Saab 99 User manual

100
General
hints
Contents
1
Service
M
1975—82
101
Special
tools
110 Service
inspections
120
Lubrication, lubricants
141
Underbody
and
rustpreventing
treatment
©
Saab-Scana
AB
1982

General
hints
General
A
neat and
tidy workshop is essential for
the
proper
servicing of vehicles.
Some
parts of the
car need to be treated with
special care
and effectively protected
against
dirt and
contamination while work
is in
progress. For
the
mechanic who
may
be new
to the job
the following points may
be of
help:
1.
Protect
fenders
and
other paintwork
with suitable coverings.
2.
Lay
protective coverings over the seats
and
upholstery to
save
them from stains
of
oil
and
dirt.
3.
Clean the insides of fenders and the
space round
the
rear
axle thoroughly
before starting
to
work on
wheel
hubs
. and
axles. This makes the job easier and
prevents grit
and
dirt
from
getting
into
bearings and other susceptible
parts.
4.
Before
unscrewing spark
plugs, clean
the recess round
the
plug thoroughly.
5.
Every job
must have its proper place.
It
is bad
practice, for example, to disas
semble an engine or
transmission on
a
bench
which
is
also used for
filing,
etc.
or where
filing
is done in
the
immediate
neighbour boo d.
Jacking
and
blocking up
rL L -1C k
I I
II Lc11 I
Ict d I
IL.j1U I O[I_
I 1 I
IJ
arid
this
lacks
the
neutral
application
points
for a
jack
that
a
girder
chassis
provides.
There
are
however
two
special
engagement
recesses
on
each
side designed
to
fit
the jack
supplied
with
the
car’s tool
kit;
these are
intended
for
use during
wheel
changing,
etc.
The
engine
compartment
floor
is also
reinforced
immediately
under
the
cross
member
that
supports
the engine
to provide
an
application
point
for the
workshop
jack.
A
similar
reinforced
jacking
point
is
provided
underneath
the
floor at
Lile buck
behind
the
fuel Lank.
As
most
workshop
jacks have
a
forked
lifting
head,
it
is
advisable
to
lay a
wooden
block
of
suitable
size
across
the
fork
to avoid
da
maging
the
floor of
the
car. For
some
jobs
it
is necessary
to
raise the
front
or rear
end
of
the car.
In such
cases
the jack
engagement
recesses
under
the
sills should
be
utilized.
I
100—1

One
side jacked
up
.
.
Front
end
raised
Rear
end raised
cD
Front
end blocked
up on
trestles Rear end blocked
up on
threstles
s*r t -lrt
100—2

Special
tools
General
A
list
containing
special
tools
is
found in
each group
of
the
hook
and in the
Spare
Parts
Catalogue.
The special
tools
in
the
Spare Parts
Cata
logue
are classified
as follows:
Tools for
engine,
transmission
and
chassis
work
Class
AO-l
Tools
used very
frequently
in service
work (e.g.
aci
justment
of
timing)
AO-2
= Tools
used
frequently
in
maintenance
work
(e.g.
re
placement
of brake
pads)
Al
Tools
necessary
for
simple
repairs
(e.g.
replacing
the
clutch or
valves)
A2
Tools necessary
for quali
fied repairs
(e.g.
recondi
tioning
of the gearbox)
i3
= Tools
which are
mainly
re
commended
for
reasons
of
operational
efficiency
Tools
for body
work
Class
Bi
= Tools
necessary
for
simple
body
work (e.g.
replace
ment
of front
fenders)
B2
Tools
necessary
for quali
fied
body
work
(e.g.
align
ment
work)
B3 =
Tools which
are
mainly re
commended
for
reasons of
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
to
find.
Thread
system
and wrench
sizes
The
standard
thread
system
used
in
Saab
cars
is mainly
the
metric thread
system
(tM)
and
the
width across
flats
is also
measured
in
mm.
However,
UN
and
LJNC
threads
with
di
mensions
in inches
are
to
be found
in some
c
0 mp onent
S.
10
1—1

0
.

