Page 71
Part No.
.|
7840937
7860695
7860703
8291395
401—20
ee
Special tools, miscellaneous
—— es a
Description Class Mlustration Remarks
ee
Pliers, contact crimping of pre-insulated Al
terminals
Also Saab 9¢
Pliers, contact crimping of uninsulated Al
terminals
Also Saab 99
Pliers, contact crimping of round pegs Al
S$ 4746
A3
Sleeve wrench
ee a
March 19
— SAAB
Page 72
—- .'*
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SERVICE INSPECTIONS
Every new Car is accompanied by a service card that should
be stamped at every service occasion.
Guarantee service at 12,000 miles (2,000 km) is made free
of charge (except for oils etc. for thish a charge is made).
Other maintenance according to the service program is
made at 6,000 miles (10,000 km) and will be billed.
The maintenance program is included in the Guide.
The maintenance program is divided into the following.
—
EXHAUST EMISSION
The authorities’ regulations governing the emission
of carbon monoxide, hydrocarbons and nitric oxide
in car exhaust fumes are becoming increasingly more
stringent. Saab cars are designed and built to meet
these requirements on the condition that the engines
are correctly tuned.
The workshops hold a key position in being able to
limit the emission of toxic gases from cars and there-
fore make a contribution to keeping pollution down.
Remember that a correctly tuned engine also en-
sures that the car runs smoothly and with low fuel
consumption.
The relevant adjustments are described in the ser-
vice program. We would like particularly to em-
phasize the importance of adjusting the ignition sys-
tem and the fuel system in accordance with the
specifications.
DELIVERY INSPECTION
1. Check the engine oil level and if necessary replenish
oil.
2. Check the gearbox oil level and if necessary replen-
ish oil.
3. Check level of coolant and its freezing point.
4. Check function of all locks, headlights, interior
lights, stop lights, direction indicators, warning
flashers, back-up lights, indicator, lights, brake war-
ning light, windshield wipers/washer, headlight
wipers/washer, heater fan and signal horn.
5. Check the headlight alignment.
6. Check the battery electrolyte level and charging
condition,
7. Tighten cable terminals at battery, starter motor,
voltage regulator and alternator.
8. Check, if necessary, adjust fan belt tension.
9. Check, if necessary, adjust the ignition setting.
10. Check the fluid level and if necessary replenish
brake fluid in the master cylinders for brakes and
clutch.
11. Check, if necessary, adjust the parking brake.
12. Check brake hoses and lines for leakage.
13. Tighten the wheel boits.
14. Adjust the tire pressure, incl, the spare wheel.
March 1979
15.
16.
17.
19.
20.
Check, if necessary, adjust toe-in.
Check, if necessary, adjust the seat rails
Check that tool kit, Guide and Service card are in
place.
Test run car and cneck the general fu rctions
(clutch, gearbox, brakes, wheel balance, instru-
ments, direction indicator return, etc).
Check that there is no rattle.
Check the steering wheel position.
Check and adjust idling, fast idling setting and CO-
value,
Check the level of washer fluid.
GUARANTEE INSPECTION AT 1,200 MILES
(2,000 KM)
NO —
10,
11,
12.
13.
14,
15.
16.
17.
18.
19,
21.
22.
Tighten cylinder head boits to prescribed torque.
Check and if necessary adjust valve clearances.
Check and tighten inlet manifold and carburetor
flange screws. Check that choke spindle moves
freely,
Check and tighten exhaust manifold flange nuts.
Check exhaust system for leaks and tighten clamp-
ing and suspension screws.
Check and tighten screws on all engine mounts.
Change engine oil (owner pays for oil).
Change transmission oil and clean megnetic drain
plug (owner pays for oil).
Check radiator coolant level and cooling system for
leaks (pressure test).
Check fluid level in clutch master cylinder and top
up if necessary. Check and if necessary adjust clutch
bearing play.
Check operation of headlights, interior lights, stop
lights, direction indicators, warning flasher, back-
up lights, indicator lights, brake warning light,
windshield wipers/washer, headlight wipers/washer,
heater fan and signal horn,
Check and if necessary adjust headlight alignment.
Check battery electrolyte level and top up if neces-
sary. Grease cable shoes.
Check and if necessary adjust alternator drive belt
tension.
Check and if necessary adjust dwell angle of breaker
points. Grease distributor breaker cam and lubrica-
ting felt. Check and if necessary adjust ignition
timing.
