Saab 99 1982 User manual

Contents
2
Engine
M
1982—
©
Saab-Scania
AB
1982
022
Specifications
102
Special
tools
200 General
201
Removal
and
installation
210
Engine
body
211
Cylinder
head
•
212
Pistons,
connecting
rodsand
cylinder
bore
214
Valve
mechanism
215
Transmission
216 Crank
mechanism
220
Lubricating
system
221
Oil
pump
222
Oil
filter
231
Carburetor,
see
separate
table of
contents
232 Inlet
system
(Air induction
system)
233
Fuel
pump
234
Fuel
tank
and fuel lines
252
Exhaust
system
254
Exhaust
emission
control
system
261
Radiator
and cooling system
262
Water
pump
and
fan
motor
271
Throttle
controls

€0

Specifications
Engine
General
data
Single-carbureted
engine
Type
4-cyl,
4-stroke
with
overhead
camshaft
Power
rating,
DIN
(SAE
net)
73
kW
(100
hp)/5.200
r.p.m.
Max.
torque,
DIN 162
Nm
(120
ft.lb.,
16.5
kpm)
3.500 r.p.m.
Compression
ratio
9.5:1
Cylinder
bore
3.543
in
(90.0
mm)
Stroke
3.071
in
(78.0 mm)
Cylinder
volume
121.0 cu.in.
(1985
cm
)
Firing
order
1-3-4-2
Engine
idlinq
speed (warm engine
and
headlamps
on
low
beam)
850
+
50
r.p.m.
Weight
md.
clutch,
throttle
valve
housing,
exhaust manifold,
starter
motor
and
oil
filter
308 lb.
(140
kg)
approx.
Fuel,
minimum
octane
number,
RON
93 (Sweden
spec.)
RON
97 (Europe
spec.)
022—1

0 p.3 p.3
.3
3
.
0

Engine
Number
B
20 C
M
tiC
01 C
000001
“B’
-
Petrol
engine—
I
Cylinder
volume
in
dl-
Mo del:
“C”
=
Single
carburetor
“T” =
Twin-carburetor
“I”
Fuel
injection
=
Turbo
Transmission
type:
“M”
=
Manual
“A”
=
Automatic
Exhaust
emission
control
level:
=
USA
“SW”
Sweden
“EU”
=
Europe
Equipment
variants
Year
designation:
“B”
=
1981
“C”
=
1982
etc.
Manufacturing
number
022—3

Cylinder
block
Material
No.
of
main
bearings
Cylinder
bore:
Standard
(A)
Standard
(B)
1st
oversize
2nd
oversize
Cylinder
head
Specially alloyed
casL
iron
5
90.000-90.010
mm
90.010-90.020
mm
90.500
mm
91.000
mm
Max.
grinding
or
facing
of
cylinder
head surface
Distance
from
cylinder
head
gasket
to
valve
cover
gasket
surface,
new
cylinder
head
Material
No.
of
rings
per
piston
Width
of
ring
grooves:
Top
Second
Scraper
Piston
diameter
perpendicular
to
gudgeon
pin
(“MAHLE”
measu
red
16
mm from
lower edge
of
piston
“KARL SCHMIDT”
measured
26
mm
from
lower edge
of
piston)
Standard
A
(not
spare
part)
Standard
AB
Standard
B
(not
spare
part)
Standard
(C)
1st
oversize
(0.5
mm)
2nd
oversize
(1.0)
Piston
clearance
Withdrawal
of
piston
Piston
orientation
Pin
diameter
Fit
of
pin
92.75
+
0.05
mm
“MAHLE”
or
“KARL
SCHMIDT”
Pistons
of
different
makes
must not
be
fitted
in
the
same engine.
Light
metal
alloy
2
compression
rings
1.79-1.81
mm
2.03-2.05
mm
4.01-4.03
mm
std
9.5:1
89.972-89.980
89.980-89.986
89.986-89.994
89.994-90.010
90.47
2-90.487
90.9
72-90.987
0.014-0.040
From
top
of
block
Croove
on
top
should
be
facing
the
transmission
end
of
engine
23.996-24.000
mm
0.005-0.014
mm
Sliding
fit
under
gentle
pressure
with
thumb
13
rn/s
at
5000
r/min
0.4 mm
Pistons
Make
j
.
.
ci
Piston
speed (average
speed)
022—4