Service
inspections
Every
new car
is
accompanied
by
a service
card
that should
be
stamped
at
every
ser
vice
occasion.
Guarantee
service
at
1,200
miles
(2,000
kin)
is carried
out
free
of charge (except
for oils
etc. for
which a
charge is
made).
Other
periodic
maintenance
should
be per
formed
according
to the
programmes
below
and
paid for
by
the
customer.
Delivery inspection
1.
Check
the function
of all
lights,
in
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.
2.
Lheck the
brake
pedal
pressure.
3.
Check
the
gear selector
lever
posi
tions
(auotmatic
transmission).
4.
Check the
differential
oil
level
(auto
rnatic transmission).
5.
Check
the
engine oil
level.
6. Check
the
transmission
oil
level.
7. Check
the
power
steering
fluid
level.
8. Check
the
oil level
in the
carburetor
damping
cylinder(s).
9.
Check
the
battery electrolyte
level
and
tighten the
holder
hooks.
10.
Tighten
the terminals
and cable
logs
on 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
in
place.
18. Check
the funktion
of
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,
di
rection
indicator
return,
etc.).
Check for
rattle,
wind or
other dis
turbing
noise.
Check
the steering
wheel
center
posi
tion.
Other deli
very
measurements:
Dewaxing,
polishing
md. check
of painted
and
bright
parts,
loose
equipment
and li
cense
plates.
Guarantee
inspection
1,200 miles
(2,000
km)
1.
Check the
functions
of
all
lights,
in
strurnent
liqhtinq,
control
and
indica
tor
liqhts, horn,
ventilator
fan,
inte
rior
and ignition
lighting,
windshield
and
headlight
washers/wipers.
2. Drain the
engine
oil.
3.
Drain the
transmission
oil. Clean
the
magnetic
drain plug.
4.
Check
the
engine
and
transmission
for
leaks.
5. Change
the ciifferential
oil (automatic
transmission).
I
Exhaust emission
u t
i ci al regulations
govern
in
cj
the
emission
of carbon monoxide,
hydro
carbons
and
nitric oxide
in
car exhaust
fumes
are becoming
increasingly
more
stringent.
Saab
cars
are designed
and
built
to meet these
requirements
on
the
condition
that the engines are
cor
rectly
tuned.
The
workshops
hold
a
key
position
in
being
able
to
limit the
emission
of
toxic
gases
from
cars
and therefore
make
a
contribution
to keeping
pollu
tion
down. Remember
that
a correctly
tuned
engine
also
ensures that
the
car
runs
smoothly
and
with
low
fuel
con
sumption.
The relevant
adjustments
are
descri
bed in
the service
programme.
We
would
particularly
like
to
emphasize
the
importance
of
adjusting
the
ignition system
and
the fuel
system
in
according
with the
specifications.
110—1

