Saab 95 Estate Instruction manual

WORKSHOP MANUAL
for
SAAB 95 / 96V .4

Saab 95 (Estate)
Saab
96 (Saloon)
Saab Monte Carlo

Engine, gearbox and
chassis number locations
Engine number Gearbox number
CHASSIS NUMBER LIMITS FOR YEAR MODELS.
SAAB95
SAAB95
SAAB95
SAAB95
SAAB96
SAAB96
SAAB96
SAAB96
Monte Carlo
Monte Carlo
1966
1967
1968
1970
1966
1967
1968
1970
1966
1967
42.001-50.197
52.001 -62.059
65.001 -74.986
80.001-
420.001 -458.526
470.001- 507.018
520.001 -552.859
560.001-
420.001 -458.526
470.001-507.018
Chassis number and paint code plates
Chassis number plate
Colour code plate
Chassis number and colour code plates,
USA versions, models 1969 onwards.
r
Chassis number
imprinted on body

Front endjacking point Front end support points
Rearendjacking
point
Rear end support points
Sidejacking point Side support points

Index
ENGINE ......................................... 2 REAR SUSPENSION
.............................. 83
COOLING SYSTEM
.................. ... . .... . . ... 21 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90
IGNITION SYSTEM ............................... 27 ELECTRICAL EQUIPMENT
....................... 105
FUEL SYSTEM
.... ... ............ ... ......... ... 31
WIRING DIAGRAMS . . . . . . . . . . . . . •. . . . . . . . . . . . . . . 120
CLUTCH . ..... . ... .... ........... .. •........... 47 TROUBLE SHOOTING
...... .. . .... ........ . ... .. 131
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 CONVERSION TABLE
............... . END of MANUAL
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
AUTOSERVICE DATA CHART ........ . END of MANUAL
FRONT SUSPENSION
............... .. ........... 75
Introduction
Our intention in writing this manual is to provide the reader with all the information necessary
together with the data, so that repairs and maintenance can be undertaken
as they become necessary.
The information
has been checked against that provided by the vehicle manufacturer. and any
peculiarities are mentioned
if they depart from normal workshop practice. Where special tools are
required
to enable a job to be undertaken. these have been described. together with their usage.
It will be observed that a fault finding and trouble shooting dtart has been inserted at end of
manual to enable a quick reference to be made. with consequent time saving. As it is impossible to
include every malfunction in a book of this nature. only the more usual faults have been included.
A linear conversion table
of millimetres to inches has been included but we would recommend that
wherever possible the metric measurements are taken, for the sake
of accuracy.
Brevity and simplicity have been the aim in compiling the manual, relying on the numerous
ilh.is-
trations and clear text to instruct and inform. At the request of the users of our manua ls, the book
has been slanted towards repair and overhaul rather than maintenance.
NO LIABILITY CAN BE ACCEPTED FOR ANY INACCURACIES OR OMISSIONS IN THIS
MANUAL, althoughevery possible care has been taken to make it as complete and accurate as possible.
Overall length (including bumpers) :
96 & Monte Carlo
models- 1967-68 .
-From 1969 .
95 (Estate) models - 1967- 68 .
-From 1969
Overall width . . . . . . . . . .
Overall height (unladen) . . . . . .
Ground clearance (with 2 people, front) .
Track -front & rear .
Wheel-base . . . . •
Turning circle :
1967 -68 models .
Models from 1969
Kerb weight :
96 models- 1967-68
-From 1969
95 (Estate) models - 1967- 68 .
-From 1969
Monte Carlo models
Number
of seats :
96 models ....
95 (Estate) models .
Monte Carlo models
Available load luggage space :
96 &Monte Carlo models
95 (Estate) models
Max. roof load . .
Max . trailer weight
GENERAL DIMENSIONS
13ft Sin
(4170mm)
13ft
9in
(4200 mm)
14ft Oin (4270
mm)
14ft lin
(4300 mm)
5ft 2in
(1580 mm)
4ft 10 in (1470 mm)
5.1 in ( 130 mm)
4ft 0 in (1220 mm)
8ft 2in
(2498 mm)
34ft 10 in ( 10.6
m)
35ft 6 in
( 10.8 m)
1940 lb
(880 kg)
2000 lb (910 kg)
2080 lb (945 kg)
2160 lb
(980kg)
2000 lb (910 kg)
5
7
2+ 2
13 cu.ft.
(0 .37 cu.m)
39 cu.ft.
(1.1
cu.m)
200lb
(100 kg)
2000lb
(910 kg)
approx.
approx.
approx.
approx.
approx.
approx.
approx.
approx.
approx.
approx.
approx.
approx.
approx.

Fig.A:l
Left-hand view of the engiJte a~~~~embly.
I. Radiator top hose connection.
i. cooiingfan.
3. Balance shaft pulley.
4. Temperature sender unit
5. Crankcase ventilation hose
6. Fuel pump.
7. Starter motor
8. Intake air pre-heater plate.
9. Engine side-stay bracket.
IO. Rocker cover.
II. Air cleaner.
I 2. Carburettor.
II
Fig.A:2
Right-hand View of the engine assembly.
I. Carburettor automatic choke.
2. Ignition distributor.
3. Water distribution manifold.
4. Clutch.
5. Cooling ry&tem by·pe:tS pipe.
6. FlywheeL
7. Oil filter.
8. Sump drain plug.
9. Radiator
bottom hose connection.
IO . Water pump .
II . Alte1711ltor .
I
2. Oil filler cap.
2

