Saab V4 User manual

Nov. 973
FOREWORD
This Service Manual has been compiled for the use of service shops as an aid to ser-
vice and repair work which, we hope, will enable all concerned to do a thorough and
successful
job. The recommendations and directions contained in this Manual are
based
on experience gained up to date. As fresh experience becomes available, the
relevant information will be passed on to Saab general agents and authorized service
shops in the form of "Service Informations" (SI). Service Informations should be
filed in a special binder.
Altered and new pages for the loose leaf edition of the Service Manual will also be
sent to General Agents, authorized service shops, and others on our mailing list.
Note! At reprints of the manual only altered pages become new dates. This
means that different dates occur in the manual, but all pages are up-to-date.
Like
the Spare Parts Catalogue, the Service Manual is arranged in sections according
to the same system as used in the Repair Catalogue issued by the Swedish Automo-
bile Servicing and Retailing Employers' Association.
Each
section begins with a brief design description followed by detailed descriptions
of the service work relevant to that section.
Technical
data such as dimensions, tolerances, tightening torques, etc. are listed in
Group 0.
SAAB-SCANlA AKTIEBOLAG
Saab Car Division
NYKOPJNG
SWEDEN

April 1975
GROUP 0 SPECIFICATIONS, TROUBLE SHOOTING
010 General
020 Specifications
030 Trouble Shooting
GROUP1
100
101
102
110
120
130
141
TOOLS, SERVICE, MAINTENANCE
General hints
Special tools
Various tools
Service inspections
Lubrication
Washing and polishing
Underbody- and rustpreventing treatment
GROUP 2 ENGINE
200 Description
201 Removal and installation of engine body
Engine body
21 0 Removal and installation
211 Cylinder head
214 Valve mechanism
215 Transmission
216
Crank mechanism
217 Oil pan
Lubricating system
221
Oil pump
222 Oil filter
fuel system
231
Carburetor. Deceleration valve, USA cars
232 Air cleaner USA cars
233 fuel pump
234 Fuel tank with fittings and fuel lines
Inlet
and exhaust system
251 Induction
manifold
252 Exhaust system
Cooling system
Radiator with connections
262 Water pump, fan and thermostat
Sundries

Jan. 1972
342 Distributor
344 Spark plugs
346 Suppression of interference
351 Lighting
Eledric equipment
Other
361 Direction indicators
362 Horns
363 Windshield wipers, headlight w1pers
and -washers -
364 Electrical controls and switches
371 Wiring and fuses
GROUP 4 TRANSMISSION
400 Description
411 Clutch
412 Clutch operation
Gear box
470 Removal and installation
Gear box
471 Disassembly and Reassembly
473 Differential and pinion -ring gear
475 Universal ioints and shafts
GROUP 5 BRAKES
500 Description
Brake
shoes with drums, discs and linings
511 Brake shoes
512 Replacement of brake linings
515 Brake drums
516 Brake discs
517 Friction pads
Hydraulic footbrake system
520 Overhaul, brake fluid
521 Master cylinder
522 Brake lines
523 Wheel cylinders
524 Brake operation
SAAB

Steering, column shift gear
641 Steering wheel and column shift gear
642 Steering gear
643 Tie-rod endi
GROUP 7 SUSPENSION, WHEELS
700 Description
Suspension
731 Coil-s-pring suspension, front
732 Coil-spring suspension, rear
Shock absorbers, Stabilizer
7 61 Shock absorbers
762 Stabilizer
Wheels and hubs
771 Wheels
772 Tires
774 Hubs
GROUP 8 BODY
800 Description
810 Body assembly
820 Hood, front panel and fenders
830 Doors and lids
843 Glass
850 Upholstery and interior fitments
860 Bumpers
890 Body finishing
GROUP 9 INSTRUMENTS, ACCESSORIES, HEATING
SYSTEM
900 Description
911 Instruments
920 Accessories,
mecanical
930 Accessories, electrical
941 Fresh air heater
952 Towhook assembly
Jan. 1972 ~...:1

Okt. 1969
CONTENTS
CONTENTS
010 General
020 Specifications
030 Trouble shooting
SPECIFICATIONS 0
TROUBLE
SHOOTING