oil.
Every
6,000
miles
(10,000
km)
Engine
Electrical
system
.
.
6.
Check the
condition
of
the
rubber bel-
37.
Tighten
the
exhaust pipe
clamp
nuts
at
lows
on
steering
gear,
inner
and
outer
the
gearbox
and
test
for
leaks.
k,N
Test
run
mc!.
qeneral
function
check
uniVCFSdI JoinLs,
tuuuer
searn
UI
UGH
joints
and
the
tie
rod
ends.
(especially
clutch,
transmission,
7.
Tighten the
lower
control
arm
bolts
to
brakes,
wheel
balancing,
direction
in-
the
body
(from
beneath).
dicator
return,
etc.)
8.
Tighten
the
exhaust
system
suspension
Check
for
rattle,
wind
or
other
distur—
bolts
and
pipe
clamps.
bing
noise.
9.
Tighten the
bolts for
the
rear
axle
suspension in
the
body.
10.
Change
the
oil
filter
cartridge
(H-
engine
only).
Regular
maintenance
inspection up
to
11.
Engine:
fill
up
with
fresh
oil.
model
year
1979
12.
Manual
transmission:
fill
up 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.
1. Change
oil
(at
least
twice
a
year)
and
16.
Check the
radiator
coolant
level
and
oil
filter.
test
the
cooling
system
for
leaks
2.
Clean
air
cleaner
insert.
(pressure
test).
Tighten
hose
clamps.
3.
Clean
fuel
pump
filter
(carburettor
17.
Check
the
brake
master
cylinder
fluid
engine).
level.
4.
Check
fuel lines
in
engine
compart
18.
Tighten
the
inlet
manifold
and
carbu- ment
for
leakage.
rator
flange
nuts.
5.
Check
and
if
necessary
top
up
oil
level
19.
Tighten
the
exhaust
manifold
retaining
in
carburettor
damping
cylinder.
bolts.
6.
Check the
exhaust system
for
condi
20.
Tighten
the
exhaust pipe
flange
nuts.
tion
and
leaks.
21.
Tighten
the
turbo
charger
retaining
7.
Pressure
test
of the
cooling
system
bolts.
(check
the condition
of
the
hoses).
22.
Tighten
the cylinder
head
nuts
and
8.
Check
coolant
freezing
point.
bolts
to
prescribed torque.
9.
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
if
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
km
as from
model
27.
Crease
the
distributor
breaker
cam
1976).
and
lubricating
felt.
Check the
dwell
12.
Check
and
if
necessary
adjust
engine
angle
and
ignition
setting.
idling
speed
and
the
emission
of
car-
28.
Check
the
exhaust system
for leaks.
bon
monoxide
(CD)
at
idling.
29.
Tighten
the
engine
mount retaining
bolts.
30.
Check
the
deceleration
device,
engine
idling
speed
and CO
emission
at
2,000
r/min.
-
31.
Check the inlet
air
preheating
for
1.
Check
condition of
V-belts
and
adjust
Summer/Winter
position.
belt
tension if necessary.
32.
Adjust,
if
necessary,
the
door
lock
2.
Check and
if
necessary adjust
head-
striker
plate.
light
alignment.
Inspect condition
of
33.
Turbo:
Check
the charging
pressure. headlights
by
eye.
3.
Adjust
spark
plugs.
4.
Check condition of
breaker points.
Automatic
transmission:
Lubricate distributor
breaker
cam
and
34.
Check the gear
selector
lever
po-
lubricating felt.
Check
and
if
neces
sitions.
sary
adjust dwell
angle
and
ignition
35.
Check
the
throttle cable
clearan-
timing.
ce
and
movement.
5. Check
battery electrolyte
level
and
36.
Check
the
transmission
oil
level,
top
up
if
necessary.
Tiqhl
en
and
grease
cable
lugs.
110—2

Brake
system
Steering,
front
suspension
and
tires
Test
driving
1.
Test
drive
car
on
road
and
check
operation
of
all
systems,
especially
brakes
and
clutch
and
operation
of
auotmal
ic transmission.
Supplementary inspection
Every
12,000
miles/20,000
km.
Supplementary
inspection
Every
24,000
miles/40,000 km.
Periodic
servicing
as from
model
year
1979
5,000
miles
(7,500
km) service
Change
engine
oil in
Saab
99 Turbo
cars
and
cars
driven
under
unusually
demanding
conditions,
such
as driving
in
extremely
hot
weather,
driving
at high
speeds
for
a consi
derable
distance,
and
driving
over
short
distances
in
extremely
cold
weather.
I
6. Check
operation
of
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.
7.
Check
condition
of
washer
jets
and
rubber
wiper
blades.
Transmission
1.
Manual
transmission:
Check fluid level
and
if
necessary
replenish
brake
fluid
in
clutch
master
cylinder.
2.
Manual
transmission:
Check
and
if
mecessur
y
adjust clutch release
bearing
play
(only up
to
and
md. mo
del
year
1975).
3. Check
transmission
oil level
and
top
up
if
necessary
(also
final drive
in
automatic
transmission).
To
be
carried
out
in connection
with
the
regular
6,000
rniles/10,000
km inspection
1.
Change
spark plugs.
2.
Change
breaker
points.
3.
Change
oil
in manual
transmission,
clean
magnetic
drain
plug
(at
least
once
a year).
4. Chanqe
oil in
final drive
of
automatic
transmission.
5.
Check
and
if necessary
adjust
camber
and
caster.
6. Adjust
rlRr’lRration-vaJve.
To be
carried
out
in
connection
with
the
regular
6,000
miles/10,000
km
inspection
and
the
supplemetary
12,000
miles/20,000
km
inspection.
1. Check
and
if
necessary
adjust
valve
clearances.
2. Change
air
cleaner
insert.
3. Change
fuel filter
(injection
engine).
4. Check
and
if necessary
replenish
steering
gear oil
level.
5.
Change
brake
fluid
(at
least
once
every
second
year).
1.
Check
level
in
riaster
cylinder,
top
up
with
brake
fluid
if necessary.
2.
Check
and
if necessary adjust.
parking
brake
(only
up to
and
md.
model
year
1974).
3.
Remove
wheels
and
check
thickness
of
brake
pads.
4.
Check
brake
lines and
hoses
for condi
tion
and
leaks.
1.
Check
and
if necessary
adjust
toe-in.
2.
Check
condition
of
rubber
bellows
on
steering
gear
and
inner
and
oLiter
uni
versal
joints,
and
of rubber seals
for
ball
joints
arid
tie-rod
ends.
3.
Check
depth
of
tire
tread
patterns.
Body
1.
L
ubricate
dour stops,
door
hinges
and
hood
lock mechanism.
The
maintenance
programme
lists
the most
important
things
that
ned
to
be done to
ensure enjoyable
and
trouble-free
motoring
at
minimum
cost.
The
1,200
miles
(2,000
km)
coupon
in
the
Service Card
entitles
to
guarantee
check-ups
free
of charge
(except
for
oils and
filters
for
which
a charge
is
made,.
The
guarantee
is not
valid
if
these
check-Lips
are not
made. Subsequent
check
ups at
10,000
miles
(15,000
km)
intervals
will
be
charged
for.
If
less
than
10,000
miles
(15,000
km)
are
covered
in
one year,
one engine
oil
change
must
be
carried
out
arid
one
complete
service
should
in
any
case
be
carried
out in
the
year.
110—3