Check fluid level in brake master cylinder. Top up
if necessary.
Check and if necessary adjust rear wheel brake
shoes.
Check and if necessary adjust the parking brake.
Check brake fiuid lines and hoses for condition and
leaks.
Check condition of rubber bellows on steering
gear and inner and outer universal joints, and of
rubber seals for ball joints and tie-rod ends.
Check and tighten screws securing rear axle to body.
Check and tighten screws securing control arms to
body (front suspension).
110—1
Page 73
23. Check and tighten rear engine mounting screw.
24. Check and if necessary adjust wheel alignment
(camber, caster and toe-in). Check the tightness of
the lock nuts on both tie-rods.
25. Test run car and check the general functions
(clutch, gearbox, brakes, wheel balance, instru-
ments, direction indicator return, etc).
Check that there is no rattle.
26. Check and if necessary adjust engine idling speed.
CONTROL PROGRAM
to be carried out by authorized workshop every 6,000
miles/10 000 km.
Engine
Check and if necessary adjust valve clearance.
Clean air cleaner insert.
Check and if necessary adjust engine idling speed and the
emission of carbon monoxide (CO) at idling.
Clean fuel pump filter.
Check fuel lines in engine compartment for leakage.
Pressure test of the cooling system (check the condition
of the hoses).
Check the choke mechanism and fast idling.
Check the vacuum hoses and connections.
Electrical system
Check condition of V-belts and adjust belt tension if
necessary.
Inspect condition of headlights by eye.
Check and if necessary adjust headlight alignment.
Check spark plugs.
Check condition of breaker points.
Check and if necessary adjust dwell angle and ignition
timing.
Lubricate distributor breaker cam and lubricating felt.
Check the condition of the ignition cables.
Transmission
Check and if necessary adjust clutch release bearing play
and the level in the clutch main cylinder.
Check transmission oil level and top up if necessary.
Brake system
Check level in master cylinder, top up with brake fluid
if necessary.
Remove wheels and check thickness of brake pads.
Check the tightness of the wheel cylinders.
Check and if necessary adjust handbrake and footbrake.
Check brake lines and hoses for condition and leaks.
110-2 SAAB
Front assembly
Lubricate the steering gear.
Lubricate ball joints and tie rod ends (not cars with per-
manently lubricated joints).
Check toe-in.
Check condition of rubber bellows on steering gear and
inner and outer universal joints, and of rubber seals for
ball joints and tie-rod ends.
Miscellanous
Test drive and function control.
SPECIAL MAINTENANCE PROGRAM
to be carried out every 6,000 miles/10,000 km or
oftener.
The owner can carry out the work or order it in connec-
tion with service.
Check the oil level in the engine.
Check the freezing point of the cooling liquid.
Check battery electrolyte level and top up if necessary.
Tighten and grease cable clamps.
Check fuel lines in the engine compartment for leakage.
Check that the choke shaft moves easily. Lubricate the
throttle control.
Check the tightness and the condition of the exhaust
system.
Lubricate the door stops, the door hinges and the hood
lock mechanism.
Check the tire pattern depth.
Check the air pressure in the spare tire.
Check operation of parking, brake and tail lights, licence
plate illumination, direction indicators, horn, back-up
lights, hazard warning signal, interior lighting, control
and indicator lights, windshield and headlight washers
and wipers, brake warning light, instrument lighting,
trunk lighting and ventilator fan.
Check condition of washer jets and rubber wiper blades.
MAINTENANCE PROGRAM
In connection with 6,000 miles/10,000 km service.
Carried out when needed by authorized workshop.
U1. Change engine oil every 6,000 miles/10,000 km or
twice a year.
U2. Change oil filter every 6,000 miles/10,000 km.
U3. Change oil in the gearbox. Clean the magnetic plug.
Every 20,000 km/12,000 miles or at least once a year.
U4. Change spark plugs every 12,000 miles/20,000 km.
March 1979
Page 74
U5. Change breaker points (after control).
U6a. Change fuel filter every 12.000 miles /20,000 km.
U6b. Change air cleaner insert every 18,000 miles/
30,000 km.
U7. Check and if necessary adjust wheel angles (cam- -
ber, caster and toe-in) every 12,000 miles/20,000 km.
U8. Change brake fluid every 24,000 miles/40,000 km
or every second year.