Engine
GENERAL
The engine is a four-stroke, V4, water-cooled unit of the overhead-valve
type.. The crlinder_ bloc is a one-pi~ce casting with the cylinder bores
machined duectly mto .t. The cast-uon crankshaft runs in three main
bearings, the. middle one of which also serves as an axial guide bearing.
The connectmg rods are shrunk onto the piston pins and are thus not
detachable
from the pistons. The aluminium pistons are fitted with two
compression and
one oil control ring.
~e three_bearing camshaft is driven by the crankshaft via a gear wheel
w1th a ratio of 2 : 1. To ensure quiet running, the camshaft gear wheel is
made of fibre . ~ balance shaft, to provide proper engine balance, is
located on the right hand
side of the block and is also driven by the crank-
shaft
_Th~ balance shaft runs in two bearings and is driven at engine speed.
The d1str1butor and the fuel pump are driven by acamshaft skew gear and
an eccentric, respectively.
The cylinder heads for both banks are identical. The heads have separate
inlet ports
and common exhaust ports for each bank of cylinders. The
valves operate in guides machined directly in the .cylinder head and there
are thus no separate valve guides and valve seats. The valves are operated
via rock~rs, push ~ods and tappets from the camshaft, the tappets being
located m the cylinder block
and actuated directly by the camshaft.
The rocker covers are ofpressed steel and the right hand one is fitted
with
an oil filler cap . The inlet manifold completely encloses the area
between the two cylinder
heads.
The oil pump is of the bi-ro tor type. The pump is mounted in the sump on
~e lower face ofthe cylinder block and is driven bya shaft from the
distnouto~ . A full-flow oil ffiter of the disposable cannister type, is
:'Crewed duectly onto the right hand side of the cylinder block. The filter
mcorporates
an overflow valve to provide a safety factor in the event of
the filter becoming inoperative due tu dirt or sludge accumulation.
Engines up to and including engine No. 16100 are equipped with a semi
closed crankcase ventilation system. With this system air is admitted into
the crankcase through the oil filler cap and then led via a hose into the
car~urettor intake at the air filter, by-passing the filter element. Late
eng~es use a crankca_se _ventilation system ?f the totally enclosed type.
In
~ case ffit~red au 1s drawn from the au ffiter via a flame trap and
hose mto the nght hand rl>':ker cover. The ventilation flow then passes
through the crankcase and mto the left hand rocker cover where it is led
via ahose to an intermediate flange beneath the carburett~r . A regulating
valve fitted at this point governs the flow of air through the system.
ROUTINE MAINTENANCE
Every 6.000 miles (10,000 km) the engine oil should be changed and the
oil filter replaced. Refer to the TECHNICAL DATA at the end ofthis
~tion for the ~t of recOffi!llended lubricants. The sump drain plug is
Situated on the right hand Side of the oil pan (8, Fig. A:2). The filter is
ofthe disposable cannister type md should be removed using Tool.
No. GC 6883 or other suitable strap wrench (Fig. A:6). Apply a ftlm of
oil to the rubber gasket on the new cartridge. Screw in the cartridge until
the gasket makes contact with the
engine block and then further tighten
halfa tum.
DO NOT overtighten the cartridge otherwise the rubber seal
may tilt in its groove and leakage will result
THE FOLLOWING OPERATIONS CAN BE PERFORMED WITH THE
ENGINE IN THE CAR :-
- VALVE CLEARANCES -Measurement and Adjustment.
-
CYLINDER HEAD -Removal and Installation.
-
FRONT COVER - Removal and Installation.
-
FAN BEARING -Replacement.
-
CAMSHAFT - Removal and Installation.
VALVE CLEARANCES -Measurement and Adjustment :
To ensure qll:iet and smooth running of the engine, the valve clearance
should be adjusted carefully and accurately with the engine warm.
With the engine at normal operating temperature, remove the airclemer.
Detach the spark plug leads
from the rocker covers, unscrew the retaining
bolts and lift offboth the rocker covers.
The cylinders are arranged with
No. 1 and 2 in the right hand bank and Nos . 3 and 4 in the left hand bank
No. ~cylinder being at the .front of the car. Check the valve clearances by'
r?tating the cranksltaft until the rocker arms at one cylinder "rock"
(1e.· one arm will be just starting to move whilst the other will be just
reaching the returned position). Both the
valves at the cylinder in the
second column below can then be checked and,
if necessary adjusted.
VALVES ROCKING VALVES TO ADJUST
(Cylinder No.) (Cylinder No .)
1 4
3 2
4 1
2 3
The correct valve clearances are 0.016 in. (0.40 mm) for both inlet and
ex!'au~t valves with the_ engine warm. To adjust the clearance, screw the
ad]ustmg
screw clockwtse to decrease the clearance and vice versa (Fig.
A:7).
Refit the rocker covers and the air cleaner. The rocker cover with the oil
filler cap must
always be installed on the right hand side of the engine.
If a roc.ker cover gasket is damaged, discard the old gasket, fit the new
gasket m the rocker cover and press the gasket tabs into the locating slots
in the cover (Fig. A:8).
CYLINDER HEAD -Removal and Installation :
Remove the air cleaner and inlet manifold as described in the FUEL
SY~~EM section. Disconnect the alternator cables, noting their respective
p~s1tions. Release the alternator adjusting and mounting bolts, remove the
drive belt and detaclt the alternator and mounting bracket.
Disconnect the
engine sire support from the bracket on the left hand side
ofthe engine (9, Fig. A: 1). Detach the pre-heater plate (8, Fig. A: 1).
Unscrew the flange nuts securing the exhaust pipes to the cylinder heads.
Unbolt the exhaust pipe clamps at the engine mountingbrackets and
remove the spacers at the cylinder heads.
Release. evenly, the two bolts securing the rocker shaft pillars to the
cy!inderhead! lift off the rocker assembly and
remove the oil return plate
(F1g. A:9). Lift out the push rods, keeping them in their correct order.
This can be acheived by pushing the rods through a piece ofcard with
"LEFT BANK· FRONT" or "RIGHT BANK· FRONT'' marked at the
appropriate end. Release the cylinder head bolts evenly, in the
reverse
order to that shown in Fig. A: 11 and lift offthe cylinder head assembly
and gasket. ~e_peat for th~ other cylinder head. Note that the outer rear
bolt on the right hand cylinder head also secures the
engine earth cable.
Before installing the cylinder heads, ensure that the mating faces
of the
cylinder block and heads are clean and
free from old gasket material.
~e cylinder head gaskets for the right hand and lefthand banks are
different and
are not interchangeable (Fig. A: 10). The gaskets are marked
"FRONT" and "TOP". Place one
of the cylinder head gaskets over the
two locating dowels on its respective face
of the cylinder block. Install the
cylinder head on the locating
sleeves. Repeat for the other cylinder head
and gasket Note that the outer rear bolt of the right hand cylinder head
also secures the engine earth cable. Tighten the cylinder head bolts in
three stages following the sequence shown in Fig. A:
11 .
STAGE 1 40 lbft. (5.5 kgm}
STAGE 2 50 lbft. (7.0 kgm
STAGE 3 68lbft. (9.5 kgm
Dip the push rods ends in engine oil and install the push rods in their
original bores. Fit the oil return plate and rocker shaft
assembly to each
cylinder head, locating the adjusting screw in the cupped end
of the push
r?ds. Secure each
~ocker shaft assembly with the two retaining bolts and
tighten evenly. Adjust the
valve clearances as described previously.
Install the inlet manifold, carburettor and
air cleaner as detailed in the
FUEL
SYSTEM section under "INLET MANIFOLD •Removal and
Installation".
3