SAAB 95 (SAAB STATION WAGON)
SAAB 96 (SAAB 2 DOOR SEDAN)
SAAB MONTE CARLO
s 2957
Nov. 1970
010-1

The illustrations below show the locations of the chassis
and engine numbers. To ensure correct identification
in the case of a particular car or engine, these numbers,
together with the mileage, must always be quoted in
warranty claims, etc. If a service engine is fitted in a car,
the number of the original engine must, without fail, be
stamped in the appropriate place. This is of the utmost
importance if customs difficulties are to be avoided in
the event that the car is subsequently used in a country
other than that of registration.
as 1
As from model 1972, the chassis number consists of elev"
en digits. Explanation of the digits is shown in the fol-
lowing example:
96 72 2 000 001
Cartype ~
Year of model
Place of manufacture l
2 = T rollhi:ittan
3==Arlov
6 = Nystad (Finland)
Serial number. Ec \. model
year begins with f0 001.
numbers
Cars made in Trollhattan
Monte Carlo 1967
1968
Saab 95 1967
1968
1969
1970
1971
1972
1973
1974
1975
1976
420001 -458526
470001 -507018
42001 50197
52001 -62059
65001 -74968
80001 -88371
95095001-95102180
95722000001 -95722008232
95732000001 -95732007767
95742000001 -95742006620
95752000001 95752002048
95763000001 -
Saab 96 1967
1968
1969
1970
1971
1972
1973
1974
1975
1976
Cars made in Arlov
Saab 95 1975
1976
Saab 96 1976
420001 -458526
470001 -507018
520001 552859
560001 -592844
96600001-96627413
96722000001 -96722021567
96732000001 -96732023028
96742000001
-96742017275
96752000001 -96752015165
96762000001 -
95753000001 -95753003018
95763000001 -
96763000001
Cars made in Nystad (Finland)
Saab 95 1970 50600001 -50600838
1971 51600001 -51601165
1972 95726000001
-95726000119
1973 95736000001 -95736000185
1974
95746000001-95746000165
1975 95756000001 -95756000281
1976 95766000001 -
Saab 96 1970 60600001 60601540
1971 61600001 -61602639
1972 96726000001 96726006009
1973 96736000001 -96736008344
1974 96746000001 -96746005605
1975 96756000001 96756007419
1976 96766000001
Oct. 1975

2
LOCATION OF CHASSIS NUMBER AND PAINT COLOR
CODE SIGNS, USA-CARS FROM MODEL
1969
1. Chassis number sign
2.
Paint color code sign
Engine number Gearbox number
The type designations are 96 V4 for the Saab V4 pas-
senger car and 95 V4 for the Saab V4 station wagon.
Oct. 1975
s
T
s
Color code and chassis
number signs
r
Chassis number im-
printed in car body
010-3

SPECIFICATIONS,
UBLE
SHOOTING
I 1
Overall length, including bumpers (approx.}
Overall width
Overall height, unladen (approx.)
Ground clearance (2 people front) (approx.)
Track, front and rear .
Wheelbase ....
Turning radius I approx.)
Empty weight, incl. fuel,
coolant, tools and spare wheel
Total
weight, incl. permissible
passengers and
luggage
Weight distribution:
Empty
Fully laden, incl. passengers and luggage
Number of seats ..
Available load luggage space
Loading area with driver + 4 passengers
Loading area with driver +1 passenger
Trunk height .....
010-4
SAAB 95
14 ft. 0 in.
.
4270 mm}
5 ft. 2 in.
(1580 mm)
4ft. 10 in.
(1470 mm)
5.1 1n.
(130 mm)
4 ft. 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 5 1n.
(5.3 m)
2080 lb.
approx. (945 kg)
3370 lb.
(1530 kg)
front 57%
front 44%
7
39 cu. ft.
11.1 m3}
SAAB 96
13 ft. 8 in.
(4170 mm)
5 ft. 2 in.
(1580 mm)
4 ft. 10 in.
(1475 mm}
5.1 In.
\130 mm}
4 ft. 0 in.
(1220 mm}
8 ft. 2 in.
(2498 mm)
17 ft. 5 in.
(5.3 m)
1940 lb.
(880 kg)
2880 lb.
(1300 kg)
front 62%
front 52 %
5
13 cu. f.t
10.37 m3)
MONTE CARlO
13 ft. 8 in.
(4170 mm)
5 ft. 2 in.
(1580 mm)
4 ft. 10 in.
(1475 mm)
5.1 in.
(130 mm)
4 ft. 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 5 1n.
(5.3 m)
2000 lb.
(910 kg)
2880 lb.
(1300 kg)
front 61 /o
front 51 %
2+2
13 cu. ft.
(0.37 m3)
39.4 x 37.4 in. 39.4 x 37.4 in. 39.4 x 37.4 in.
(1000 x 950 mm) (1000 x 950 mm) (1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4in.
(800 mm)
18.1 in.
(460 mm)
18.1 in.
(460 mm)
Oct. 1975

