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