0 a A SERVICE MANUAL = ° SAAB SAAB 95, 96 AND MONTE CARLO YEAR MODEL 1967, 1968, 1969, 1970— Ordering No. 788626 SAAB-SCANIA automotive group TROLLHATTAN SWEDEN Copyright SAAB-SCANIA Endast f6r spridning utomlands, SPECIFICATIONS, TROUBLE SHOOTING TOOLS, SERVICE, MAINTENANCE TRANSMISSION BRAKE SYSTEM FRONT ASSEMBLY, STEERING, COLUMN SHIFT GEAR SUSPENSION, WHEELS INSTRUMENTS, ACCESSORIES, EATING SYSTEMFOREWORD > This Service Manual has been prepared to cid SAAB service shops in their work and to contribute towards the attainment of the best results. The recommendations and instructions given in the Manual ore based on our accumulated experience up to date. As further ex- perience is gained, or if design modifications ore introduced, all SAAB general agents and service shops will be informed accordingly, either through Service Information Bulletins or through complementary pages for the loose-leaf edition of the Service Manual. The Service Information Bulletins should be kept in a special binder, while complementary manual pages should be inserted in the appropriate position according to their chapter, section and page numbers. The Service Manual, the Repair Timetable and the Spare Parts List are arranged in the same order as the Repair Timetable issued by the Swedish Automobile Servicing and Retailing Employers’ Association. This arrangement in similar groups facilitates the use of the different publications. Description This comprises a brief description of the design and construction, intended primarily for those wishing to become more familiar with the construction and function of the car. Shop instructions Technical data such as dime ions, tolerances, torque ratings, etc., will be found in chapter O. These sections include detailed descriptions of all service jobs and are primarly intended for servicemen who are not familiar with work on the Scab. They include plenty of illustrations, in the belief that a good picture is often more instructive than a lengthy explanation. ‘SAAB-SCANIA AUTOMOTIVE GROUP Car Division TROLLHATTAN SWEDEN Nov. 1970? 2 v Produced and edited by Technical Publications SAAB-SCANIA, Trollhattan, Sweden Nov. 1970,oct. 1969 CHAPTER 010 020 030 CHAPTER 100 101 102 no CHAPTER 200 201 210 21 214 215 216 27 221 222 231 232 233 234 CHAPTER 300 311 321 322 331 341 0 SPECIFICATIONS, TROUBLE SHOOTING General Specifications Trouble Shooting 1 TOOLS, SERVICE, MAINTENANCE General hints Special tools Various tools Service inspections General Lubrication Washing and polishing Underbody- and rustpreventing treatment 2 ENGINE Description Removal and installation of engine body Engine body Removal and installation Cylinder head Valve mechanism Transmission Crank mechanism Oil pan Lubricating system Oil pump Oil filter Fuel system Carburetor. Deceleration valve, USA cars Air cleaner Fuel pump Fuel tank with fittings and fuel lines Inlet and exhaust system Induction manifold Exhaust system Cooling system Radiator with connections Water pump, fan and thermostat Sundries 3. ELECTRICAL SYSTEM Description Battery Generator Voltage regulator Starter Ignition coiloct. 1968 342 SE 351 CHAPTER au 412 4an 524 551 CHAPTER 600 601 631 632 Spark pls Pl Ignition cables Suppression of interference uPPr Electric equipment Other Direction indicators Horns Windshield wipers end wosher lectrical controls and switches Wising ond fuses 4 TRANSMISSION Description ‘Clutch Gear box psec ied and installation Semety eaal Reassembly iHferential ond pinion ~ ring gear Universal joints end shafts 5 BRAKES Description Broke shoes with drums, discs ond linings Raplocenses of bike Re cement of ce lini Broke drums — Brake discs Friction pads Hydraulic footbrake system Overhaul, brake fluid Master cylinder Brake lines Wheel cylinders Brake operation Handbrake system Handbrake operation 6 FRONT ASSEMBLY, STEERING, COLUMN SHIFT GEAR Description Wheel alignment Front assembly Steering knuckle housing and ball joints Control armsoct. 