10,000 miles
(15,000
km)
Service
To
he carried
out
by
euthorzed
Saab
Dealer.
Engine
1. Change
oil and
oil filter
(at
least
once
a year).
2.
Clean air
cleaner
insert.
3. Clean fuel
pump filter
(carburettor
engine).
4. Check fuel lines
in
engine
compart
ment for leakaqe.
5.
Check
the damper
oil
level.
Top-up if
ncceSary.
(Carburettor
engine).
6.
Check engine
idling speed
setting and
check
emission
of carbon
monoxide
as
prescribed
by
thc
authorities
(where
applicable).
7.
Check
the exhaust system
for condi
tion
and leaks.
8. Pressure
test
of the
cooling
system
(check
the condition
of
the
hoses).
9.
Check coolant
freezing
point.
10.
Check hoses
and nipples for
the crank
case ventilation.
11.
Adjust deceleration
valve.
12.
Check the
synchronizing
of the car
burettors
(twin-carburettor
engine).
13.
Check
the
choke
control.
14.
Check
the tightness of
the
valve cover
screws.
15.
Saab 99
Turbo: Check
the seal
on
the
charge
pressure regulator.
16.
Saab 99
Turbo:
Check
the charging
pressure and
adjust as
necessary.
17.
Saab 99 Turbo:
Check the
pressure
guard and
the
fuel enrichment
device.
Electrical
system
1.
Check condition
of
V-belts
and adjust
belt tension
if
necessary.
2.
Check
and
if
necessary
adjust
head
light
alignment.
3.
Adjust spark plugs.
4.
Check the breaker
points.
[_ubricate
distributor breaker
cam
and lubrica
ting felt.
Check
and
if
necessary
ad
just dwell
angle and
ignition
timing.
5.
Check
battery electrolyte
level and
top up if
necessary.
Tighten
and
grease cable
logs.
6.
Check operation
of parking, brake
and
rear
lights,
licence plate
illumination
light, direction
indicators,
horn, hack
up ligths,
hazard warning
flashers,
in
terior lighting,
warning
and indicator
lights,
windshield
and headlight
washers
and
wipers, brake
warning
light,
instrument
lighting, luggage
compartment
lighting and
ventilator
fan.
7. Check
the
vacuum
hoses
and their
connections.
8. Check
the
condition
of the
ignition
cables.
Iransmission
1.
Check transmission
oil level
and top
up if necessary
(also
final drive
in
automatic
transmission).
Brake
system
1.
Check level
in
master
cylinder, top
up
with brake fluid
if
necessary.
2.
Remove
wheels and check
thickness
of
brake pads.
3.
Check brake
lines and hoses
from
condition
and leaks.
4.
Lubricate
the front wheel
brake units.
Steering, front
suspension
and
tyres
1.
Check
condition
of
rubber
bellows on
steering
gear and
inner and outer uni
versal
joints,
and of rubber
seals for
hail
joints
and
tie-rod ends.
2.
Check
depth
of tire
tread
patterns.
3.
Check
the
tire
pressure in the
spare
wheel.
4.
Check
the
fluid
level in the
power
steering
fluid
container.
5.
Check
the
wear in inner
and
outer
steering joints.
Body
1.
L ubrir’ate door stops.
door
hinges and
hood lock mechanism.
2.
Check
condition
of washer jets
and
rubber
wiper
blades.
Test driving
1.
Test drive
car on road
and
check
operation of
all
systems.
especially
brakes
and
clutch.
.
110—4