Fig. A:3
Engine lubrication system.
1. Oilpump .
2. Oil filter.
3. Balance shaft.
4. Crankshaft.
5. Camshaft Fig.A:4 Semi-closed crankcase ventilation system
6. Cylinderhead.
7. Rocker assembly.
8. Main
oll galle ry .
9. Oil pressure
swit ch.
Fig. A:6 Removing the oil filter
Fig. A:S Closed crankcase ventilation system
4

CYUNDER HEAD- Decarbonising:
Plug all push rod cylinderhead bolt and water-way apertures in the
cylinder block
and cylinder head faces. Using a suitable tool, scrape all
carbon deposits from the cylinderhead faces, combustion chambers,
valve heads and piston crowns. Care should be taken toprevent damage to
the metal faces and toprevent carbon particles from contaminatingany
parts
of the engine. Clean all carbon particles from the cylinder head and
cylinder block.
If it is required to grind the · valves and valve seats, refer to "CYLINDER
HEAD -Overhaul" in this section.
CYUNDER
HEAD- Overhaul :
Remove the spark plugs. Compress one ofthe valve springs, using a
suitable
valve spring compressor (Fig. A:12). Extract the split tapered
collets from around the
valve stem. Release the compressor and remove
the valve spring retainer and valve spring. Remove the rubber oil seal
fitted to the valve stem and withdraw the valve (Fig. A:l3). Repeat for
the other valves.
Rocker shaft assembly :
Drive the roll pin out of one end of the rocker shaft, using a suitable <4ift,
and detach the spring washer which bears against theend rocker arm. The
rocker
arms, rocker shaft pillars, spring and second spring washer can now
be removed from the shaft (Fig. A:l4).
Qean
all parts thoroughly and inspect. Check that all oil passages are clear.
Inspect the rocker shaft and rocker
arm bore for nicks, scratches, scores,
scuffs or excessive wear. Inspect the pad at the valve end of the rocker
arm for any indication of scuffmg orabnormal wear. If the pad is grooved,
replace the rocker
arm. DO NOT attempt to true this surface bygrinding.
Replace any damaged adjusting screws.
Assemble the rocker shaft in the reverse order of removal. The rocker shaft
must be
assembled with the grinding mark downwards (indicated by the
arrow in Fig. A:14), so that the rocker arm lubrication holes will be
correctly positioned. The rocker shaft pillar with the oil feed hole must be
positioned
at the rear on the right hand cylinder head and at the front on
the lefthand cylinder head.
Push rods :
Check the rods for straightness. DO NOT attempt to straighten push rods.
Inspect the ends
of the rods for nicks, grooves, roughness or excessive wear.
Replace as necessary.
Cylinder head :
CheCk the cylinderhead for cracks and inspect the machined face for bum,
scratches or nicks. Replace the head if it is cracked. Remove any burrs or
scratches with an oil stone. Check themachined face for flatness, using a
straight
edge. Check the sparlc. plugholesfor stripped or damaged threads
and rectify
as necessary.
Valves:
Clean all carbon deposits from thevalvesand inspect the face and edges
for pits, grooves, scures or otherdamage. Check the valve face run-out. If
run-out is excessive, or if any other of the above faults are present, the valve
can be corrected by refacing. Remove only sufficientmetal to correct the
fault.
If the edge of the valve head is less than 1/32 in. (0. 79 mm) thick
aftergrinding,
the valve should be replaced as it will run too hot in use.
Check the valve head for signs of burring. warpage, erosion or cracking.
Minor pits, grooves, etc., may be removed. Inspect the end of the valve stem
for
grooves or scores. Minor damage may be rectified bygrinding. Check
that the
valve stem is notbent. Diacard valves that are severly damaged.
ValYe guides :•
Check the valve stem to valve guide clearance of each valve inits respective
guide. Refer to the
TECHNICAL DATA at the end of the section for the
specified clearances.
If the clearence is excessive or the guide bore isworn
oval, the bore must be reamed to asuitable outsize (Fig. A: 1 5). Reaming
must be done in stages, startingwith the smallest diameter and working up,
to
the largest diameter. Use paraffm (Kerosene) as cutting oil while reaming.
After reaming the valve guide bore the valve seat must be recut toensure
that the seat is concentric with the
valve guide.
Valve seats :
Inspect the
valve seats for pitting or burning. Check the valve seat run-out,
using an accurate
gauge. If run-out is excessive, or if any other of the above
faults are present, the valve seats must be recut. The valve seats should also
be recut after reaming the valve guides and when fitting new valves.
Refacing of the valve seat should be closely co-ordinated with the refacing
of the valve face so that the fmished seatand valve face will be concentric
and the correct interference fit will be maintained.
Cut the
valve seats to a true angle of 45° removing only sufficient metal
toclean up pits and grooves,
or tocorrect the valve seat run-out. If there
is ahard carbon deposit on the seat, thismay be removed with a flange
breaker.
After refacing, the
valve seat width will probably be excessive. Determine
where the valve seat contacts the valve face by coating the seat with
Prussian Blue and rotating
the valve lightly in the seat. If the blue is
transferred to the centre of the valve face, metal must be removed from
bothsides
of the seat to narrow it. Blue on the top edge of the valve face
indicates thatthe seat should be narrowed witha top-face cutter. Blue on
the bottomedge indicates thatmetal should be removed from the
~rt
edge of theseat. Narrow the seat with the appropriate cutter. A 11 cutter
should be used for the topface and a
75° cutter for the port(Fig. A:16).
The
valves may be lapped in using fme grinding paste (Fig. A:17). When a
uniform seating surface
has been obtained, carefully clean all grinding paste
offthe seat and
valve.
Valve sprinp :
Check the
valve springs for squareness, using a steel rule and a flat surface.
Revolve the spring slowly and observe the space between the topcoil of
the spring and the square. Check that the valve spring tension is within the
prescribed specificati001. Inspect the
valve sprin~ valve spring _!etainers
and valve retaining conetsfor wear or damage. Diacard any Visually ·damaged
parts.
When replacing valve springs it is recommended that they be replaced
insets.
To reassemble the cylinder head, install one of the valves in its respective
port.
Fit the rubber oil seal over the valve stemwith the open end in the
cylinder head and fit the valve spring and retainer over the valve stem.
Compress the
valve spring. locate the two split tapered collets in the
groove in the valve stem and slowly release the springcompreasor to engage
the collets in the retainer taper. Repeat for theother valves. Fit the spark
plugs.
FRONT COVER - RemOYBI and Installation :
Disconnect
the batteryearthlead. Drain the cooling system. Release the
alternator adjusting and mounting bolts. Unscrew the four retainingbolts
and detach the cooling fan and drive pulley from the bearingflange.
Disconnect the water hoses
at the water pump. Unscrew the retlinlngbolts
and withdraw
the balance shaft pulley. Remove the front bolts securing
the oilpan. Unscrew the 9 retaining bolts and separate the front cover
from the cylinder block.
If the balance shaftoil seal is to befe£laced, drive the old oil seal out of
the front cover usingTool GC 6059 (Fig. A:18). Drive the new seal into
place from
the rear, using Tool GC 760Q.B, until itbottoms (Fig. A:l9).
Ensure that the mating faces
of the front cover and cylinder block are clean
and free from old gasket material. The portion
of sump gasket beneath the
front cover isinevitably damaged during the
retmVal operation. The old
sump gasket should becut off, level with the cylinder block front face,
using a sharp knife. Cut acorresponding portion
of new sump gasket, coat
itwith suitable jointingcompound
at the endsand place carefully in posi-
tion on the engine.
Apply a thin coating
of sealing compound to the mating surfaces of the s