1968 CHAPTER 700 731 732 761 762 m 772 774 CHAPTER 800 810 820 830 843 850 860 890 CHAPTER 900 an 920 930 941 Steering, column shift gear g wheel and column shift gear ring ge Tie-rod ends 7 SUSPENSION, WHEELS Description Suspension Coil-spring suspensi Coil-spring suspension Shock absorbers, Stabi Shock absorbers si front Wheels and hubs Wheels Tires Hubs 8 BODY Description Body assembly Hood, front panel and fenders Doors and lids Glass Upholstery and interior fitments 9 INSTRUMENTS, ACCESSORIES, HEATING SYSTEM Description Instruments Accessories, mecanical Accessories, electrical Fresh air heater0) ()SPECIFICATIONS TROUBLE CONTENTS SHOOTING CONTENTS 010 General 020 Specifications 030 Trouble shooting — saaSPECIFICATIONS, TROUBLE 0 GENERAL SHOOTING SAAB 95 (SAAB STATION WAGON) SAAB 96 (SAAB 2 DOOR SEDAN) SAAB MONTE CARLO. $2967 Nov. 1970 sans 010-1SPECIFICATIONS, TROUBLE SHOOTING (CHASSIS AND ENGINE NUMBERS , The illustrations below show the locations of the chassis tand engine numbers. To ensure correct identification in the case of © particular cor or engine, these numbe together with the mileoge, must always be quoted in ‘warranty claims, etc. Ifa service engine is fitted in a cor, the number of the original engine must, without fail, be stomped in the appropriate place. This is of the utmost importance if customs difficulties ore to be avoided in the event thot the cor is subsequently used in a country other than that of registration. Chassis number limits for different year models: SAAB 95 1967 42001— 50197 SAAB 95 1968 52001— 62059 SAAB 95 1969 65001— 74986 SAAB 95 1970 20001—88371 SAAB 95 1971 95001— SAAB 96 1967 420001458526 SAAB 96 1968 470001507018 “ ‘SAAB 96 1969 20001-552859 SAAB 96 1970 ‘540001592844 SAAB 96 1971 600001 Monte Carlo 1967 420001458526 ‘Monte Carlo 1968 _-470001~507018 CARS MADE IN FINLAND SAAB 95 1970 50600001 — 50600838 SAAB 95 1971 51600001 — SAAB96 1970 60600001 — 60601540 SAAB 96 1971 61600001 — Engine number Georvox number ‘The type designations are 96 V4 for the SAAB V4 pas senger car and 95 V4 for the SAAB V4 station wagon. 010-2 GENERAL GENERAL TIGHTENING TORQUES Normal tightening torques for stonderd bolts and nuts For special nuts and belts see the technical data for the ‘oppropriote section, Size Wrench torques kom Fab, 1A O71 7 ene 15-25 N= 38 25-40 18-28 me 40-70 23-50 wr" 70-109 72 one 100-140 72-100 5/8” 140-200 100145 ue Wrench torques lem fab. ext B12 oF MBx1 1-25 1218 MBX 1,25 16-20 1215 Ml0x1.5 3543 a3 Miox1 44-52 28 Mi2x15 76-90 5545 MI2x175 69-83 50-60 —_——— Color code and chasis umber signe Chassis numb i rinted in ear Booy Nov. 1970SPECIFICATIONS, Overoll width Wheelbase .. wate Empty GENERAL TROUBLE 0 SHOOTING LOCATION OF CHASSIS NUMBER AND PAINT COLOR CODE SIGNS, USA.CARS FROM MODEL 1969 1. Chasis number sgn 2 aint color code stn GENERAL DATA Model 1967-1968 SAAB 95 SAAB 96 MONTE CARLO Overall length, including bumpers (approx) WiOin 19h 13-8 in 270 mm) (A170 mm) (A170 5h.2in 5. 2in 5 ft. 2in (1580 mm} (1580 mm) (1580 mm Overall height, unladen (opprox) 4h Win A Win A in (1670 mm) (75 mm) 1475 mm) Ground clearance (2 paople fron! (opprox) 51 in 51 in 51 in (130 mm) (150 mm) 0130 mn) Track, font ond rear 4 On 4.0 44.0 in (1220 mm) (1220 mm) 20 mm) ef. Zin 8.2 in Bf. 2 in, (2656 mm) 2658 mm) 2058 mn) Turing rodivs(opprox) VRSin —-HSin A Sin (53 m) (53 m) 653 a) Empty weight, inc ue tools and spore whee! 200 Ib. 1900 Ib 2000 tb Total weight, incl. permissible approx. (45 kg) (t80 tg) (910 kg) possengers ond luggoge ‘70 tb. 2880 I 220 To (1530 kg) (1300 kg) (1300 kg) Weight distribution front 57% front 62% front 61% Fully laden, inl. posiengers ond luggoge front M% front 52% front 51% Number of seat 7 5 242 Available load loggage space Wow ft Bent ew. f. 0 99) O27 (037 m) Loading érea with driver +4 passengers BO4X374in, 394x37.46in, 34x74, (1000 x 960 mm) {1000 x 950 mm) (1000 x 950 mm) Loading area with driver +1 pastenger 63% 97.4, - - (1600 x 950 mm) - an Trunk height. 