20,000
miles
(30,000
km)
service
To
be
carried
out
in
connection
with
the
10,000 miles
(15,000
km)
service.
1.
Saab
99 Turbo:
Check
and
if necessary
adjust
valve clearances.
2. Saab
99
Turbot
Change
air
cleaner
insert.
3.
Change
oil
in
automatic
transmission,
clean
filter
and
magnet.
Adjust
gear
selector
cable.
rear
brake
lining
and
throttle
cable.
Only
first
20,000
miles
(30.000
km).
30,000
miles
(45,000
km)
service
To
be carried
out
in
connection
with
the
10,000
miles
(15.000
km) and 20.000
(30,000
km)
service.
1.
Check
and
if
necessary
adjusi
valve
clearances.
2. Change
air
cleaner
insert.
3.
Change
fuel
filter
(injection
engine).
4.
Change
oil
in
final
drive
of
automatic
transmission.
5. Change brake
fluid
(at
least
once
every
two
years).
6.
Check
and
if
necessary
adjust
toe-in,
camber
and
caster.
7. Saab
99
Turbo:
Clean
the
charge
pressure
regulator.
110—5

a

Lubrication,
lubricants
Automatic
transmis
sion
Brake
fluid,
grade DOT
4.
Oleitmo
540
Brake
fluid, grade
as above.
Follow
recomenda
tions,
see later
on in
this section
Follow
recommenda
tions,
see later
on
in this
section.
Brake
fluid
to
be
changed
every
24,000
miles
(40,000
km)
up
to model
year
1978,
every
30,000
miles
(45,000
km)
from
model
year
1979
or
at
2
year
intervals,
whichever
comes
first.
Lubricate
the sliding
sur
faces
between
yoke and
brake
housing.
Change
the
oil and the
oil
filter
cartridge
every
6,000
miles
(10,000
km)
up to model
year
1978,
every
10,000
mi
les
(15,000
km) from
model
year
1979.
Every
5,000
miles
(7,500
km)
on turbo
models
and cars used
in
se
vere driving
conditions.
Note:
Use only
genuine
Saab
filter
cartridges.
Up
to
model
year
1978
check
the
oil
level
every
6,000
miles
(10,000
km) change it
every
20,000
miles
(30,000
km).
From model
year
1979,
check
the
oil level
every
10,000
miles
(15,000
km),
change it
every
30,000
miles
(45,000
km).
Up
to model
year
1978,
check the
oil
level
every
7,000
miles
(10,000
km),
change
it every
20,000
miles
(30,000
km) in connection
with
special inspection.
From
model
year
1979,
check
the
oil level
every
10,000
miles
(15,000
km),
change
it every
20,000
miles
(30,000
km, in
connection
with
special
inspection.
Lubrication
in
connection
with
service
inspection
Ref. Lubrication
point.
Oty.
Lubricant Instructions
I
1
2
1
1
2
3
4
Brake
system
Front.
wheel
brake
yoke
Hydraulic
clutch
operation
Engine
Manual
transmission
120—1

Ref. Lubrication
point Oty. Lubricant Instructions
Final drive, auto-
Follow
recommenda- Up
to model
year
1978,
check
matic transmission tions, see later on the
oil level
every
6,000
in this section.
miles
(10,000
km), change it
every
20,000
miles
(30,000
km).
From
model year
1979,
check
the
oil level every
10,000
miles
(15,000
km),
change
it
every
30,000
miles
(45,000
km).
5
Carburettor (oil
1
Automatic traps- Check in connection with in-
damper)
mission oil, type spection.
Ford M2C.330
6
Distributor,
1
Bosch
Ft
1
v
4.
Oreas th
corn.
breaker
cam
Distributor, lubr.
1
SAE
40
oil. Oilcan, sparingly.
felt
7
Throttle control,
1
SAL 40 oil.
Oilcan
(do
riot uil
pulley bearing the
throttle wire).
Hood
lock mechanism
1
SAE
40
oil. Oilcan.
Door hinges
and
4+4
SAE
40
oil.
Oilcan.
door stops or
8+8
4
64
S
3694
47
Note
Saab
special chassis grease
must
be
used
with care, as
it
is
apt to discolor
the
paintwork of the car.
35
120—2