Adjusting the valve clearances
FigA:8
Rockercovergasket location
Fig.
A:9
Removing/Installing the rockerassembly. Fig. A:10 Installation
of the cylinder head gaskets
I. Rocker shaft with ro cker arms.
2. Oil return plate.
Fig.. A:13
Cylinderhead assembly
Fig.
A:12 Removing the valves and valve springs I. Split tapered
collet~
2. Spring retainer
Fig. A: 11 Cylinderhead bolt tightening sequence 3.
Valve spring.
4. Valve stem oil seal .
.5. Cylinder head.
6. Inlet valve .
7. Exhaust valve.
6

Fig. A:14
Rockerassembly.
I. Rocker shaft.
2.
Rocker arms.
3. Adjusting screws.
4. Rocker shaft pillars.
S. Spring.
6. Rollpins.
7. Cover plate.
8. Spring washers.
9. Plugs.
Fig. A:16 Valve seat angles
Fig. A:18 Removing the front coveroil
seal
Fig. A:1S Reaming the valve guides
Fig. A:17 Grinding the valves
Fig. A:19 Installing the front cover oil seal
'7

front cover. Position a new gasket on the front cover. Install the front
cover, align it using Tool GC 6059 and tighten the retaining bolts. Secure
the oil pan to the front cover with the 5 retaining bolts. Lightly oil the
sealing surface of the balance shaft pulley, install the pulley and secure
with the retaining bolt
and washer. ··
Install the cooling fan and drive pulley. Reconnect the water hoses to the
water pump. Install the alternator and
drive belt and adjust the drive belt
tension
as described in the COOLING SYSTEM section. Refill the cooling
system . Reconnect the battery earth lead. Start the engine and check for
oil and water leaks.
FAN BEARING -Replacement :
Remove the front cover as described above. A piece of tubing with an inside
diameter
of 2 in. (SO mm) isrequired to support the front cover during
the removal and installation operation. Support the front cover around
the
fan bearing with the piece of tube and press out the bearing and shaft
assembly with an arbor (Fig. A:21). The bearing sealing washer willbe
djsplaced from the underside of the cover.
Remove the piece of tubing from under the cover and press the new shaft
and bearing assembly into the cover. Place the cover on the tubing again
and press in the new bearing, until it bottoms out, using Tool No.
GC 8501 -A(Fig. A:22). Suitably support the inner end of the fan shaft
and press the flange onto the shaft until the flan~ top face is 3.75 in.
(95.5 mm) f
rom the front cover mating surface (Fig. A:23). Tum the
cover over, hold in thehand and tap a new sealing washer into position
(Fig. A:24). Install the front as descn"bed above.
CAMSHAFT -Removal andInstallation :
Remove the cylinder heads as described previously. Remove the tappets
from the cylinder block with the aid of a bar magnet ora piece of bent
wire (Fig. A: 2S) . Keep the tappets in their correct order. Unscrew the 2
retaining bolts
and detach the fuel pump and gasket and push rod. Mark
the end of the push rod that rests against the camshaft to ensure correct
assembly . Remove the front cover as described previously. Unscrew the
retaining bolt and withdraw thecamshaft
gear byhand. Unscrew the two
retaining bolts
and detach the camshaft thrustplate (Fig. A:27).
Carefully withdraw the camshaft from the cylinder block. Extract the
key from the shaft and
remove the spacer.
Lubricate the camshaft bearings withengine oil
and carefullypass the
camshaft intothe cylinderblock.
Fit the spacer ring over the camshaft,
countersunk
inwards, and insert the key. Position the thrust plate on the
front
of the cylinder block so that it covers the main oil j!allery hole and
secure with the two retaining screws and spring washers (Fig. A:27).
Check the camshaft end-float. If required, the spacer thickness can be
adjusted
to bring the end-float withinspecifications. The spacer is avail-
able in two different thicknesses. A red marking identifies the thinner
spacer whilst the thicker one has a blue marking.
Tum
the crankshaftuntil one of the marks on the crankshaft gear aligns
with the mark on the balance shaft gear and the other faces the camsliaft
(Fig. A:28). Fit the gear
wheel onto the camshaft so that the mark on the
gear aligns with the mark on the crankshaft gear. Secure the camshaft gear
with the retaining boltand washer. Install the front cover as described
under the appropriate heading. Install
the fuel pump push rod with the
same end against the cam as originally. Install the fuel pump and gasket
and secure with the two retaining bolts. Install the cylinderheads as
described previously in this section.
ENGINE -Removal andInstallation :
The engine may be removed independently or as a unit with the trans-
mission. In the latter case, refer to the TRANSMISSION section for the
details
of the additional operations required.
To
remove the power unitonly the associated components should be
removed or disconnected in the follwing sequence :-
1. Disconnect battery earthlead.
2. Remove the retaining clips from bonnetpivot pins. Bend one of the
stays inwards
to release it from the ~ivot bracket and, with the aid
of an assistant, lift off the bonnet, (Fig. A:29).
3. Drain
the cooling system including the heater.
8
4. Disconnect wiring from headlights and side/indicator lights.
S. Disconnect cord from radiator blind, if fitted.
6. Disconnect the
cable from bonnet lock mechanism .
7. Remove four retaining screws from front panel (Fig. A:30). Unbolt
two support
arms at wheel housings and two brackets at radiator
and lift offfrontpanel (Fig. A:31).
8. Disconnect top and bottom radiator
hoses at engine. Unscrew two
radiator lower rataining bolts and
remove radiator. Remove expansion
tank,
if fitted.
9.
Remove the air cleaner. It is recommended that acover be placed
over the carburettorintake
to prevent entry of foreign matter,
10 . Disconnect a) Alternator leads (NOTE positions)
b) Distributor
low tension lead
c)
Coil high tension lead
d)
Oil pressure switch lead
e)
Water temperature sender unit lead
f) Starter motorleads.
11. Disconnect a) Heater hoses
b) Fuel pipe
at pump inlet
c) Throttle
linkage
d) Engine side -stay at engine bracket
12 . Remove pre-heater casing from lef t side of the engine (8, Fig. A: l) .
13. Remove the nuts from exhaust pipe flange at cylinder head.
Remove exhaustpipe clamps at engine mountings. Detach middle
exhaust pipe mounting from underbody. Remove spacers atcylinder
heads and lower silencer
as f ar as possible.
14.
Remove alternator and mounting bracket.
IS. Remove water distribution manifold
from rear of engine (Fig. A:33).
16. Attach suitable lifting tackle to engine (eg. LiftingHook, Tool
No . 766202) Remove both front engine mounting brackets and
raise unit approx. 2 in. (SO mtn) to clear sump (Fig. A:32).
17 . Remove startermotor. Remove protective plate in front of the
flywheel.
18. Suitably support gearbox and remove clutchhousing
to engine bolts.
19. Draw engine forward offclutch shaftsplines and lift out.
Installation is the
reverse of the removal procedure with special attention
to the following points :·
a)
b)
c)
d)
e)
When reassembling the exhaust pipes, tighten the flange nuts at the
cylinder heads, the clamps at the engine mounting brackets
and the
middle exhaust pipe mounting in thatorder.
DO NOT confuse the alternatorleads. If necessary refer to the
ELECTRICAL EQUIPMENT section at the end of this manual for
correct pointing
of the leads.
If necessary, adjust the clutch pedal free play as described in the
CLUTCH section.
Refill the cooling system and,
if drained, the engine sump.
After installation is complete, road test the car.
ENGINE -Disaslembly :
Drain the
engine oil. If notalready removed, detach the drive belt,
alternator and mounting bracket. Remove the cooling
fan. Remove the
fuel pump, pump push rod and gasket from the left
side of the cylinder
block (see Fig. D:S).
Unscrew the oil pressure switchlocated below the
fuel pump (Fig. A:34). Remove
the oil ffiter, usingTool No. GC 6883
orother suitable strap
wrench (Fig. A: 6) .
Disconnect
the spark plugleads, release the retainingclips and lift offthe
distn"butor cap. Disconnect thevacuum pipe, fuel pipe
and choke water
hoses
at the carburettor, uniiCrew the two retaining nuts and lift offthe
carburettor and gasket. Release the clamping bolt and
remove the
distn"butor.
Unscrew
the retaining bolts and lift otT the rocker covers. Release, evenly,
the bolts securing the rocker shaft pillars to the cylinderheads and lift the
rocker assembly and oil return plate from each cylinderhead (Fig. A:9).
Remove
the push rods, keeping them in their correct order. This can be
done by pushing the rods through a piece ofcard with "LEFT BANK -
FRONT' or "RIGHT
BANK- FRONT" marked at the appropriate end.
Remove the water outlet housing from the inlet manifold and lift out the
thermostat and gasket (see Fig. B:9).
Unscrew the inlet manifold retaining
bolts and nuts, separate
the manifofd from the gasket and lift otT the

