Saab 99 User manual

100

General

hints

Contents

Service

1975—82

101

Special

tools

110 Service

inspections

120

Lubrication, lubricants

141

Underbody

and

rustpreventing

treatment

Saab-Scana

1982

General

hints

General

neat

and

tidy workshop

essential

for

the

proper

servicing

vehicles.

Some

parts

the

car

need

treated

with

special

care

and

effectively

protected

against

dirt

and

contamination

while

work

progress.

For

the

mechanic

who

may

be new

the

job

the

following

points

may

be of

help:

Protect

fenders

and

other

paintwork

with

suitable

coverings.

Lay

protective

coverings

over

the

seats

and

upholstery

save

them

from

stains

oil

and

dirt.

Clean the

insides

fenders

and

the

space

round

the

rear

axle

thoroughly

before

starting

work

wheel

hubs

and

axles.

This

makes

the

job

easier

and

prevents

grit

and

dirt

from

getting

into

bearings

and

other susceptible

parts.

Before

unscrewing

spark

plugs,

clean

the

recess

round

the

plug

thoroughly.

Every

job

must

have

its

proper

place.

bad

practice,

for

example,

disas

semble

engine

transmission

bench

which

also

used

for

filing,

etc.

where

filing

done

the

immediate

neighbour

boo

Jacking

and

blocking

-1C

Lc11

Ict

IL.j1U

O[I_

arid

this

lacks

the

neutral

application

points

for

jack

that

girder

chassis

provides.

There

are

however

two

special

engagement

recesses

each

side

designed

fit

the

jack

supplied

with

the

car’s

tool

kit;

these

are

intended

for

use

during

wheel

changing,

etc.

The

engine

compartment

floor

also

reinforced

immediately

under

the

cross

member

that

supports

the engine

to provide

application

point

for

the

workshop

jack.

similar

reinforced

jacking

point

provided

underneath

the

floor

Lile

buck

behind

the

fuel

Lank.

most

workshop

jacks have

forked

lifting

head,

advisable

lay

wooden

block

suitable

size

across

the

fork

avoid

maging

the

floor

the

car.

For

some

jobs

necessary

raise

the

front

rear

end

the

car.

such

cases

the

jack

engagement

recesses

under

the

sills should

utilized.

100—1

One

side

jacked

Front

end

raised

Rear

end

raised

Front

end

blocked

trestles

Rear

end

blocked

threstles

s*r

-lrt

100—2

Special

tools

General

list

containing

special

tools

found

each

group

the

hook

and

the

Spare

Parts

Catalogue.

The

special

tools

the

Spare

Parts

Cata

logue

are

classified

follows:

Tools

for

engine,

transmission

and

chassis

work

Class

AO-l

Tools

used

very

frequently

service

work

(e.g.

aci

justment

timing)

AO-2

Tools

used

frequently

maintenance

work

(e.g.

placement

brake

pads)

Tools

necessary

for

simple

repairs

(e.g.

replacing

the

clutch

valves)

Tools

necessary

for

quali

fied

repairs

(e.g.

recondi

tioning

the gearbox)

Tools

which

are

mainly

commended

for

reasons

operational

efficiency

Tools

for

body

work

Class

Tools

necessary

for

simple

body

work

(e.g.

replace

ment

front

fenders)

Tools

necessary

for

quali

fied

body

work

(e.g.

align

ment

work)

Tools

which

are

mainly

commended

for

reasons

operational

efficiency.

Tool

racks

and

brackets

Tool

racks

with

suitable

brackets

and

hol

ders

for

the

special

tools

are

recommended

for

keeping

the

tools

readily

accessible

and

easy

find.

Thread

system

and

wrench

sizes

The

standard

thread

system

used

Saab

cars

mainly

the

metric thread

system

(tM)

and

the

width

across

flats

also

measured

mm.

However,

and

LJNC

threads

with

mensions

inches

are

found

some

onent

1—1

Service

inspections

Every

new

car

accompanied

service

card

that

should

stamped

every

ser

vice

occasion.