GENERAL 1
Overall length, including bumpers (approx.)
Overall width
Overall height, unladen (approx.)
Ground clearance (2 people front) (approx.)
Track,
front and rear .
Wheelbase ....... .
Turning radius (approx.)
Empty weight, incl. fuel,
coolant, tools and spare wheel
Total weight, incl. permissible
passengers and luggage
Weight distribution:
Empty ...
Fully laden, incl. passengers and luggage
Number of seats . . ....... .
Available load luggage space
Loading area with driver +4 passengers
Loading area with driver +1 passenger
SAAB 95
14ft. 1 in.
(4300 mml
5 ft. 2 in.
(1580 mm)
4 ft. 10 in.
(1470 mm)
5.1 in ..
(130 mm)
4 ft. 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17ft. 9 in.
(5.4 m)
2160 lb.
approx. (980 kg)
3370 lb.
(1530 kg)
front 57%
front 44%
7
39 cu. ft.
(1.1 m3)
FICATIONS,
UB
SHOOTING
SAAB%
13 ft. 9 in.
(4200 mm)
5 tt. 2 in.
(1580 mm)
4 ft. 10 in.
(1475
mm)
5.1 In.
(130 mm)
4 ft. 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17ft. 9 In.
(5.4 m)
2000 lb.
(910 kg)
2880 lb.
(1300 kg)
front 62%
front 52 %
5
13 cu. f.t
(037 m3)
39.4 x 37.4 in. 39.4 x 37.4 in.
(1000 x 950 mm) (1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
Trunk height . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 in.
(800 mm)
18.1 in.
(460 mm)
Oct.1975 ~
010-5

1
Overall length, including bumpers (approx.)
Overall width
Overall height, unladen (approx.)
Ground clearance (2 people front) (approx.)
Track, front and rear
Wheelbase
SAAB 95
14ft.1 in.
(4300 mm)
5 ft. 2 in.
(1580 mm)
4ft.10.5in
(1490 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8ft. 2 in.
(2498
mm)
Turning radius (approx. 17ft. 6 in.
(5.4 m)
Empty weight, incl. fuel, coolant, tools and spare wheel 2150 lb.
approx. (975 kg)
Total incl. permissible passengers and luggage 3395 lb.
(1540 kg)
distribution:
Curb weight incl. driver
Total weight
Max. roof load
Max.
trailer weight
Number of seats
Available load luggage space
loading area with driver+ 4 passengers
area
with driver + 1 passenger
Trunk
010-6
SAAB
front 58 %
front 45%
220 lb.
(100 kg)
2000 lb.
(910
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in.
{800 mm)
SAAB 96
13ft. 9 in.
(4200 mm)
5 ft. 2 in.
(1580 mm)
4ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8ft. 2 in.
(2498 mm)
17ft. 6 in.
(5.4 m)
2000 lb.
(905 kg)
2990 lb.
{1350 kg)
front 62 %
front 51 %
220 lb.
(100 kg)
2000 lb.
{910 kg)
5
13 cu. ft.
(0.37 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
60.5 x 37.4 in.
(1540 x 950 mm)
18.1 in.
(160 mm)
Oct. 1975

Overall length, including bumpers (approx.)
Overall width
Overall height, unladen (approx.)
Ground clearance (2 people front) (approx.)
Track, front and rear
Wheelbase
Turning radius (approx.
SAAB 95
14ft.1 in.
(4300 mm)
5 ft. 2 in.
(1580 mm)
4 ft. 10.5 in.
(1490 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17ft. 6 in.
(5.4 m)
Empty weight, incl. fuel, coolant, tools and spare wheel 2.200 lb.
approx. (1000 kg)
Total weight, incl. permissible passengers and luggage 3395 lb.
(1540 kg)
Weight distribution:
Curb weight incl. driver
Total weight
Max. roof load
Max.
trailer weight
Number of seats
Available load luggage space
Loading area with driver+ 4 passengers
Lo~>dir]g area with driver+ 1 passenger
Trunk height
Oct. 1975
front 58 !'o
front 46 /'o
220 lb.
(100 kg)
2000 lb.
(91 0 kg)
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in.
(800 mm)
SAAB 96
13ft. 9 in.
(4200 mm)
5 ft. 2 in.
(1580 mm)
4ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8ft.2in.
(2498 mm)
17ft. 6 in.
(5.4 m)
2020 lb.
(920 kg)
2990 lb.
(1350 kg)
front 62 !'o
front 52 %
220 lbs.
(100 kg)
2000 lb.
(910kg)
5
13cu.ft.
(0.37 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
60.5 x 37.4 in.
(1540 x 950 mm)
18.1 in.
(460 mm)