Fig. A:21 Pressing out the fan shaft and~~
Fig.A:20
Installing the front cover.
I. Front cover .
2. Aligning tool GC '6059
.Fig. A:23 Installing the fan pulley flanJe
Fig. A: 22 Installing the fan bearing
Fig. A:24 Installing the fan bearingcover plate
Fig. A:25 Removina
the tappets
9

0
Fig. A:26 Measuring the camshaft thrust plate
Fig.
A:29 Removing the bonnet
Fig. A:27 Camshaft thrustplate, spacer washer and woodruffkey
Fig. A:30
Front panel retaining screws
Fig. A:28 Tunin&
gear aligrunent marks
10

manifold. Disconnect the engine side stay bracket from the left hand side
of tne engine (Fig. A : 1). Release the cylinder head bolts evenly, in the
reverse order
to that shown m Fig. A : 11 and lift off the cy Iinderhead
and gaskets. Repeat for the other cylinderhead. Note
that the outer rear
bolt on the right hand cylinder head also secures the engine earth
cab_le.
Remove thetappets from their boresin the cylinder block with the a1d of
a magnet or a piece of bent wire (Fig. A : 25). Keep the tappets in their
correct order.
Unscrew the sump retaining bolts and remove the sump and gaskets.
Remove the oil pump andpump drive shaft(Fig. A:35).
Unscrew the retaining bolt and withdraw the pulley from
the balance
shaft. Remove the 9 boltsretainingthe front cover
to the cylinderblock
and
tapthe rear of the water pumpwith a plastic mallet or similar, to
separate the cover from the intermediateplate. If required, the water
pump can be unbolted from the front cover(see Fig. B:12).
Unscrew the retaining
bolt and remove the camshaft fibre gear wheel by
hand. Remove the retaining bolt and withdraw the balance shaftgear
wheel. Unscrew the intermediate plate retaining bolts(2, Fig. A:36), and
detach the plate. Remove
the camshaft thrust plate, woodruff key and
spacer (Fig. A:27), and carefully withdraw the camshaft.
Unscrew the big end bolts several turns
on one of the connecting rods and
tap them
to release the cap. Co~pletely remove the bolts andbig e!ld cap
and push the piston and connecting
rod assembly up out of the cylinder
bore. Repeat
for the otherpiston andconnecting rod assemblies. Remove
the crankshaft gear retaining
bolt andwithdraw the gear using a suitable
puller (eg: Tool786218).Mark
the relativeposition of the flywheel and
crankshaftflange and remove the flywheel.
Drive out the balance shaft sealingwasher
by tapping the balance shaft
towards the rearusing a plastic mallet
or similar and then carefully
withdraw thebalance shaft from the rear (Fig. A:39). Release
the main
bearingcap boltsevenly and
lift off eachcap. Carefully lift out the
crankshaftand slide the oil seal
off the rearend of the shaft.
ENGINE -Inspection and Overhaul :
Cylinder HeadAssembly :
The components
of the cylinderhead assemblies, including the pushrods,
have been dealt with previously under "CYLINDERHEAD -Inspection
and Overhaul".
Cylinder Block :
Thoroughly clean the dismantled block. Remove
the oilgasket material
from the surfaces. Clean andblow
out all passages, bolt holesetc. Ensure
that the threads in the cylinderhead
bolt holes are clean.
Check
all machined gasket surfaces for burrs, nicks, scratches and scores.
Remove minor imperfections with
an oil stone. Check the cylinder head
gasket surfaces for flatness and
if necessary, have the cylinderblockface
corrected
by planing. Replace any core plugs which show signs of
leakage.
Cylinder Bores :
Inspect
the cylinderwalls for scoring, roughness or othersigns of wear.
Check the cylinder bore for out-of-round and taper. Measure
the bore with
an accurate bore gauge, following the equipmentmanufacturers instructions.
Measure the diameter
of eachcylinder bore at the top, middle and bottom
with the gauge placed first at right angles (A) and then parallel (B) to the
centre line of the engine. The difference betweenA and B will give the
out-of-round, and the difference between A
at the top of the bore and A
at the bottom of the bore will give the taper. It may be possible to remove
minor surface imperfection
by honing, but cylinders whichare deeply
scored excessively worn, must
be rebored to the next oversize.
Pistom andConnecting
Rod Assemblies :
The piston, connecting rod and piston
pin form an integral unit and are
serviced assuch.
No attempt, therefore, should bemade to separate them.
When removing
the piston and connecting rod assemblies from the engine,
check that the connecting rods and big-end caps have beennumbered
correctly (Fig. A:37). Where
the rods and capsare unmarked they should
be suitably stamped unless the assemblies are being scrapped.