Every
i0,000
miles
(:15,000
km) or
at
least
twice
a
year
1.
Brake
system:
-
The
brake
fluid
reservoir
shall
be
kept
topped up.
Check
the
level
in
the
reservoir
and
make
sure
that
the
hole
in the
cap
is
not
clogged.
Fol
low
the
recommendations
in
the
lub
rication
chart.
as
regards
brake
fluid.
-
Lubricate
the
sliding
surfaces
be
tween the
front
brake
yoke
and
the
brake
pads
as
follows:
a.
Remove
the
front
wheel.
b.
Wash
off
any
loose
dirt
round
the
sliding
surfaces
of
the
yoke
in
the
brake
housing.
c.
Press
the
yoke
back
and
forth
against
the yoke
spring,
applying
drops
of
lubricant
to
the
sliding
surfaces at
the
same
time.
d.
Refit
the
wheel.
2.
Hydraulic
clutch:
Check
that
the
reservoir
is
full.
3.
Engine:
Oil
capacity:
6
Imp.
pints
(3.5
litres)
inclusive
of
oil
filter.
For
oil
specifications
see
“Lubricants
general”.
Check the
engine
oil
level
at
regular
intervals.
The
engine
should
be
at
a
standstill for
about
one
minute
before
the
check
is
made.
The
level
should
never
be
allowed
to
drop
below
the
lower
mark
on
the
dipstick
but
neither
should
the
oil
be
filled
above
the
level
of
the
upper
mark
as
this
will
result
in
abnormally
high
oil
consump
tion.
The
distance
between
the
upper
and
lower
marks
corresponds
to
a vo
lume
of
one
liter
(roughly
1
3/4
Imp.
pints).
Top
up
with
oil
of the
recommended
grade
as
necessary. The
first
oil
change
should
he
carried
out
after
1,200
miles
(2,000
km).
The
oil
should
subsequently
be
changed
every
6,000
miles
(10,000
km)
up
to
model
year
1978
and
every
]0,000 miles
(15,000
krn)
from
model
year
1979 or
at
least
once
a year.
When
changing
the
oil,
the
oil filter
cartridge
should
also
be changed.
The
drain
plug
in the
engine
block
hasa
hexagon
head.
S
6672
120—3

4.
Manual transmission:
Check the oil
level
in conjunction
with
servicing
(up to
and
including
1978
mo
dels
every
6,000
miles
(10,000
km)
and
as from
1979
models every
10,000
miles
(15,000
km).
Up to
and md.
1977
mo
del,
check
the
level
by
removing the
level
plug.
As from
1978
models check
the level
on
the
dipstick.
When
changing
oil, drive
the car from
15-20
minutes
before
draining off the
old oil. Clean
the magnetic
drain plug,
then
add
fresh
oil
through
the
transmis
sion
filler
plug
opening until
it runs out
of
the level
plug opening.
Remember
that
it
takes
some
time
for the
oil
to
run from
the primary
gear
housing into
the
transmission
case.
Transmissions
with
gear-train
primary
gear hold
3.0
litres of oil,
and
transmis
sions
with chain-drive
primary
gear,
2.5
litres. The
first oil change
should be
carried
out after
1,200
miles
(2,000
km).
Subsequent
oil changes
should be
made
every
20,000
miles
(30,000
km) up
to model year
1978,
every
30,000
miles
(45,000
km)
from
model
year
1979.
Oil
specifications,
see “summary
of lubri
cants”.
Automatic
transmission:
Check
the oil level
in the
automatic
transmission
in conjunction
with servi
cing up to
and including
1978
models
every
6,000
miles
(10,000
km)
and
as
from
1979
models
every 10,000
miles
(15,000
km).
Concerning
oil
changes,
see “Inspection
of
automatic
transmis
sion
every
20,000
miles
(30,000
km)’.
The
filler tube
with graduated
dipstick
is located immediately
behind
the ra
diator.
Apply
the handbrake.
Run
the
engine
for at least
15
seconds
at
idling
speed
with
the gear
selector
in
position
[).
Then
at least
15
seconds
in
position R
and
15
seconds
in position
P,
following
which the
oil
level
should
be
checked
with the selector
still
in
position
P.
The
Drain plugs, cars with
manual transmission
1.
Engine
2.
Transmission
Drain
plugs,
transmission
1.
Engine
2.
Transmission
3.
Final drive
Tightening torques
Drain plug, 22-30
ft.lb.,
30-40
Nm
engine
(3-4
kpm)
Drain
plug,
30-45
ft.lb.,
40-60
Nm
transmission
(4-6
kpm)
Level/filler
22-30 ft.lb.,
30-40
Nm
plug
(3-4
kpm)
cars with
automatic
120—4