Guarantee

service

1,200

miles

(2,000

kin)

carried

out

free

charge (except

for

oils

etc.

for

which

charge

made).

Other

periodic

maintenance

should

per

formed

according

the

programmes

below

and

paid

for

the

customer.

Delivery inspection

Check

the

function

all

lights,

strument

lighting,

control

and

indica

tor

lights,

horn,

ventilator

fan,

inte

rior

and

ignition

switch lighting,

wind

shield

and

headlight

washers/wipers,

license

plate illumination,

trunk

ligh

ting

and

electrically

heated

rear

win

dow.

Lheck

the

brake

pedal

pressure.

Check

the

gear

selector

lever

posi

tions

(auotmatic

transmission).

Check

the

differential

oil

level

(auto

rnatic transmission).

Check

the

engine

oil

level.

Check

the

transmission

oil

level.

Check

the

power

steering

fluid

level.

Check

the

oil

level

the

carburetor

damping

cylinder(s).

Check

the

battery electrolyte

level

and

tighten

the

holder

hooks.

10.

Tighten

the

terminals

and

cable

logs

battery,

starter

motor,

alternator

inc1

,nItrna

rni

iIf-nr

11.

Check

the

radiator

coolant

level

and

freezing

points.

12.

Test

the

cooling

system

for

leaks

(pressure

test).

13.

Check

the

windshield

washer

fluid

container

level.

14.

Check

the

brake

master

cylinder

fluid

level.

15.

Turbo:

Check

the pressure

switch

function

and

charge

pressure

regulator

seal.

16.

Check

the

ignition

setting.

17.

Make

sure

that

the

tool

kit,

warning

triangle,

Owners

Manual

and

Service

Card are

place.

18.

Check

the

funktion

all

locks.

19.

Check

doors,

trunk

lid

and

sunroof

for

leaks

and

closing

power.

20.

Check

the

carburetor

synchronizing

(twin-carburetor

engines

only).

21.

Check

the

engine

idling/fast

idling

speed.

22.

Turbo:

Check

the

fuel

enrichment

function.

23.

Check

the

inlet

air

preheating

for

Summer/Winter

position.

24.

Tighten

the

wheel

bolts/nuts.

25.

Check

the

tire

pressure

(md.

spare

wheel).

26.

Check

the

headlight

alignment.

27.

Test

run

md.

general function

check

(especially

clutch,

transmission,

bra

kes, wheel

balancing,

instruments,

rection

indicator

return,

etc.).

Check for

rattle,

wind

other

dis

turbing

noise.

Check

the

steering

wheel

center

posi

tion.

Other

deli

very

measurements:

Dewaxing,

polishing

md.

check

painted

and

bright

parts,

loose

equipment

and

cense

plates.

Guarantee

inspection

1,200

miles

(2,000

km)

Check the

functions

all

lights,

strurnent

liqhtinq,

control

and

indica

tor

liqhts,

horn,

ventilator

fan,

inte

rior

and

ignition

lighting,

windshield

and

headlight

washers/wipers.

Drain the

engine

oil.

Drain

the

transmission

oil.

Clean

the

magnetic

drain

plug.

Check

the

engine

and

transmission

for

leaks.

Change

the

ciifferential

oil

(automatic

transmission).

Exhaust emission

regulations

govern

the

emission

carbon monoxide,

hydro

carbons

and

nitric

oxide

car

exhaust

fumes

are becoming

increasingly

stringent.

Saab

cars

are designed

and

built

meet these

requirements

the

condition

that

the engines are

cor

rectly

tuned.

The

workshops

hold

key

position

being

able

limit the

emission

toxic

gases

from

cars

and

therefore

make

contribution

keeping

pollu

tion

down.

Remember

that

correctly

tuned

engine

also

ensures

that

the

car

runs

smoothly

and

with

low

fuel

con

sumption.

The

relevant

adjustments

are

descri

bed

the

service

programme.

would

particularly

emphasize

the

importance

adjusting

the

ignition system

and

the fuel

system

according

with the

specifications.