Remove all deposits from the piston surfaces. Clean
gum or _varnish.from
the piston skirt andrings with solvent. DO NOT use a caustic cleanmg
solution
or wire brush to clean the pistons. Clean the ring grooves and
make sure
that the oil ring slots are clean. Clean the connecting rods, caps
and bearing shells with solvent and
dry with compressed air.
Inspect the pistons for fractures at the ring lands, skirts and pin bosses, and
for scuffed, rough
or scored skirts. A shining surface on either pin-boss side
of the piston usually indicates that the connectingrod ~bent. If the lower
portion
of the ring groove has a high step, replace the piSton. Spongy,
eroded areas near the edge
of the piston crown are usually caused by
detonation or pre-ignition. Replace pistons that show siAAS of excessive
wear, wavv ring lands
or fractures, or damage from detonation or pre:
ignition. Although,
in production, pistons are graded to ma~ch the cylinder
bore, pistonsobtained as service replacements are
not classified. The
diameter of replacement pistonslies within the u~r part of the t~lerance
range so that in most cases the cylinder bore requues to be honed m order
to get the correct piston clearance with a new piston. If the clearance.
obtained is excessive,
the cylinders must be rebored to the next oversiZe.
The piston clearance
in the cylinder bore should be 0.0011 • 0. 0024 in.
(0.03 • 0.06 mm).
If the clearance is excessive, the piston must be rep~ed
with one of suitable diameter or the cylinder rebored to the next overstze.
The piston
fit in the cylinderbore can be che~ked with a piston pull-~ale,
fitted with a feeler blade 1/2 in . (12.7 mm) w1de and0.0012 • 0.0020 m.
(0.03 • 0.06
mm) thick. Place the feeler blade at one side of the ~ylinder
bore and then slide the piston (without pistonrings) crownflrst mto the
cylinder bore to trap the feeler bladebetween the piston and the cylinder
wall. The piston should
be inserted with its front markingpointingtowards
the front
of the engine. Hold the piston in the bore without applying any
side
thrust and withdraw the feeler blade with a steadypull on the piston
scale (Fig. A:46).
If the clearance is correct, the pullrequired will be
2.2lb (1 kg). Repeat the test at several different depthpositions in the bore.
Inspect
the connectingrods for signs of fracture and the big end bearing
bores for out-of-round and taper. Abnormal big-endbearing wear
c~ be
caused
by eithera bent connectingrod, a worn or damaged crankpm, or a
tapered big-end bearing bore.
If any unsatisfactory conditionis found, the
connecting
rod should be replaced. New connecting rod boltsshould be
used every time the bearingcaps are removed.
Piston Rings :
Replace all piston rings which are broken, cracked, chipped, scored or worn.
Rings should NOT
be transferred from one piston to another regardless of
mileage. Locate each piston ring in turn in its respective cylinder bore,
using the inverted piston
to position the ring squarely in the bore, and
check
the piston ring gap (Fig. A:47). With worn cy~der bores_ the ~g
should be located at the lower limit of travel of the piSton as this port10n
of the bore will be least worn. If the piston ring gap is too small, the ends
of the ring must be trimmed with a special file.
Check the clearance
of eachpiston ring to its respective groove in the
piston at several points by rolling the ring around the piston. Refer to
TECHNICALDATA at the end of this section for the specified clearances.
When assembling
the piston rings to the pistons, position ~e gap in the
oil control ring main segment at 180° to the mark on the piSton crown and
stagger
the gaps in the ring rails 1 in. (25 mm) on either side of the gap.
The compression ring gaps should be positioned
150° on eitherside of the
oil control ring main segment gap.
Crankshaft :
Clean
the crankshaft with solvent andblow out the oil passages with
compressed air. Inspect the bearingjournals for cracks, scratches,
groov~s or
scores and the rear oil seal surface for nicks, sharp edges or burrs that nught
damage
the oil seal or cause premature 'Seal wear. Use emery cloth to
remove the minor imperfections.
Measure
the diameter of eachjournal in at least four places to d_eterrnin~
out-of-round, taper and undersize. If the taper or out-of-round IS exceSSIVe,
or if any of thejournal surfaces are severelymarred, the_ crankshaft ~ust
be reground. If thejournalwill not clean up to the m3Xllllum undefSIZe
bearing available, replace the crankshaft.
11