graduations are for
cold oil
100°F
(+40°C)
and
hot oil
195°F (+90°C).
Note
that
at
extremely
low temperatures,
the
oil level
may
therefore
be appre
ciably below
the cold level, which
a
plies
to
a
temperature of
100
F
(+40°C).
The
difference between MIN
and MAX marks
is pint
(0.5
litres).
Use
a
nylon
rag,
lint-free paper or
chamois leather
to wipe off the dipstick
- do not use rags
that may leave fluff
on
the dipstick.
If it is necessary to
top
up
the oil, use
only special oil for
automatic transmis
sions as in
the following recommenda
tions: automatic
transmission oil to
Ford specification M2C.330.
The most scrupulous
cleanliness must
be observed during filling.
The oil
in
the
final
drive unit must
be
checked:
- Up to and
including
1978
models
every
6,000
miles
(10,000
km).
- as from
1979
models
every
10,000
miles
(15,000
km)
and changed:
- Up to
and including
1978
models
every
20,000
miles
(30,000
km)
- as from
1979
models
every
30,000
miles
(45,000
km).
Use
EP-oil
SAE 80 W
acording to
API
OL-4.
5.
Oil
damper
in carburetor:
Type M2C.33G automatic
transmission
oil
or
the
equivalent
should
be
used.
The oil level should
be at least
0.4
in.
(10
mm) below the
top of
the damper
cylinder.
6.
Distributor,
breaker
cam:
Lightly grease the cam.
Apply
a small
amount of
grease to the rivet
securing
the
pad to the contact
breaker.
Distributor, lubricating
felt
pad: Apply
a
few
drops of oil.
7.
Throttle control:
Lubricate the cable bearing
(do
not
lubricate
the cable itself).
Hood lock mechanism:
Lubricate
by
means
of oil
can.
Door
hinges,
door stops:
Oil the hinges
through the
lubricating
groove in the
top of the
hinge pin.
The
hinges
are accessible once
the hood
has
been
opened.
I
0_
MIN
MAX
+u
MIN
MAX
+40°C
S 1 001
120—5