110—1

oil.

Every

6,000

miles

(10,000

km)

Engine

Electrical

system

Check

the

condition

the

rubber

bel-

37.

Tighten

the

exhaust

pipe

clamp

nuts

lows

steering

gear,

inner

and

outer

the

gearbox

and

test

for

leaks.

k,N

Test

run

mc!.

qeneral

function

check

uniVCFSdI

JoinLs,

tuuuer

searn

UGH

joints

and

the

tie

rod

ends.

(especially

clutch,

transmission,

Tighten the

lower

control

arm

bolts

brakes,

wheel

balancing,

direction

in-

the

body

(from

beneath).

dicator

return,

etc.)

Tighten

the

exhaust

system

suspension

Check

for

rattle,

wind

other

distur—

bolts

and

pipe

clamps.

bing

noise.

Tighten the

bolts for

the

rear

axle

suspension

the

body.

10.

Change

the

oil

filter

cartridge

(H-

engine

only).

Regular

maintenance

inspection

11.

Engine:

fill

with

fresh

oil.

model

year

1979

12.

Manual

transmission:

fill

with

fresh

13.

Check

the

powec

steering

fluid

level.

14.

Check the

battery electrolyte

level

and

grease

the

cable

lugs.

15.

Check

the

V-belt

tension.

Change

oil

(at

least

twice

year)

and

16.

Check the

radiator

coolant

level

and

oil

filter.

test

the

cooling

system

for

leaks

Clean

air

cleaner

insert.

(pressure

test).

Tighten

hose

clamps.

Clean

fuel

pump

filter

(carburettor

17.

Check

the

brake

master

cylinder

fluid

engine).

level.

Check

fuel lines

engine

compart

18.

Tighten

the

inlet

manifold

and

carbu- ment

for

leakage.

rator

flange

nuts.

Check

and

necessary

top

oil

level

19.

Tighten

the

exhaust

manifold

retaining

carburettor

damping

cylinder.

bolts.

Check the

exhaust system

for

condi

20.

Tighten

the

exhaust

pipe

flange

nuts.

tion

and

leaks.

21.

Tighten

the

turbo

charger

retaining

Pressure

test

the

cooling

system

bolts.

(check

the condition

the

hoses).

22.

Tighten

the cylinder

head

nuts

and

Check

coolant

freezing

point.

bolts

prescribed torque.

Tighten

cylinder

head

bolts

(only

first

23.

Check the

valve

clearance.

6,000

miles/10,000

km).

24.

Check the

front

wheel

alignment

10.

Check

and

necessary

adjust

carbu

(camber,

caster

and

toe-in).

rettor

synchronization

(two-carburet

25.

Tighten

the

tie

rod

end

nuts.

tor

engine).

26.

Tighten

the

upper

control

arm

re-

11.

Adjust

deceleration-valve

(only

first

taming

bolts.

6,000

miles/10,000

from

model

27.

Crease

the

distributor

breaker

cam

1976).

and

lubricating

felt.

Check the

dwell

12.

Check

and

necessary

adjust

engine

angle

and

ignition

setting.

idling

speed

and

the

emission

car-

28.

Check

the

exhaust system

for

leaks.

bon

monoxide

(CD)

idling.

29.

Tighten

the

engine

mount

retaining

bolts.

30.

Check

the

deceleration

device,

engine

idling

speed

and CO

emission

2,000

r/min.

31.

Check the inlet

air

preheating

for

Check

condition

V-belts

and

adjust

Summer/Winter

position.

belt

tension

necessary.

32.

Adjust,

necessary,

the

door

lock

Check

and

necessary

adjust

head-

striker

plate.

light

alignment.

Inspect

condition

33.

Turbo:

Check

the charging

pressure. headlights

eye.

Adjust

spark

plugs.

Check

condition

breaker

points.

Automatic

transmission:

Lubricate

distributor

breaker

cam

and

34.