31.41 ein 18.10, (800 mmm) (460.mm) (460 mm) et 1989 snap 010-3SPECIFICATIONS, TROUBLE GENERAL SHOOTING GENERAL DATA Model 1969 SAAB 9S SAAB 9% COveral length, inclding bumpers (opprox) Wate tin 13 f.9in (4300 mm) (4200 mm Overall width Si in Si. 2m (1580 ren) (1580 mm) Overall height, unladen (opprox) sH.10m 4A 10 in (1470 nj (1475 re} Ground clearance (2 people front (opprox:) 51 in 51 in 130 mm) (190 rm) Trock, front and rear 4h. 0%m 48.0%, 1220 mm) (1220 om) Wheelbase Bf.2in Bf. 2im (2498 mm) (2078 ro) Taming rodive fopprox) 17 93m 171.91 Gam Gam Empty weight nd fuel, wale, tools ond spore wheel 21601. 2000 w. Tool weight, inl. permissible cpprox. (980 ks) (9109) panergerend areas 3370 ts, 280 I e (i530 el (1300 Ke) Weight distribution Empty front 57 front 62% Fully Toden, inl. possengers ond luggage from M% front 52% Number of sects 7 5 Aveilble lood loggoge space Raut Bett tw) (037 we} Loodiog sree with driver $4 pamengers 304x374 in. 39.4x37-4in. (1000 x $50 mem) (1000 x 850 mm) Loading area with driver +1 passenger 63x 37.4in. - | (9600x950 mm) = Trunk height 31.4in 18.1 in, (800mm) (460-mm) o10-4 saaB xx 1968SPECIFICATIONS, 0 TROUBLE GENERAL SHOOTING GENERAL DATA Model 1970 SAAB 95 Overall length, including bumpers approx.) 14 ft. Tin. (4300 mm) Overatt width 5 ft. Zin. (1580 mm) ‘Overall height, unladen (approx.) 4 ft 10in i (1490 me) (1490 mm) Ground clearance (2 people front) (approx.) 5.1 in. 5.1 in, (130 mm) (130 mm) Track, front and rear 44. 0in, 4ft.0in, (1220 mm) (1220 mm) | ‘Wheelbase B ft. Zin. Bit. Zin. (2498 mm) (2498 mm) Turning radius (opprox. 17 ft. in. 17 ft 6 in. (5.4m) (5.4m) Empty weight, incl. fuel, water tools and spare wheel 2150 ib 2000 tb. - approx. (975 ka) (908 kg) Total weight, inc. permissible passengers and luggage 3396 Ib. 2990 tb (1540 ka) (1350 kg) Weight distribution: Curb weight incl. driver front 58 % front 62 % Total weight front 45 % front 51% Max. roof load 2016 220 16, (100 kg) (100 kg) Max. trailer weight 2000 tb. 2000 tb. (910 ko) (9109) Number of seats 7 5 Available load luggage space 39cu.ft. Wu. ft (1.1m) (0.37 m3) Loading area with driver + 4 passengers 39.4% 37.4 in 30.4 x 37-4 in. (1000 x 950 mm) (1000 x 950 mm) Loading area with driver + 1 passenger 63x 37.4 in 605% 37.4in. (1600 x 950 mm) (1540 x 950 mm) st ‘Trunk height: 31.4 in, 18.1 in. (800 mm) (460 mn) Now. 1970 SAAB 010-5SPECIFICATIONS, TROUBLE GENERAL SHOOTING GENERAL DATA Model 1971- SAAB 95 SAAB 96 Overall length, including bumpers (spprox.) 14 ft. Tin 13 ft. 9in, (4300 mm) (4200 mm) Overall width 5 ft. in, 5ft.2 (1580 mm) (1580 mm) Overall height, unladen (approx.) 4 ft. 10 in, 4 ft. 10in. (1490 mm) (1490 mm) Ground clearance (2 people front) (approx.) 5.1 in. 5.1 in, (130 mm) (130 mm) ‘Track, front and rear 4 ft. On, 4ft.0in. (1220 mm) (1220 mm) Wheelbase 8 ft. 2in, 8 ft. 2in, (2498 mm) (2498 mm) ‘Turning radius (approx. 17 ft. Bin 17 ft. Bin. (5.4m) (6.4m) Empty weight, inl. fuel, water tools and spare whee! 2.200 tb. 22000 Ib. (1000 kg) (920 ka) Total weight, inc. permissible passengers and luggage 3395 Ib, 2990 Ib. (1540 ka) (1350 kg) Weight distribution: Curb weight incl. driver front 58 % front 62 % Total weight front 46 % front 52 % Max. root load 220'b. 220 Ibs. (100 ks) (100 kg) Max. trailer weight, 2000 Ib, 2000 ib (910k) (910k) Number of seats 7 5 Available load luggoge space 39cu. ft 19. (1.1.3) (0.37 m3) Loading area with driver + 4 passengers 39.4 x 37.4in. 39.4 x 37.4 in, (1000 x 950mm) (1000 x 960 mm) Loading area with driver + 1 passenger 63x 37.4 in. 60.5 x 37.4 in, {1600 x 950 mm) (1540 x 950 mm) Teunk height 31.4 in, 18.1 in. (800 mm) (460 mm) 010-6 SAAB Now. 1970SPECIFICATIONS, 0 TROUBLE SPECIFICATIONS SHOOTING ENGI USA CARS AS FROM General data MODEL 1971 Engine, type VA Astroke, 4 cylinders stroke, 4 cylinders Power DIN at 4700 rpm ‘6 bhp ‘5 bhp ‘Max torque at 2500 7pm 85 Fill, (17 kpm) 85 ftlb. (117 bpm) Compression rtio, nominal 901 801 Number of cylinders 4 4 Cylinder bore 354 in, (90 mem) 3.54 in, (90 mm) Stroke 2:22 in. (5886 erm) - 263 in. (68 em) Cylinder volume 1A cu. in. (498 ce) 104 cu. in, (1698 ce) Firing order 32 2 Placement of cylinders (from front of ear): Right hand side oo) 2 Left hand side a4 Par) Idling speed 800-900 rpm 300 rpm Engine suspension point suspension 3.