U9. At the first 6,000 miles/10,000 km program: Tor-
quing the inlet manifold.
U10. Saab 95: Check and if necessary adjust liquid level
in the rear shock absorbers every 12,000 miles/20,000
km.
U11. Every 12,000 miles/20,000 km as from model
1976: Check the crankcase ventilation hoses. Remove,
wash and fit the guiding sleeve. Clean the strainer in
the oil filling cap.
March 1979 Sans 110-3
Page 75
LUBRICATION
Engine
THE MOTOR OIL should be changed for the first time
after 1,200 miles (2,000 km), after which it should be
changed every 6,000 miles (10,000 km) or twice a year.
ORAIN PLUGS, OIL
1. Engine
2. Transmission
Use oil according to Service Class SE in the API system
or to Ford specification ESE—M2C—101C. Viscosity
SAE 10 W 30 or 10 W 40. In extremely cold weather, i.e.
at constant temperatures below —4°F (—20°C), use oil
of viscosity SAE 5 W 20. NOTE! This oil may not be
used at temperatures above 32°F (0°C).
Oil quantity 5 imp. pints (3 liters), incl. oil filter 5.8 imp.
pints (3.3 liters). The distance between the upper and
lower marks on the dipstick corresponds to a volume of
2.5 imp. pints (1.5 liters).
THE OIL FILTER should be changed every 6,000 miles
(10,000 km) in connection with oil change. The filter is
removed with tool 78 62 014.
THE THROTTLE CONTROL BEARINGS, accessible from
the engine compartment, should be oiled every 6,000
miles (10,000 km) with motor oil.
ELECTRICAL SYSTEM
The DISTRIBUTOR LUBRICATING FELT should be
oiled every 6,000 miles (10,000 km) with motor oil.
The felt is placed in the upper part of the shaft under the
distributor arm, which must be removed first.
THE DISTRIBUTOR BREAKER CAN is at the same time
lubricated with Bosch Ft 1v4 grease.
NOTE
Avoid excessive lubrication of distributor parts, as
grease on the breaker points causes burning of
these and can disturb the ignition.
March 1979
TRANSMISSION
THE TRANSMISSION OIL should be changed for the
first time after 1,200 miles (2,000 km), and thereafter at
intervals of 12,000 miles (20,000 km) or at least once
every year. Use EP oil, SAE 80 W alt SAE 75, according
to API GL—4 all the year round.
Gearbox and differential are filled and drained through
the same openings.
FILLER AND LEVEL PLUGS, TRANSMISSION
1. Filler plug
2. Level plug
The oil level should be checked every 6,000 miles (10,000
km).
The level should not be lower than 0.2 in. (5 mm) below
the hole for the level plug.
Use dipstick 78 62 444 after unscrewing the filler plug.
CHECKING THE GEARBOX OIL LEVEL
120—1
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THE CLUTCH FLUID CONTAINER should be filled
with brake fluid according to specification. The fluid
level should be checked regularly and it should coincide
with the level mark on the outside of the container,
BRAKE SYSTEM
THE BRAKE FLUID CONTAINER should be filled with
brake fluid according to specification DOT3, DOT4 or
SAE J 1703. The level should be checked regularly, At
the same time check that the bleeding hole in the cover
is not clogged. The brake fluid should be changed every
24,000 miles (40,000 km) or at least every second year.
CHASSIS
BALL JOINTS AND TIE ROD ENDS should, if not per-
manantly lubricated, be greased every 6,000 miles (10,000
km) with Saab Special Chassis Grease, The front end of
the car should be lifted so that the front wheels are free
from the floor.
THE STEERING GEAR should be greased every 6,000
miles (10,000 km) with Saab Special Chassis Grease.
While greasing, turn the steering wheel to full left lock so
that the grease penetrates also to the righthand part of
the steering gear.
Check that rubber bellows are not abnormally swollen
after lubrication and that they are free of defects likely to
cause loss of grease.
REAR SHOCK ABSORBERS (Saab 95). The oil level
should be checked every 12,000 miles (20,000 km). This
should be level with the filling opening. Replenish if neces.
sary with hydraulic oil suitable for shock absorbers,
BODY
THE DOOR HINGES AND THE ENGINE HOOD LOCK
MECHANISM should be lubricated every 6,000 miles
(10,000 km) with motor oil. The door hinges have special
holes equipped with rubber plugs with a through hole.