SHOOTING
1
Overall length, including bumpers (approx.)
Overall width
Overall height, unladen (approx.)
Ground clearance (2 people front) (approx.)
Track, front and rear
Wheelbase
SAAB 95
14ft. 1 in.
(4300 mm)
5 ft. 2 in.
(1590 mm)
4ft. 10.5 in
(1490 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8ft. 2 in.
(2498
mm)
Turning radius (approx. 17ft. 6 in.
(5.4 m)
Empty weight, incl. fuel, coolant, tools and spare wheel 2180 lb.
approx. (990 kg)
Totai weight, incl. permissible passengers and luggage 3395 lb.
(1540 kg)
Weight
distribution:
Curb weight incl. driver
Total weight
Max. roof load
Max.
trailer weight
USA weights:
Curb weight:
Without air conditioning
With air conditioning
Gross vehicle weight rating
Gross axle weight rating:
Front axle
Rear axle
Vehicle capacity weight:
Without air conditioning
With air conditioning
Weight distribution by curb weight front
Weight distribution by gross vehicle weight rating front
Number of seats
Available load luggage space
Loading area with driver+ 4 passengers
Loading area
with driver+ 1 passenger
Trunk height
010-8
front 58-59 %
front 46-47%
220 lb.
(100 kg)
2000 lb.
(910 kg)
2,180 lb. ( 990 kg)
2,250 lb. (1,020 kg)
3,300 lb. (1 ,495 kg)
1,590 lb. ( 720 kg)
1,770 lb. (
800 kg)
1,050 lb. ( 475 kg)
1,050 lb. ( 475 kg)
58-59%
46-47%
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in.
(800 mm)
SAAB 96
13ft. 9 in.
(4200 mm)
5 ft. 2 in.
(1590 mm)
4ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8ft. 2 in.
(2498 mm)
17ft. 6 in.
(5.4
m)
2020 lb.
(920 kg)
2980 lb.
(1350 kg)
front 62-63 %
front 52-53 %
220 lb.
(100 kg)
2000 lb.
(910 kg)
2,030 lb. ( 920 kg)
2,100 lb. (
950 kg)
2,950 lb. (1,335 kg)
1,590 lb. ( 720 kg)
1,540 lb. ( 700 kg)
850 lb. ( 385 kg)
850 lb. ( 385 kg)
62-63%
52-53%
5
13 cu. ft.
(0.37 m3)
39.4 x
37.4 in.
(
1000 x 950 mm)
60.5 x 37.4 in.
(1540 x 950 mm)
18.1 in.
(460 mm)
Oct. 1975