-poin suspension Weight, incl elect. equipment and carburetor 245 Ib. (120 kg) as Ie. (128 te) Cylinder block Type 60° Vee formation, block ond crankcose costed in one piece Motericl Cost icon of @ special alloy Number of main bearings 3 Cylinder block bores for camshoft bushings: fronts AMgS—4468 mm conte: 4427430 mm Teor: 389892 mm Cylinder block bores for balance shaft bushings: front: 5442054445 mm 57.6057 5S mm Cylinder bore: Standard 90.020-50.040 mm Oversize 002 in. (05 mm) 905070540 mm Oversize 004 (10 mm) $1.030—91.040 mm Diometer main bearing bore: red. €062—C063 mm blue 60A3—40.44 mim Thrust beoring with: 262265 mm Pistons Material Alriniom Number of piston rings, on each piston 2 compression and 1 oil contol ring (tripartite) Permissible difference in weight (piston ond connecting rod) in one and the some engine 0.46 oz. (13g) Fiston-riog groove with upper 2030—2055 mm center 3030-3056 mm lower 50175042 mm Piston diometer (The piston is out-of-round ond spherical) Stondard 89:978—90.002 mm oversize 05 90478-90502 mm oversize 1,0 90978—91.002 m Piston clearance (0.0011 in—0.0024 in. 0.030.065 mm Piston, removal From the upper side of the cylinder block Position of the piston The jog to be turned forward Piston and connecting rod must not be separated. Therefore, only piston with connecting rod mounted is evailable os a spore part. Nov. 1970,020-2 SPECIFICATIONS, TROUBLE SHOOTING Piston rings SPECIFICATIONS == Upper compression ring (chrome plated) bower compression ring _——ao TERRAIN Center spring = Segment S97 Upper compression ting: Thickness With Piston-ing clearance in groove Gop in position Lower compression ring: Thicxness with Piston ring play (in groove) Gop in position Oil control ring (tripartite): ‘Thickness (total) Width (segment) Piston ring play in groove (total) Gap in position (Segment) Connecting rods Bore diameter in the big-end Vertical inner diameter of fitted con-rod bearing inserts: Journal clearance in main bearing. Crankshaft Crank pin diameter Number of main bearings ‘Main bearing diameter Jo ona sig 1.978 1.990 mm OS in. max. (max. 376 mm) 0.0394—0077 mm (0250-0.500 mm 2978-2990 mm 0.15 in. max. (max. 376 mm) stondord und i BSeaeaF Fe i i af standard red blue vundersize 0,05 025 050 075 1100 (0040-0078 mm (0250—0.500 mem see obove S7.200—56.990 mm 56990-56980 mm 5692-56919 mm 56746565736 mm 56492 —56.482 mm 5623856228 mm 55.984—55.974 mm et. 1969‘SPECIFICATIONS SPECIFICATIONS, TROUBLE SHOOTING Vertical inner diameter of fitted main bearing inserts: standard blue 57.004—57.020 mm Clearance between insert and crank pin: ‘Thrust journal length (center main bearing) Crankshaft end play ‘Thrust (axial) bearing insert width Balance shaft Number of bearings ‘Cleorance in bushing Bolance shaft end float Inner diometer of bushings: Beoring diameter of bolance shaft: Bochlash, new drive geor Bocklash, wearing limit Camshaft Number of bearings: Insert diameter Bearing clearence Inner diameter of bushings Comshatt end float Spocer thickness Camshaft drive Number of teeth on pinion Number of teeth on camshaft gear Backlash, new drive gear Backlash, wearing limit Com litt Com to-1oe dimension: Valve mechanism ‘Angle of seat (cylinder head) intoke and exhaust Sect width, intake and exhoust Stem diameter: Intoke Exhoust red 57.014—57.030 mm undersize 0,25 56760-56776 mm 050 56506-56522 mm 075 56252-56268 mm 1,00 55.998—56014 mm stondard 0.012—0.048 mm undersize 0014—0.058 mm 6A —26.39 mm (0102—0.203 mm 26.29-26.24 mm 2 front 0.02 —0.08 mm rear 0.03 —0.07 mm 005 0.15 mm front 50.85—50.88 mm reor 54035405 mm front 50.83-50.80 mm reor 54.00—53.98 mm 0.05—0.14 mm 0.40 mm 3 front 41.516—41.542 mm center 41.135—41.161 mm ear 40.754—4.780 mm all 0.077—0.0025 mm front 41.587—41.5%3 mm conter 41.186—41.212 mm wor 40.805—40.831 mm (00025—0.076 mm red 40644089 mm blue 40894114 mm ‘gear pinion 34 e 005-020 mm 040 mm (0.256 in. (6490 mm) 3420133998 mm o 01059-0070 in. (1517 mm) standard 8043-8025 mm oversize 8243-8225 mm 8.443-8.425 mm 8643-8.4625 mm 88G8825 mm stondord 8.017—7.999 mm ‘oversize 82178199 mm 84178399 mm 86178599 mm 8817-8799 mm 0 