicator repeating light. Flashes green in
time with the indicators,
. Fuel gauge. The amount of fuel in the tank is shown
when the ignition is switched on. An indicator light
glows red when there is less than 1.5 Imp. gals (7 lit.)
left.
High beam indicator light. Shows a blue light when the
headlights are on with the beam undimmed.
. Charge indicator light. Glows orange when the alterna-
tor is not charging.
. Temperature gauge. The green zone indicates normal
Operating temperature.
. Electric clock with setting screw. The regulating screw
isat the back of the clock. (De Luxe version only.)
. Brake warning light. Will glow red as soon as the brake
pedal travel becomes too large due to any of the fol-
lowing faults:
a, Leakage in one of the two brake system circuits,
b. Rear brakes need adjustment.
If the warning light glows an authorized Saab Service
garage should be consulted for investigation and neces-
Sary remedy.
Model 1969
CONTROLS
Ll @83es6pen 8 8 10
7% tf B
3s tt @ i %
CONTROLS, MODEL 1969
Heating and ventilation controls.
Switch for extra equipment.
Ventilator fan switch.
Rheostat for instrument illumination. The intensity
of the instrument lights is adjusted by turning the
knob clockwise, (functioning only when the lights
are on).
5. Switch for lighting units. In the first position, when
pulling out the knob, the parking lights are on as
well as the licence plate lights. In the second posi-
tion, the knob pulled all the way out, also the head-
lights are switched on.
6. Direction indicator switch. Also functioning as dim-
mer switch and switch for high beam headlight sig-
nal when the lever is moved towards the steering
Pie ys
wheel.
7. Ashtray. Also provided in rear passenger compart-
ment. z ; ‘
8. Switch for signal horn, windshield wipers/washer.
Operation:
The lever moved towards the steering wheel —
signal horn activated. .
b. Position 1. (See symbols) — windshield wipers,
low speed. » ii
Position 2. — windshield wipers, high speed.
4 Position 3. — windshield wipers, high speed and
windshield washer.
a.
900—3