Check the gear

selector

lever

po-

lubricating

felt.

Check

and

neces

sitions.

sary

adjust

dwell

angle

and

ignition

35.

Check

the

throttle

cable

clearan-

timing.

and

movement.

Check

battery

electrolyte

level

and

36.

Check

the

transmission

oil

level,

top

necessary.

Tiqhl

and

grease

cable

lugs.

110—2

Brake

system

Steering,

front

suspension

and

tires

Test

driving

Test

drive

car

road

and

check

operation

all

systems,

especially

brakes

and

clutch

and

operation

auotmal

transmission.

Supplementary inspection

Every

12,000

miles/20,000

km.

Supplementary

inspection

Every

24,000

miles/40,000

km.

Periodic

servicing

from

model

year

1979

5,000

miles

(7,500

km)

service

Change

engine

oil in

Saab

Turbo

cars

and

cars

driven

under

unusually

demanding

conditions,

such

driving

extremely

hot

weather,

driving

high

speeds

for

consi

derable

distance,

and

driving

over

short

distances

extremely

cold

weather.

Check

operation

parking, brake

and

rear

lights,

licence

plate

illumination

lights,

direction

indicators,

horn,

back-up

ligths,

hazard

warning

flashers,

interior

lighting,

warning

and

indicator

lights,

windshield

and

head

light

washers

and

wipers,

brake war-

fling

light,

instrument

lighting,

luggage

compartment

lighting

and

ventilator

fan.

Check

condition

washer

jets

and

rubber

wiper

blades.

Transmission

Manual

transmission:

Check fluid

level

and

necessary

replenish

brake

fluid

clutch

master

cylinder.

Manual

transmission:

Check

and

mecessur

adjust clutch

release

bearing

play

(only

and

md.

del

year

1975).

Check

transmission

oil

level

and

top

necessary

(also

final drive

automatic

transmission).

carried

out

connection

with

the

regular

6,000

rniles/10,000

inspection

Change

spark

plugs.

Change

breaker

points.

Change

oil

manual

transmission,

clean

magnetic

drain

plug

(at

least

once

year).

Chanqe

oil

final

drive

automatic

transmission.

Check

and

necessary

adjust

camber

and

caster.

Adjust

rlRr’lRration-vaJve.

carried

out

connection

with

the

regular

6,000

miles/10,000

inspection

and

the

supplemetary

12,000

miles/20,000

inspection.

Check

and

necessary

adjust

valve

clearances.

Change

air

cleaner

insert.

Change

fuel

filter

(injection

engine).

Check

and

necessary

replenish

steering

gear

oil

level.

Change

brake

fluid

(at

least

once

every

second

year).

Check

level

riaster

cylinder,

top

with

brake

fluid

necessary.

Check

and

necessary

adjust.

parking

brake

(only

and

md.

model

year

1974).

Remove

wheels

and

check

thickness

brake

pads.

Check

brake

lines

and

hoses

for

condi

tion

and

leaks.

Check

and

necessary

adjust

toe-in.

Check

condition

rubber

bellows

steering

gear

and

inner

and

oLiter

uni

versal

joints,

and

rubber seals

for

ball

joints

arid

tie-rod

ends.

Check

depth

tire

tread

patterns.

Body

ubricate

dour

stops,

door

hinges

and

hood

lock

mechanism.

The

maintenance

programme

lists

the most

important

things

that

ned

done to

ensure enjoyable

and

trouble-free

motoring

minimum

cost.

The

1,200

miles

(2,000

km)

coupon

the

Service Card

entitles

guarantee

check-ups

free

charge

(except

for

oils and

filters

for

which

charge

made,.

The

guarantee

not

valid

these

check-Lips

are

not

made. Subsequent

check

ups

10,000

miles

(15,000

km)

intervals

will

charged

for.

less

than

10,000

miles

(15,000

km)

are

covered

one

year,

one

engine

oil

change

must

carried

out

arid

one

complete

service

should

any

case

carried

out

the

year.

110—3

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