Piston
rings
Top
compression
ring:
Thickness
Gap, fitted
in
new
cylinder
Piston
ring
play
in
groove
Second
compression
ring:
Thick
ness
Gap,
fitted
in
new
cylinder
Piston
ring
play
in
groove
Oil
scraper:
Thickness
(segment)
Gap
fitted
in
new
cylinder
(segment)
Thickness,
middle
ring
Connecting
rods
lv
ate
r i
a
1
Diameter
of
drilling
in
big-end
Small-end bush
installed
Max.
permissible
weight
varia
tion
per
set
Crankshaft
[vi
at
er i
a 1
Surface
treatment
Journal
hardness
No. of
main
bearings
Crank
pin
diameter:
1.73-1.75
mm
0.35-0.55
mm
0.050-0.082
mm
1.98-1.99
mm
0.30-0.45
mm
0.040-0.072
mm
0.58-0.64
mm
0.38-1.40 mm
2.63-2.73
mm
Forged
steel
56.000-56.019
mm
24.005-24.010
mm
0.2
oz.
(6
g)
F- orged
steel
Tenni
fer-coa
ted
HV
800
approx.
5
Standard
1st
undersize
2nd
undersize
3rd
undersize
4th
undersize
Main
journal
diameter:
Standard
1st
undersize
2nd
undersize
3rd
undersize
4th
undersize
Radius
at
journal
end
Max.
ovality
of
journals
(out—
of —
r
otin
d)
Max.
conicity
of
journals
(taper)
E3earing
material
Crankshaft
end
float
Main
bearing
clearance
E3ig-ericl
bearincj
clearance
51.981-52.000
mm
51.731-51.750
mm
51.481-51-500
mm
51.237-51.250
mm
50.987-51.000
mm
57.981-58.000
mm
57.731-57.750
mm
57.481-57.500
mm
57.237-57.250
mm
56.987-57.000
mm
2.2-2.5
mm
0.005 mm
0.005
mm
Lead
-
bronze
0.08-0.28
mm
0.020-0.062
mm
0.026-0.062
mm
Colour
marking,
main
arid
connecting
rod
beaririq
shells:
Standard
1st
undersize
2nd
undersize
-[
hi
ii
P e
d
Ye
110w
White
Thick
Blue
Green
Brown
022—5

Camshaft
Number
of bearings
Bearing
diameter
Camshaft
end float
Cam
lift
(at 0
valve
clearance):
Inlet
Exhaust
Valve
timing (at
0
valve
clearance):
Inlet
- opens
- closes
Exhaust
- opens
- closes
Valve
mechanism
Valve
face angle,
inlet and exhaust
Valve
seat angle
in
cylinder head,
inlet.
and
exhaust
Valve
seat width,
inlet
and exhaust
Valve
stem
diameter:
5
28.94
mm
0.08-0.25
mm
Inlet
Exhaust
Stem
to guide
clearance
Valve
head
diameter:
Inlet
Exhaust
7.960-7.975
mm
7.955-7.980
mm
0.5
mm
Measured
on valve head
raised
3
mm
above
seating
42.0
mm
34.5 mm
Valve
guides:
Length
Outer
diameter
Bore
for valve guides
in
cylinder
head,
diameter
Valve
springs:
Installed
length
Free
length
Length
at full
elevation
Load
at
full elevation
Valve
depressors:
Diameter
Height
Bore
in cylinder
head
for
valve
depressors
(camshaft
bearing assy.)
diameter
46.65
mm
13.040-J3.051
mm
13.000-13.018
mm
39.5 mm
43.1
mm
29.5
mm
755-815
N
(170-183
Ib,
77-1] 3
kg)
37.87-37.98
mm
33
mm
38.000-38.016
mm
0
10.8
mm
11.0
mm
10°
BTDC
540
ABDC
46°
BBDC
18° ATDC
4450
450
1-2 mm
.
.
022—6

Pallets
for
valve
adjust-
men
t:
Diameter
Thickness
Exhaust valves
Inlet
valve
Valve
guides
Valve
seats
Valve
clearances,
cold
engine
(30
minutes
after
driving
the
engine
warm:
Inspection
tolerance
zone:
Tn
1
(?
t
Exhaust
Adjustment
tolerance
15.5mm
1.77-2.89 mm
There
are
23
pallets
of
different
thicknesses
at
intervals
of
0.50
mm
Stellited
steel
Steel
(Valve
stems
are chromium
plated)
Cast
iron
Sintered metal
0.006-0.012
in
(0.15-0.30
mm)
0.014-0.020
in
(0.35-0.50
mm)
zone:
Inlet
Exhaust
Lubrication
system
0.008-0.010
in
(0.20-0.25
mm)
0.016-0.018
in
(0.40-0.45 mm)
Type
Pressure-lubricated
points
Splash-lubricated
points
Oil
filter
Crankcase
ventilation,
fully
enclosed
L_ubricat
ing
oil,
grade:
Oil volume
mci.
filter
Oil pump
pressure-reducing
valve
opens
at
Oil
pressure
warning
light
comes
on at
Oil pressure
at
2.000
r/min
(oil
SAE 10
W
40
at
1767°C
F,
80°C)
Forced-flow
circulating
oil
system
Gear-type
oil
pump
with eccentric
ring
gear
Camshaft,
crankshaft,
idler shaft,
connecting
rods
Gudgeon
pins, cylinder
walls, valve
depressors,
valve
stems
and timing
chain.
Full-flow
type
From
crankcase
through valve
cover
-
rest
riction
to
inlet
manifold.
Valve
cover
is
connected
to
atmospheric
pressure
via the
air
cleaner.
SAt
10
W
30,
10
W
40,
or
5
W
30.
If
no oil
meeting these
speci
fications
is
available,
oil
with
a
viscosity
or
SAE
15
W
40
or
1
5
W
50
may
be
used.
The use of
additives
is
not
recommended.
Service
SF in
API-system
or
rord spec.
ESE-M2C-IO1C
6
Imp. pints
(3.5 litres)
3.6-5.2
bar
(kg/cm 2 ,
51-74
lb/in 2 )
0.3-0.5
bar
(kg/cm 2 ,
4.2-7.1
lb/in 2 )
Mm.
3.0
bar
(kg/cm 2 ,
43
lb/in 2 )
Materials
022—7