020-3SPECIFICATIONS, TROUBLE SPECIFICATIONS SHOOTING 6069-8088 mm Cleoronce between stem and guide intoke 0020063 mm exhoust 0046-0089 mm Disc diometer intake 1.46 in 37 mm) exhoust 126 in. (32 mm) Valve tft 038 in, (7 rm) Valve clearance, cold engine: a Intake 0.014 in. (0.35 mm Exhaust 2.016 in. (0,40 mm) MODEL 1967 AS FROM MODEL 1968. MONTE CARLO Free length of springs 178 in. 452 mm) 190 in (485 mm) 1S in. (7,0 mm) Fully meters, 1p a 1.13 in. (28,6 mm) 1.13 in. (28,6 mm) 1.06 in. (27,0 mm) Load for compression to in, (40.26 mm): 39-47 Ips. 60-00 Ibs. 59-66 IDs. (178-2159) (272-208kp)—«27,0-30.0kp) Valve toppet diameter 222-2190 mm Clearance between loppet and bore 0023-0060 mm Valve timing Intake opens ne sToc Intoke shots 82° ATDC | meosured ot © volve ploy Exhovst opens BIDE: | 0a wm Exhaust shot fo ADE Lubrication system Type < Pressore lubricated bearings Splath lubrication Tronamission gear lubrication Oil filter, ype CCrankcose ventilation, semi enclosed Cronkcase ventilation, totally enclosed Oil type Engine oil lt, Winter, constant temperature below —4°F =20°C Warning! This grade of oll must not be used at temperatu- res above +32°F (0°C). valve opens ot Oil pressure worning light operates ot Draining plug, thread Oil pump: Clearance rotor to housing Clearance rotor to secling surface Circulgtion syitém lubrication under pressure (il pump of rotor type Comshott, crankshaft, bolonce shaft, Oil spraying “Fullflow’” type From the oil filler cop vio crankcase to the air filter From oir filter vio cronkcose ond NOVO-valve to inlet manifold, SAE 10W 30 SAE 10W 40, Fords spec. ESE—M2C- 10H SAE SW 20 33.US. quorts (33 liters) 30 US. quorts (3 liters) 47555 Ib.Jsqin. (33-39 kplem? 43-85 psi. (03-06 kplcm*) 14x15 (width ocross flats 075 in, = 19 mm) 0.012 in. (0.3 mam) (0.004 in. (0.1 rom) Nov. 1970,SPECIFICATIONS, SPECIFICATIONS TROUBLE 0 SHOOTING Wrench torques BOLT Joints kom feb, Main bering ca bots 10 2 Connecting rod nuts 35 25 Crankaha® gear bolt 50 38 Frywheel retaining bles, eranksatt 70 0 Carhatt thrust plate, biock 20 8 Bolt ~ camshat gear 50 26 Cylinder head 0 block (to be tightened in 3 stages) 55 * ¥ 70 50 95 3 Inlet manifold up to and ine!. chassis No. 95/66.249, 96/524.379. To be tightened in 2 stages. Stage 1 Bolts 29-58 = 5 16-21 Stage 1 Nuts 22-36 “a0 11-13 From chassis No. 95/68.250, 96/524,380 Stage 1 Bolts 29-58 a ae 15-18 Stage 1 Nuts 29-58 2a 15-18 Intermediate plate to block 6 ‘Transmission cover 16 Water pump to transmission cover 7 Pulley to balance shaft 36 Oil pump to block u" Oil pan to block 4 Thermostat housing to induction manifold 15 Valve cover to cylinder head 4 Rocker shaft bracket 2 ~ il filter half a turn after contact between gasket and engine block et. 1969 SAAB 020-5SPECIFICATIONS, TROUBLE SHOOTING SPECIFICATIONS FUEL SYSTEM _ Carburetor MoDeL vweycioes > ngine equipped with Free Exhaust Emis- Type Solex 2832 POSIT? AZ PDSIT-A on “Control Device. Choke ducati, tomants | Amant in as "a3 Chote be 253 253 Envtdon 110 "00 I jet, fuel 0 co 425 ling fe (ing 3 3 13 Hot velve 13 3 3 Poet weight 23 gen Box Bee ~ Aeon ‘2 2 ‘* econo bop spec 062012 (eu, in) 102 ent10srokes aa soonl 300900 rpm 0900 pe residing Soge | D130 rpm Siege I 7001900 rpm Stoge I 27002300 rom Float eel when iaing Nom: 0992004 in 1521 mm] trom gorket level Pct level fully closed fat valve — s - Flt level tally open float vale = = = ign epeped h MopeL 1969 Softee Bxhoos Emir Son Conol Dei Tyee Feloce C8GHISI0G Coon asi0—H Croke ioae oemate Moin et 135 ts Mot tae 20 20 Aecsaration pump copacty 039-045 cu in. (5575 en 10 stoke ling speed 200-90 ‘pm 9700 «pm Fest iling, tird top 1800200 pm 702100 rpm Pow nl fiky loed ter bv "tn 108020.10 a5 wml (2752025 wm) ih bye ac vt ‘atin (azoe0g0 in (340 mm (352025 mm) Engine equipped with MopeL 1970 Eafe thors bale don Contol Device. Tye FoMoCo CAGH95I0G 70 "tw9510-AA Croke sooner ‘huomate fiom is ts Flot ave 20 20 Acealartion pomp copay 030-045 cu, in. (55-75 cn 10 srokes Sang sed 200-70 rpm 00 om Fmt eels tins jower beam on third Sep 12002200 rom 1900-2100 rom Foe level fly closed foot