To lubricate, press the oil can against the rubber plug.
MISCELLANEOUS
THE SEAT RAILS should, if the seats are difficult to
move, be lubricated with vaseline. Wipe off excessive
grease so that clothes are not stained.
THE GEAR SHIFT ROD BEARING at the dash panel
should be lubricated with motor oil if necessary. The felt
bushing in the gear shift rod bearing should be oiled spa-
ringly with paraffin base oil, if removed for other reason.
AT OVERHAUL front and rear wheel bearings and shaft
joints should be repacked with Saab Special Chassis Grease.
120-2 SAAB
Febr 1977
Page 77
UNDERBODY AND RUSTPREVENTING uo es ano RUBBER PLUGS IN THE BODY
TREATMENT
TOUCHING-UP UNDERBODY COATING
To retain the advantages afforded by underbody coating,
the underbody, too, should be regularly inspected and
the underbody coating touched up as necessary, Apart
from protecting against corrosion, the underbody coating
improves sound insulation, This protection is particularly
important with regard to the fenders, which are continu-
ously exposed to wear from a constant barrage of flying
stones and gravel. Before covering worn or bare parts with
fresh underbody coating composition, clean the metal
thoroughly with a scraper and a steel-wire brush and then
wash with gasoline or suchlike. Before applying fresh com-
position, coat the metal with a reputable make of rust in-
hibitive, and then apply about 0.06 in. (1.5 mm) thick
coating of composition before the rust inhibitive has
dried. Excessive application will result in the composi-
tion running and it may even pull right away from the
metal which it is intended to protect.
Naturally, new metal panels, such as fenders, must always
be treated in a similar manner after fitting. If underbody
coating is applied prior to spraying, it is essential that all
composition be washed off the surfaces which are to be
enameled.
RUST-PREVENTING TREATMENT
The cars are treated with a rust preventive agent before
leaving the factory. As from model 1974, spraying with
rust-preventive oil has been greatly increased. The under-
side of the floor is sprayed after the underbody com-
pound is applied. The rust preventing treatment which
the car receives at the factory should be repeated within
12 months after delivery. The reason for this is that some
settlement of the electrophoretic paint may occur in the
welded body joints after the car has been driven for some
time. Provided that this treatment is performed in accor-
dance with the instructions issued by Saab-Scania, further
spraying with rust-preventive oil will only be necessary
every second or third year,
The parts of the body which must be sprayed with rust-
preventive oil are listed under the heading Treatment
program. On cars as from model 1974, no new holes
need be made for this treatment. On older cars, some
new holes must be drilled. The hole dimensions are 0.8 in.
(20 mm) dia. and 0.4 in. (11 mm) dia. The holes are sealed
with slitted rubber plugs (20 mm dia. 84 59 497 and
11 dia. 84 59 513).
PRELIMINARY WORK
1,
nN
Clean the car's underside, wheel housings, engine com-
partment, dash panel wall and sheet metal welds on
the front floor,
. Remove any gaps in the underbody sealing compound.
. Remove all wheels and mask the brake discs and drums.
Mask the surfaces of the rear axle studs against the sus-
pension straps.
. Withdraw the seat belts and fix them in the withdrawn
position until the treatment is finished. (Applies only
to Saab 96 cars in cases where reel belts are fitted).
. Make 20 mm (0.8'') and 11 mm (0.4”) holes where
indicated in the treatment program and pictures. (App-
lies only to models up to and incl. model 1973). After
the treatment is finished, seal the new holes with slot-
ted rubber plugs 84 59 497 (20 mm/0.8") and 84 59 513
(11 mm/0.4"').
OIL, PRESSURE AND TEMPERATURE
About 3 1/2 pints (3 litres) of oil are used in the treat-
ment. Information on pressure for spraying should be
obtained from the oil manufacturer. Use heavy oil for
the underbody and wheel housings and light oil for the
members, cavities and welds. Heavy oil should be used
for application with a brush or oil can. In order to assure
sufficient penetration, the temperature of the car should
not be less than 50°F (+10°C).
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Page 78
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EQUIPMENT
Two high-pressure compressors for airless spraying with a
40:1 pressure increase for heavy oil and 48:1 for light oil.
Two spray guns and nozzles which permit access to cavi-
ties, members, doors and through slitted rubber plugs.