Fig. A:32 Removing/installing the engine
Fig. A:31 Removing the front panel
Fig. A:33
Water distribution pipe Fig. A:
34 Removin2/installing the oil pre~re switch
Fig. A:3S Removing/installing the oil pump
1. lntermed14te plate.
2. Plate retaining bolts.
12

Fig.A:37 Connecting rod and cap numbering Fig. A:38 Removing
the crankshaft sprocket
Fig. A:40 Placing plastigauge on
the bearing cap
Fig. A:39 Removing the balance shaft
C>D
A>B
Fig. A:41 Measuring the plastigauge width Fig. A:42 Crankshaft out-of-round Fig. A:43 Crankshaft taper
13

786217
•
\ ~
1-: ~ ~~
.,
--
_; ~8- ~
... -... -........... ... I! • ~
-;
Fig. A:45 Installing the crankshaft rear oil seal
Fig. A:44 Removing
the crankshaft rear oil seal
Fig. A:47 Checking the piston ring gap
Fig.
A:46 Checking the piston fit with a puU-scale
Fig.A:49
Oil pump, dismantled.
I. Pump housing.
2. Inner and outerrotor.
3. Cover plate.
4. Relief valve.
5. Spring.
6. Valve cap.
7. Gasket.
Fig. A:48 Removing the ring gear from the flywheel 8. Oil pick-up pipe.
14