vlve ein tas0=0.10 28 mm (2752025 mm) a Wi SRY Be ‘in vasa (245 ml (3620.25 mm) 020-6 SARE Now 1070SPECIFICATIONS, TROUBLE 0 SPECIFICATIONS SHOOTING Engine equipped wih MODEL 1971 Safree Exhoust Enis: sion Control Device tres FoMoCo7ITW.9510-J8C TITWa9stOLA Choke ‘Automatic ‘Automatic Main jet vas 7 Float valve 20 20 Acceleration pump capacity 027-04 evin, 456.5 em? strokes (ding. speed 00500 rpm $500 rpm Fast idling speed with headlights lower beam on third step 1800—2000 rpm 1900-2100 rpm Float level, fully closed float valve 108 in 108020010 in 5 mm (2752025 mm) Float level, fully open floot vol 134 in 1Az020010 in 340 mm (3620,25 mm) W35Am o1mansis Roted voltoge uy Roted rpm 200 ‘Max. permissible continous lood BA tion of rotation Clockwise ond counterclockwise ssh-spring pressure 10.514 7. (200-400 9) Rotio pulley, engine — alternator 189 Testing volves, see chapter 3 Charging regulator, Bosch Type dangers BOSCH AD 1 14 v (not radio suppressed) 020-8 sans Now. 1070SPECIFICATIONS, ‘SPECIFICATIONS TROUBLE 0 SHOOTING Starter motor, Bosch MODEL 1967—1968 AS FROM MODEL 1969 Type designation &F 12V 08 FS 0001208029 GFI2v 10S coor3iva2 Number of teeth on pinion 9 9 Number of teeth on ring gear 138 138 Output 08 hp 10 he Testing volves Mechanic valves: Brush-spring pressure 45—46 ox. (11501300 p (a) 45M o2. (11501300 p (9) Pinion backlash 0.0138—-0.0236 in. (035-06 mm) 0,0138—0,0236 in (0,350 mm) Distance between pinion 0,0985—0,118 in. (25-30 mm) 0.0785—0,118 in. (25-30 mm) ‘ond ring gear Contact reserve 0.0395 in. (1.0 mm) 00395 in. (10 mm) Rotor axial clearance 0,00197—-0,0118 in, (0050.3 mm) 0,00197—0,0118 in. (005-03 mm) Rotor broke friction torque 10,290 filbs (2.540 koem) 0,181—-0,290 f.lbs (2.540 kpem) Pinion clearance torque 0,074-0,130 frlbs (131.8 kpem) ——0,094-0,130 fibs. (1.3—1.8 kpem) Electric valve Idle speed 11,5V och 30—50A 6500-7700 pm 11,5V och 35—55A 6500-8500 rpm Charged BV och 170—200A 1150-1450 rpm 9V och 205—235A 10001300 rpm Locked starter motor 6¥ 250-200 A 6V 325-3754 Lowest pul-in voltage for operating solenoid switch 7 Bv Distribut ASFROM — USA CARS Trae den Basch, MODEL 1969 AS FROM Ue anigtos aes MODEL 1971 Previous designation {0 731 M6 O44 or fsignation 19 231 14s 024 (0 231.146 033 or eter designation Za} us O73” 0 201 146 OBA 0 23116 08 Copocitor: 1 237 330 91 1 237 330 196 Copecity 02 4 FEI0% 02, F10% 02 ,, FIO % lonition setting: Basic setting with test lamp 6, BDC 3 BIDC of Basic setting with stroboscope ot mox 800 rpm with ‘max 800 rpm disconnected vacuum hose 6, BTC and both Remark! vacuum hoses 1° on the balance shatt pulley corresponds 10 approx. 0.05 in. (1,2 mm) on the circum disconnected pulley 1 evi. Vis the furhermost R-H. one 342 Breaker gop 0.016 in. (044 mm) Dwell angle oer Contoct pressure 14-19 ox. (400-520 9) Direction of rotation clockwise Resistonce in distributor orm 3000 ohm#20 % NOTE! Re ignition advance curves, see chopter 3 usa cans ASFROM AS FROM MODEL 1969 MODEL 1971 Vacuum chamber Previous designation 1 237 121 215 127121 3851-27 121 Bae Loter —"= Varian w Nov. 1970 saaB 020.9SPECIFICATIONS, TROUBLE SPECIFICATIONS SHOOTING Ignition coil, Bosch: Type designation Kn Performances ot o primary voltage of 12 ‘4000 sparks mine (1.000 distributor revolutions) Spork length minimum (0.55 in, (14 mm) 16000 sporksiminute (L000 disibutor revolutions) Spark length minimum 024 in. (6 mm) Primary-winding resstonce (between connections 1 ond 15) 3136 ohm Spark plugs Up to chasis No. 95'55765961487.638, As from chasis No, 95155767, 96/487 439 (black or slverpointed engine) (bive engine) USACARS For USA up to chosss No. 95/54854, For USA os from chou Nov S5iseiss, AS FROM 96:482197 96148219 MODEL 1971 Auto Aen ac-ze ac-2 ‘Ato-tte interference oppressed Acn22 Bosch W 225 135 w 200 120 wusr90 Champion vey Nov Naty NGK 7H BP 7 aP-6e Electrode gop 0240.28 in. 06-07 mm) Tightening torque DB thd, (30—40 kpm) Ignition cables Resstonce in spark plug connection 1006 ohms10 % Bulbs UP TO MODEL 1968 ary. cap EFFECT MONTE sagas saapos | MONTE Headlights, Sealed Beam 2 2 a so/40w Headlights, asymmetric 2 2 2 past 45/40 W Pacing light and direction indicator light, front 2 2 2 BAYISD (2S Ww Stop light and direction indicator light rear 4 4 4 pais zw Tai tight 2 2 2 BASS sw Number plate light 2 2 2 sas 5w Backup light - - 2 BAYISD a8 W Dome light 2 1 1 sas sw Fog: and spot tight - - 2 BAz0s 45 Temp.