FICA TIONS,
0
TROUB
SHOOTING
Model -1
Overall length, including bumpers (approx.)
SAAB 95
14ft.1 in.
(4300 mm)
USA cars:
14ft.3in.
(4350 mm)
Overall width 5 ft. 2 in.
(1590 mm)
Overall height, unladen {approx.) 4ft. 10.5 in.
(1490 mm)
Ground clearance (2 people
front ) (approx.) 5.1 in.
(130 mm)
Track, front and rear 4ft. 0 in.
(1220 mm)
Wheelbase 8
ft. 2 in.
(2498 mm)
Turning radius (approx.) 17ft. 6 in.
(5.4
m)
Empty weight, incl. fuel, coolant, tools and spare wheel 2135 lb.
approx. (970 kg)
Total weight, incl. permissible passengers and luggage 3395 lb.
(1540kg)
Weight distribution':
Curb
weight ind. driver
Total weight
Max. roof load
Max. trailer
weight
USA weights:
Curb weight:
front
front
58-59%
46-47%
220 lb.
(100 kg)
2000 lb.
(910kg)
2,180 lb. ( 990 kg)
Without air conditioning
With-'a ir wnd itionihg
Gross vehicl-e weight rating
Gross axle
weight rating:
2,250 lb. (1,020 kg)
Front axle
Rear axle
Vehicle capacity weight:
Without air conditioning
With air conditioning
Weight distribution by curb weight
Weight distribution by gross vehicle weight rating
Number
of seats
Available. load Juggage space
Loading area with driver+ 4 passengers
Loading
area with driver +1 passenger
Trunk height
Oct. 1975
3,300 lb. (1,495 kg)
1,590 lb. (
720 kg)
1,770 lb. (
800 kg)
1,050 lb. ( 475 kg)
1,050 lb. ( 475 kg)
front 58-59%
front 46-47%
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in.
(1600 x 950 mm)
31.4 in.
(800 mm)
SA.IJS
SAAB 96
13ft. 9 in.
(4200 mm)
USA cars:
14ft. 1 in.
4250 mm)
5 ft. 2 in.
(1590 mm)
4ft. 10 in.
(1470 mm)
5.1 in.
(130 mm)
4ft. 0 in.
(1220 mm)
8ft. 2 in.
(2498 mm)
17ft. 6 in.
(5.4 m)
2000 lb.
(910 kg)
2980 lb.
(1350 kg)
62-63%
52-53%
220 lb.
(100 kg)
2000 lb.
(910kg)
2,030 lb. (
2,1001b. ( 920 kg)
950 kg)
2,950 lb. (1,335 kg)
1,590 lb. (
720 kg)
1,540 lb. ( 700 kg)
850 lb. ( 385 kg)
850 lb. ( 385 kg)
62-63%
52-53%
5
13cu.ft.
(0.37 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
60.5 x 37.4 in.
(1540 x 950 mm)
18.1 in.
(460 mm)
010-9

Overall
Overall width
Overall
Ground clearence (2
Track, front
Track,
rear
Wheelbase
Turning radius (approx.)
Empty
weight, incl. fuel, coolant, tools and spare wheel
approx.
Total weight, incl. permissible passengers and luggage
Weight distribution: Total
Max. roof load
Max. trailer weight
Number of seats
Available load luggage space
loading area with driver + 4 passengers
loading area with driver + 1 passenger
Trunk height
SAAB 95
14ft. 1 in.
(4300 mm)
5 ft. 2 in.
mm)
5 ft. 10.5 in.
(1490 mm)
5.1 in.
(130 mm)
4 ft. 0.3 in.
(1228 mm)
4ft.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 6 in.
(5.6 m)
2135 lb.
(980 kg)
3395 lb
(1540 kg)
46%
220 lb.
(100 kg)
2000 lb.
(910 kg)
7
39 cu. ft.
(1.1 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
63 x 37.4 in,
(1600 x 950 mm)
31.4 in.
(800 mm)
SAAB 96
13 ft. 9 in.
(4200 mm)
5 ft. 2 in.
(1590 mm)
4 ft. 10 in.
mm)
5.1 in.
(130 mm)
4 ft. 0.3 in.
(1228 mm)
4 ft.
(1220 mm)
8 ft. 2 in.
(2498 mm)
17 ft. 6 in.
(5.6 m)
2000 lb.
(910 kg)
2980 lb.
(1350 kg)
52 Ofo
220 lb.
(100 kg)
2000 lb.
(910 kg)
5
13 cu. ft.
(0.37 m3)
39.4 x 37.4 in.
(1000 x 950 mm)
60.5 x 37.4 in.
(1540 x 950 mm)
18.1 in.
(460 mm)
Oct. 1975