Crankshaft Rear Oil Seal :
The crankshaft rear oil seal can be replaced without major disassembly of
the engine. With the engine removed from the car, unbolt the clutch and
flywheel . Withdraw the old crankshaft seal using Tool No. 786216 by first
retracting the tool spindle pressure, screwing
it on with the conical
threaded part in the
seal and then advancing the pressure spindle to pull
out the
seal (Fig. A:44). Lubricate the inner diameter of the new seal
with engine oil, push it onto Tool No. 786217 and drive it into the main
bearing until
it bottoms out(Fig. A:45).
Main Bearings :
Clean the bearinginserts and caps thoroughly in solvent and dry with
compressed air. DO NOT scrape gum or varnish deposits from the bearing
shells. Inspect each bearing carefully. Bearings that have a scored, chipped
orworn surface should
be exchanged. The bearing base maybe visible
through the bearing overlay butthis does not mean thatthe bearing is
worn. It is not necessary to replace the bearing if theclearance is within
the recommended limits.
Check the clearance of bearings which appear to be satisfactory, using
Plastigage. Plastigage is available under spare part No. 786050 and is
supplied
in three different thicknesses. Use type PG·1 (green) as thisis
suitable for clearance measurements,
of 0.00098 •0.00299 in.
(0.025 · 0.076
mm).
Position the engine with the sump face upwards and install the crankshaft
and main bearinginserts. Ensure that the parts to bemeasured are free from
oil and dirt Install a dry bearing insert in the main bearingcap and place
a
piece of plastigage across the full width of the insert about 1/4in. (6 mm)
off-centre (Fig. A:40). Position the crankshaftabout
30° B.B.D.C. and
install thebearing cap with insert andPlastigage. Tighten the bearing cap
bolts
to the normal specified torque.
NOTE :- DO NOT turn the crankshaft while the Plastigage isin place.
Remove the bearingcap and, using the Plastigage scale,check the width of
the Plastigage strip (Fig. A:41). The widest pointwill give theminimum
clearance and the narrowest pointthemaximum clearance. The difference
between the readings
gives the taper on thejournal.
To check the crankshaftjournals for out-of-round, rotate the crankshaft
90° and repeat the measuring procedure. The difference between the
readings indicates the out-of-round of the journal.
NOTE :-All bearings and journalsmust be cleaned of Plastigage material.
The main bearing clearance should be0.012- 0.048 mm for standard
journals
and 0.014 · 0.058 mm for undersize joornals.
Standard bearinginserts
are supplied in two different thicknesses, the
thicker ofthe two being identified
by a blue dot and the otherby a red
dot. Red bearinginserts should be fitted for the initial measurement
of
the bearingclearances. If theclearance is excessive a blue and a red, or
two blue inserts shoold be installed. If the clearance is still excessive,
even with two blue inserts, the crankshaft must be reground to the next
undersize and correspondingundersize inserts fitted.
NOTE :- If blue inserts are used on more thanone journal, ensure that
they are
all installed on the cylinder block side of the bearing.
NOTE :- All main bearing inserts are interchangeable.
When refitting the main bearingcaps, the arrows on the centre and front
caps must point to the front. Care should be taken to avoid confusing the
cylinder head boltswith those for the main bearing
caps. Although the
bolts
have the same diameter, the main bearings cap bolts are approximately
0.4 in (10mm) longer than those for the cylinderhead.
As from engine
No. 74900 the cylinderhead bolts have beenlengthened to make.them
the
same, thus eliminating posSibility of confusion.
The centre main bearing also serves as anaxial guide bearing for the
crankshaft.
Big-End Bearings :
The big-end bearing inserts should beinspected and the bearing clearances
checked in the
same manner as already described for the mainbearings.
When measuring a bearing clearance with Plastigage, ensure that the
connectingrod
is notmoved. The crankpin to bearing clearance shoold be
0.014- 0.054
mm for standardjournals and 0.014- 0.064 mm for under-
size journals. Similar remedial procedure should be carried out.
Camshaft:
Clean the camshaft in solvent and wipe dry.lnspect thecam lobes for
scoring and
signs of abnormal wear. Lobe wearcharacteristics may result
in pittingin the general wear
of thelobe toebut thisis not detrimental
to the operation
of thecamshaft. The camshaft should not, therefore, be
replaced until the lobeliftloss has exceeded 0.005 in(0.127 mm).Check
the distributor
drive gear for broken orchipped teeth and, if this condition
ispresent, the camshaft must be exchanged.
The camshaftend-float iscontrolled by a thrust plate and spacer ring, the
spacer ring being slightly thicker
than the thrust plate (Fig. A:27). The
end-floatcorresponds to the difference in thickness between the spacer
ring and thrust plate.
This should be 0.025 • 0.076 mm. The spacer ring is
available in different sizes, the size group being indicated by red orblue
markings. A red spacer decreases the end-float while a blue one increases
the end-float. When fitting new parts, select a spacer to give the specified
end-float.
Camshaft Followers :
The cam followers can bewithdrawn from thetip
of the cylinder block
after thecylinder heads have been removed (Fig. A:25). Thoroughly
clean the followers inclean solvent and wipe them witha clean, lint-free
cloth. Check them for wear or scoring. Replace followers which are scored,
worn, or
if the bottom is not smooth. It is recommended thatonly new
cam followers beused when fitting a new camshaft.
TuningGears :
To ensure quiet running, thecamshaft gear wheel
is made of flbre. Check
all three gear wheels for cracks and worn or damaged teeth. If required,
the gear wheels can bereplaced separately. -
The backlash for the timing
gears should be as follows :-
New gear wheels
Worn gear wheels (max.)
Camshaft Gear
0.0020• 0.0079 in.
(0.05 • 0.20 mm)
0.0157 in. (0.4mm)
Balance Shaft Gear
0.0020. 0.0055 in.
(0.05 • 0.14 mm)
0.0157 in. (0.4 mm)
Abacklash
of 0.0157 in. (0.4mm) at the balance shaft gear wheel is
equivalent to 0.022 in. (0.56 mm) on the outside diameter of the
balance shaft pulley.
FrontCover :
If the balance shaft oil seal is to be replaced, drive the old oil seal out of
the front cover using Tool GC 6059 (Fig. A:1g), Drive the new seal into
place from
the rear, using Tool No. GC 7600-B, until it bottoms(Fig.
A:l9).
Flywheel:
If required the flywheel rlng gear can be replaced by drilling ahole, 0.28 •
0.
32 in(7 • 8mm) in diameterbetween two adjacent teeth of the ring at
two diametrically opposite points(Fig. A:48). As a rule the ring gear splits
offduring drilling,
but otherwise it can be split with the aid of a chisel.
During the drilling operation, ensure that the drill
passes through the ring
gear only and not into the flywheel.
Heat the new
gear evenly to a temperature of not in excess of 554Df
(290°C). The ring gear is induction hardened and loses itshardness
if
heated above this temperature. Once expanded with the heat, fit the ring
gear over the flywheel so that it drops down onto the flywheel lug. Allow
the ring gear to cool naturally in air. DO NOT QUENCH.
IS

Fig. A:SO Removing the reliefvalve cap Fig. A:SI Checking the rotorend-float
Fig. A:S2 Checking the rotor radial clearance
Fig. A: S3 Tightening the centre main bearingcap
Fig. A:SS lmtalling the balance shaft
. Fig.A:S4 Installing the piston and connecting rod assemblies
16