-and fuel gauge, speedometer — 4 BATS 2w Lighting, clack 7 = 1 Bags aw Lighting, tachometer = 1 Bags 2w Control iamps 9 n 6 BATS 2w Other instr. lamps 2 = = Bags 2w Trunk ight - 1 1 Bags aw Fuses 2 2 2 8A SAAB Now. 1970 020-10SPECIFICATIONS, 0 TROUBLE SPECIFICATIONS SHOOTING MODEL 1969-1970 Heodlights, Secled Beam 2 2 - soo Headlights orymmetrie 2 2 Past 45140 W Parking light, front 2 2 BA ISS sw Direction indicator tig 2 2 BA ISS aw Parking ond direction indicator US No. 1073 lights, front (USA) r 2 BAY 15D 521W Direction indicator light, rear 2 2 BAISS 2W Taillight 2 2 BA ISS sw Stop light 2 2 BA ISS aw Number plate tight 3 2 5.85 sw Control: and instrument lamps 0 10 Gloss 12w Control lamp, hazard warning signol 1 1 BATS 2w Dome light 2 1 885 sw Trunk light = 1 BAIS aw Bock-up light 2 - BA ISS nw Side position light (USA) 2 = BA 9S Minioture bulb 4W Lighting tachometer (USA) - 2 BA9 5S Minioture bulb 2W : AS FROM MODEL 1971 2 2 = 040W Headlights asymmetric 2 2 Past 450. W Porking light, front 2 2 BA ISS sw Direction ingicator light, front 2 2 BA 15S aw Porking ond direction indicator US No. 1073 lights, front (USA) 2 2 BAY 15D saw ction indicator light, reor 2 2 BA ISS aw Toil ight 2 2 BA ISS sw Stop light 2 2 BAISS aw Number plate light 3 2 5.85 sw Control and instrument lomps 0 10 Gloss zw Control lamp, hazard warsing signal 1 1 BA 75, 2w Dome light 2 1 S85 sw Trunk light ~ 1 BAGS aw Bockeup light 2 - BA ISS aw Side position light (USA) 2 = BA 9S Miniature bulb 4W XN Lighting tochometer (USA) - 2 BA 9S Minioture bulb 2W Fuse, heodlight wipers 1 1 254 Flasher unit UP TO MODEL 1968 AS FROM MODEL 1969 hs Trvsidesonoton Lucas FS 12V 42 WW Tungsol 850-12 Hello 91 PSt2x32Cp 12V Hella 91P3V2-4x21W-12 Horn, Hella Type designation 85-12 Heater fan motor Type designation, Electrolux KS 34307200 12 Windshield wiper motor ‘Type designation, Lucas up to and incl. model 1969 DL3A ‘Type designation, Lucas as from model 1970 15 Nov. 1970 SAAB 020-11SPECIFICATIONS, TROUBLE SHOOTING Windshield washer Monte Carlo mode! 1967 Windshield washer from model 1968 (all models) Headlight wiper motor Type designtion Output Tightening torque, wiper orm screw Transmission Oil capacity Type of oil Gear ratios, tote Ist gear 2nd gear 3rd gear 4th gear Reverse Differential gear ratio, pinion: ring gear Number of teeth, pinion: ring gear Road speed SAAB 95 Tire dimension 5,60 15" Ist gear 42mpn, 68km/n 2nd gear TAmpr 11.4km/h 3rd gear 11.5 mph. 18.5 km/h 4th gear 17.7 mph. 28.4 km/h Reverse 47mph — 7.5km/h inion/ring-gear adjustment: specified dimer SPECIFICATIONS Make Dahiberg Make MEAB 463876 ‘opprox. 25 W 7,23 ftelbs. (100 kpem) (locked with Loctite) ‘opprox. 1.4 US. quarts (approx. 14 liters) mph. ot 1000 rpm engine speed: EP-oil SAE 80 oa r024 63:1 aa 1551 488:1 37 SAAB 96 MONTE CARLO 5,20 15 155x 15” 42mph. 67 km/h 42mph. 67 km/h 7.0mph. 11.2km/h 69mph. 11.1 kmh 13mph. 18.2 km/h 12mph. 180 km/h 2mph. 27.8km/h 17.Amph. 27.6 km/h 47 mph. 7.4km/h 45mpn, 7.3km/h 19 0.002 in, (0,05 mm) Ring-gear backlash: specified dimension 0,002 in, (0,05 mm) MATCHED GEAR SETS 3rd speed geor Pinion shaft 3rd geor 4th speed gear Pinion shaft 4th geor Ring gear ion shaft Syachromesh Tightening torques, gear box T Tightening torques Bolt joints | Gon] se | ten] Ath Transmission cate end cover 6 | sie 25 18 4 | 38 ‘ 2 2 | sre 25 8 Pinion-shaft nut. Fits tightening 1 | 7a 2 2 ‘Thea slacken ond retighten ‘ “ imary shaft 1 | oo 5 % 1] one a o 020-12 SAAB 1970SPECIFICATIONS, 0 ct. 1968 TROUBLE ‘SPECIFICATIONS SHOOTING Clutch Fichtel_& Sache Clutch Clutch type single dry plate Clerance, release bearing — clutch measured of the slave cylinder Clecrance between releose plate and flywheel Pressure-plate springs: Length compressed Tension when compressed Dimensions of clutch focing