Oil can and brush for treatment of welds between wheel
housings and fenders
EQUIPMENT FOR RUST-PREVENTIVE TREATMENT
1. Nozzle for spraying doors,
2. Nozzle for spraying members and cavities.
3. Nozzle with reduced pressure for treatment of welds between
wheel housings and fenders. Can be substituted by brush or
oil can.
TREATMENT PROGRAM
The treatment is divided up into four groups. The first
group is done from underneath, the second group from
the sides, and groups 3 and 4 from the horizontal refer-
ence line. The underbody and wheel housings are sprayed
on the outside. Cavities and members are sprayed on the
inside. The doors are treated through holes in the rear
edge and sprayed on the bottom and approx. 100 mm
(4.0’’) up the side.
NOTE
Points of treatment with slitted plugs can be treated
through the plug if the right nozzle is used.
Group 1 (from below)
1.1
1.2
1.3
1.4
1.5
1.6
The cavity formed between the front floor and the
bottom panel on the bearing bracket for the front
suspension. Two holes 11 mm (0.4’’) in diameter
accessible in the front floor panel.
The cavity formed by the front seat member against
the center floor. Hole 11 mm (0.4”) in diameter
accessible in the center floor panel.
The cavity in the spring shaft by the rear axle attach-
ment. Hole 11 mm (0.4’’) in diameter accessible in
the center floor panel.
The cavity in the spring shaft to the side of the cen-
ter bearing attachment. Two holes 11 mm (0.4)
in diameter in the center floor plate.
Spray the underbody and the wheel housings with
oil. Pay special attention to the points of attach-
ment of the chassis components and the jack.
The joint between the lower dash panel, front floor
and front wheel housing through the hole 20 mm
(0.8’’) in diameter in the front floor.
Group 2 (from the sides)
2.1
2.2
141~2 SAAB
Inside the scuff plates.
Cavities between the sill members and the outer
side panels. The Saab 96 can be treated in either of
the following two ways. Only alternative B can be
used for the Saab 95.
A. Spraying through the drain plug in the underside
of the front side panel. Aim the nozzle at the
wheel housing and hold it about 10 mm (0.4’’)
above and parallel with the lower edge of the
side panel. Twist the nozzle a few degrees to the
side, first in the direction along the side panel
and then in the direction along the sill member,
spray once in each direction. Spraying in any
other direction entails the risk of getting spots
on the reel belt, side board and adjoining trim.
The trouble with this method is that it is diffi-
cult to cover the whole bottom surface of the
side panel and that the oil tends to splash out
into the space under the back seat.
B. Application from the inside with a brush.
Fold the seat cushion forward and detach the
strap between the cushion and the lower portion
of the back cushion. Detach the wires from the
sill members by removing the rubber plugs and
unhooking the wires. Fold the seat cushion for-
Febr 1977
Page 79
ward even more and detach it from the hinge to
the right. Remove the back cushion by undoing
the screws which hold the hinge in place. Detach
the side trim. Begin with the padded strip under
the side window and continue with the top por-
tion of the side board and then the front edge
of the side board. Try not to damage the side
board. If you pull too hard, the board around
the clip attachments will tear. Then coat the
bottom surface of the side panel and the adjoi-
ning free sheel surfaces up to a height of 100
mm (4.0°') from the bottom. After the treatment
is finished, replace the side trim and back and
seat cushions.
Groups 3 and 4 (from horizontal reference line)
Engine compartment
3.1 The cavity between the front wheel housing panel
and the spring support. Hole 40 mm (1 1/2") is
provided in the front wheel housing panel. right
and left.
3.2 The cavity formed by the front edge of the roof
against the dash panel. Both outside corners should
be treated. Two holes 11 mm (0.4") in diameter are
accessible in the roof panel. The doors should be
closed.
3.3. The cavities in the points of attachment of the front
shock absorbers, right and left.
a. —_
Febr 1977
Trunk lid, Saab 96
4.1. Treat the trunk lid through the holes provided.
Rear door, Saab 95 nyt
4.2 Treat the cavities on the bottom edge of the rear aa
door through the run-off holes provided. ie
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AFTER THE TREATMENT a
Wipe off the excess oil from the application points on
the doors, fender sides and painted surfaces. Use a rag
dampened with minteral spirits. Clean the sheet surfaces
around the joints and sealing beads. Don’t use so much
solvent that the oil in the joints is thinned out. Remove
the masking from the brake discs and drums. Mount the
wheels.
141-3
Page 80
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