20,000
miles
(30,000 km)
inspection
-
automatic transmission
To
ensure good
automatic transmission
operation
and
long
life,
the
following addi
tional
work
is
recommended
in
connection
with
the
regular
20,000
miles
(30,000
km)
service.
1.
Drain
the
oil.
2.
Remove the
protective
plate
and
front
oil
sump.
3.
Clean
the
filter
and
the
magnet.
4.
Check the
setting
of
the gear
control.
Adjust if
necessary.
For
type
393
and
type
399
automatic
transmissions,
the
following
applies:
a.
Feel
for
the
centre
of
the
D
position
in
the
manual valve
of
the
automa
tic
transmission
with
the
pawl
but
ton
depressed.
b.
Release the
pawl
button. Move
the
lever
back
against the
stop
in
the
selector
lever
housing
and
note
the
clearance.
c.
Feel
for
the
centre
of
the
N
position
in
the
manual
valve
with
the
pawl
button depressed.
d.
Release
the
pawl
button.
Move
the
lever
forward
against the
stop
in
the
selector
housing
and
note
the
clearance.
The
clearances
noted
should
be
the
same.
Adjust as described
in
the
work
shop
manual,
section
444.
For type
487
and
type
489
automatic
transmissions,
the
following
applies
(introduced
from
chassis numbers
99781015740,
99786007567.
a.
Feel
for
the
centre
of
the
N
position
in
the
manual valve
with the pawl
button depressed.
b.
Release
the
pawl
button
and
check
that
the
N position
of
the
manual
valve,
and
the depression
in
the
le
ver
segment
which
marks the
N
po
sition
of
the
selector
housing,
coin
cide.
For
adjustment,
see
section
444.
5.Check
the
rear
band
and
adjust
if
necessary.
6.Check the
movement
and
setting
of
the
throttle
cable.
The
clearance
between
the
clip
on
the
wire
and
the
threaded
part
of
the
sheathing
should
be
1-2
mm.
Adjust
if necessary.
7.Fit
the
front
oil
sump
arid
protective
plate
in
position.
Fill
up
with
fresh
oil.
3.0-3.5
litres
for
type
393
and
type
399
automatic
transmissions.
2.5-3.0
litres
for
type
487
and
type
489
automatic
transmissions.
Steering gear,
check
oil
level
(up
to
model
year
1978)
Interval:
every
12,000
miles
(20,000
km)
1.Raise the car
until
the
front
wheels
are
clear
of
the
floor.
2.Turn the
steering wheel
to
Full
right
lock
and
undo
the
bellows clamp
on
the
left-hand
tie
rod.
3.Check the
oil
level
by
inserting
a
screwdriver
between
bellows and
tie
rod.
If
grease
drops
out,
refit
the
clip.
If
necessary, pack
with
grease
(max
1.5
dl).
4.Fit
the
clip
in
place. This
will
he
facilitaded
if
the
steering wheel
is
turned slightly
hack
to
the
centre
position.
5.Lower
the car to the
floor.
L
u
br i
cant:
Manual steering
gear:
BP
energrease FOL,
part
No.
(45)
30 08
703
Power steering gear:
API
service 0L5
SAE
75
or
SAE
80/90
In
conjunction
with
overhaul
The
following lubrication
points
should
be
repacked with
chassis
grease
in
conjunction
with
an overhaul.
Tie
rod
ends and
upper
and
lower
ball
joints:
Pack
the
bellows
3/4
full.
1_ubricant: Saab
special chassis
grease.
Rear
wheel
bearings:
Pack
with
grease.
Lubricant: Saab
special chassis
grease.
Inner
universal joint:
Pack
with
grease. The
correct quantity
will
be
obtained
by
fully
packing the
axle
shaft.
Remove any
surplus grease
once
the
drive
shaft
has
been
fitted.
Lubricant:
A soft
EP
grease
with
a
lithium-lead
base
and
which
can
with
stand
wide
variations
in
temperature
and
load.
Consistency
type L5SO
Beacon
EP
2,
or
the
equivalent.
.
120—6

Outer
universal
joint:
The
correct
quantity
of
grease
will
be
obtained
if
the
ball
retainer
is
fully
packed
with
grease.
Lubricant:
Saab
Special
chassis
grease.
Alternatives:
ESSO
EF
125
(NEBULA
EP2)
OPTIMOL
OLISTAMOLY
2LN
584
K.S.
PAUL 0
800
MOLYCOTE
VN
2461
C
Release
bearing
(model
year
1975):
Fill
the
groove
3/4
full.
Lubricant:
Saab special
chassis
grease.
(From
model
year
1976
the
release
bearing
is permanently lubricated).
Steering gear
Manual
steering
gear
After
an
overhaul
the
steering
gear
should
be
filled
with
5.3
fl.oz.
(1.5
dl)
BR Ener
grease
FGL
liquid
grease.
Grease
inner
ball
joint
sockets
and
balls
with
rnolybden
paste.
Power-assisted
steering
gear
(type
Adwest
up
to
model
year
1978)
Iii
connection
with
reconditioning
the
steering
gear, fill
one
of
the rubber
bellows
with
6.5
fl.oz.
(2
dl)
of
lubricant.
Type of
lubricant:
ER
oil
SAE
75
or
SAL
80/90.
Servo oil:
In
connection
with
hydraulic
system
ser
vice, fill
up
with
hydralulic
fluid as
fol
lows:
1.
Add
fluid
to
a
level
approx.
0.4
in
(1
cm)
above
the
lower
part of
the
strainer
in
the
oil
reservoir.
2.
Start the engine
and
top
up
to
the
above-mentioned
level.
Type of
oil:
Texaco
power
steering
fluid
4634 part
No.
(45)
30
09
800.
The entire
hydraulic
power
steering
system
contains
2.0
pints
0.2
litres).
120—7