New clutch disc: Thickness, unloaded Thickness, loaded with 825 Ibs. (375 kg) Max theow clutch dite Engagement pressure Clutch operation, hydraulic UP TO MODEL 1968 Moke ond type Cyimier cmetor Mex permisibe stroke Hore conection Hose loth between toster end save finder Distance from clutc-pedal foot pate to the lower pert ofthe dash pone! (imax. pedal stroke) Cleoronce,releose bearing — clutch mmeosured atthe slave cylinder AS FROM MODEL 1968 Make and type Cylinder diameter Stroke Hose connection Hose length between master and slave cylinder Distance from clutch—pedal foot plate to the lower part of the dash panel (max. pedal stroke) Clearance, release bearing—clutch ‘measured at the slave cylinder BRAKE SYSTEM General Make Type, front Type, rear Footbrake up to and incl. model 1968 Footbrake, from mode! 1969 Handbrake On R.H.D. cars there are no vacuum servo. 0.16 in. (4 me) ‘approx. 1 in, (26 mm) 0.96 (245 mm) 134-147 Ib. (61—67 kp) 5-45 in. (1271905 mm) 0330.04 in, (8.40.1 mm) (0280.01 in. (7.2403 mm) 0.024 in. (08 mm) 750-935 Ib. (340—425 kp) Master cylinder Slave cylinder Girling 5/8" Girling 3/8" 58" aye" 1.38 in, (85 mm) 318" UNF-24 3/8” UNF-24 14 in, (556 mm) epprox. 63 in. co 160 mm) 0.16 in. 4 men) Lockheed 5/8” Girling 374” 5/8” aa" 1.22 in. (31 mm) 7/6"-20UNF-28 — 7/16"—20 UNF-28 15.3 in. (38,6 mm) 8.1 in, (130 mm) 0.16 in, (4 mm) Lockheed Dise broke ‘One leading shoe Hydraulic, diagonal twocircuit type Hydraulic, diagonal twocircuit type with vacuum servo!) Mechanica! 020-13SPECIFICATIONS, TROUBLE SHOOTING 020-14 ‘SPECIFICATIONS As from model 1971, LHD-cars. ‘Master cylinder Dimensions, etc.: Broke disc, front Brake drum, rear Master cylinder model 1967, 1968 Master cylinder as from model 1969 Wheel cylinder, front Wheel cylinder, rear ATE 10%" (26670 mm) ‘8° (2032 mm) br rae, SAAB 96, Monte Carlo: 5/8” SAAB 95 up to and incl. mode! 1969: 3/4" ‘SAAB 96 as from model 1970: 5/8" Broke shoes, rear Brake hoses, front, length of Brake hoses, rear, length of Other broke lines Clearance between master-cylinder piston ‘ond push-rod Some clearance at tip of broke pedal Distance from brake-pedal footplate to the lower part Of the dash panel max. stroke approx. Broke fluid BxTA" ay" SAAB 96 ond Monte Carlo 8/5" SAAB 95 6)" 3/16" Bundy tube 00240047 in, (0612 mm) 0120.24 in, G6 mm) 6.3 in. (160 mm) Satisfying the requirements of spec. SAE J 17080 or SAE 70R3 Grinding of broke dite permitted to min. thickness: 0.355 in. (9 mm) ‘Adjustment machining of brake drums permitted to max. diameter: Rear ‘Max. total indicated radial brake- ‘Also SAAB 99] s 2064 786062 | Key, bolts, inlet manifold 1 exon 786051 | LOCTITE locking liquid [Also SAAB 99} 786805 | Atmosit sealing compound, inlet manifold 726050 | Plostigage, for measuring bearing |1 clearance | | i zt. 1969 101-54 TOOLS SERVICE MAINTENANCE SPECIAL TOOLS Special tools — transmission ond Description =| 4 tMstration Remorks Teal No. _ iy | 724064 | Centering too! | cluteh—cluteh se {4 | | | MDE | Dil indicator (nc Wo spare points) |1) | | \| 784146 | Measuring fixture, pinion adjustment | (2 \| Why | | 79020 | nstating and removing tool freewheel | | mas caaee 79001 | Steve ewan | Key | se pee | | | if 7aczx7 | testing device for shimming of end-cover | 21) Wl | ids 721069 | Holders, poppet balls (2) I \| | TROP | Wrench, intermediate shaft end nut, 2 Up to and incl. gearbox ly gearbox No. | hf il F 108.910 reo |) fo || box No. tt F 108.911 i — 101-6 SAAB Nov. 1970TOOLS SERVICE SPECIAL TOOLS MAINTENANCE A Special tools — transmission (cont.) |Spare-part| Indis- ‘ond Description = tastration Remorks Tool No. Era 784100 | Assembling ond disassembling fixture) |2 ‘ronsmission case mam | Anecher, diol indicator mens | serew rae | beshing | | Spore parts to 784100 naw | ne 7a | Sepplamentry it for eerie fstra, which) | ‘rar designed for 3apeed transmission oaly 7es101 | Puller, pinionshoh bearing 2 ja 7es102 | Aligning arbor, pinion shoft 2) | ap | 71104 | Dsving-out arbor, primary sho | | =a 78410 | Driving-on sleeve, pinion shoft P| — | u no | tien eee || Oct. 1969 SAAB 101-7