1
Saab 95
Overall length, including bumpers (approx.) . . . . . . . . . . . . . 14ft. 5.6 in. (4410 mm)
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ft. 2 in. (1590 mm)
Overall height, unladen (approx.). . . . . . . . . . . . . . . . . . . . . 5 ft. 10.5 in. (1490 mm)
Ground clearance
(2 people front) (approx.) . . . . . . . . . . . . . 5.1 in. (130 mm)
Track, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ft. 0.3 in. (1228 mm)
Track,
rear..... . ............................ 4ft. (1220 mm)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8ft. 2 in. (2498 mm)
Turning radius (approx.) . . . . . . . . . . . . . . . . . . . . . . . . . .
17 ft. 6 in. (5.5 m)
Empty weight, incl. fuel, coolant, tools and spare wheel approx. 2150 lb. (980 kg)
Total weight, incl. permissible
passengers and luggage . . . . . . . 3395 lb. (1540 kg)
Weight
distribution: Total weight . . . . . . . . . . . . . . . . . . . . 46%
Max. roof load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 lb. (100 kg}
Max. trailer
weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 lb. (1000 kg)
Number of seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Available load
luggage space. . . . . . . . . . . . . . . . . . . . . . . . 26 cu.ft. (731 dm3)
Loading
area with driver+ 4 passengers . . . . . . . . . . . . . . . . 41.1 x 36.6 in.
(1045 x 930 mm}
Loading area with driver+ 1 passenger . . . . . . . . . . . . . . . . . 66 x 36.6 in.
(1680 x 930 mm)
Trunk height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 in. (900 mm)
Oct. 1975
Saab 96
14ft. 1.3 in. (4300 mm)
5 ft. 2 in. (1590 mm)
4ft. 10 in. (1470 mm)
5.1 in. (130mm}
4 ft. 0.8 in. (1232 mm)
4ft. (1220 mm}
8ft. 2 in. (2498 mm)
17 ft. 6 in. (5.6 m)
2050 lb. (930 kg)
2980 lb. (1350 kg}
52%
220 lb. (100 kg}
2200 lb. (1000 kg)
5
19 cu.ft. (544 dm3)
38.4 x 37 in.
(975 x
940 mm}
63 x 37 in.
(1600 x 940 mm}
15.9 in. (405 mm}
o1o~n

SPECifiCATIONS,
TROUBLE
SHOOTING
USA CARS AS FROM AS FROM
MODEL 1971 MODEL 1976
Engine, type V4
Power DIN at 4700 r/min
Max torque at 2500 r/min
Compression ratio, nominal
Number of cylinders
Cylinder
bore
Stroke
Cylinder volume
Firing order
4-stroke, 4 cylinders
48 kW (65 bhp)
115 Nm (85ft. lb., 11.7 kpm)
9.0:1
4
3.54 in. (90 mm)
2.32 in. (58.86 mm)
91.4 cv. in. (1498 cc)
1---3---4--2
4-stroke, 4 cylinders
47 kW (65 bhp)
115 Nm (85ft. lb., 11.7 kpm)
8,0:1
4
3.54 in. (90 mm)
2,63 in. (66,8 mm)
104 cu. in. (1698 cc.)
1-3-4-2
Placement of cylinders (from front of car):
Right hand side
left hand side
Idling
speed
Engine suspension
Weight, incl. electr. equipment
and carbvretor
1-2
3-4
800-900 r/min
3-point suspension
265 lb. (120 kg)
1-2
3-4
900 r/min
3-point suspension
265 lb. (120 kg)
Cylinder block
Type
Material
Number of main bearings
60° Vee formation, block and crankcase casted in one piece
Cost iron
of a special alloy
3
Cylinder block bores for camshaft bushings:
Cylinder block
bores for balance shaft bushings:
Cylinder
bore:
Stal'ldord
Oversize 0.02 in. (0,5 mm)
Oversize 0.04 (1 ,0 mm)
Diameter main bearing bore:
Thrust bearing width:
front: 44.65--44.68 mm
center: 44.27--44.30 mm
rear: 43.89-43.92 mm
front: 54.4ID-54.445 mm
rear: 57.620-57.645 mm
90.030-90.040 mm
90.530-90.540 mm
91.030-91.040 mm
red 60.62-60.63 mm
blue 60.63-60.64 mm
22.61-22.66 mm
850-900 r/min
Pistons
Material
Number of piston rings, on each piston Aluminium 2 compression and
1 oil control ring (tripartite)
AS FROM ENGINE
NUMBER 59835
(USA CARS AS
FROM NO. 53921)
Permissible difference in weight (piston and connecting rod)
in
one and the same engine
0.46 oz. (13 g)
upper 2.030-2.055 mm
center 3.030-3.050 mm
Piston-ring groove width:
Piston
diameter:
(The piston is out-of-round and spherical)
Piston
clearance
lower 5.017-5.042 mm 4.000-4.020 mm
Standard 89.978-90.002 mm
oversize 0,5 90.478-90.502 mm
oversize 1,0 90.978-91.002 mm
0.0011 in.-0.0024 in.
0.03-0.06 mm
Piston, removal From the upper side of the cylinder block
Position
of the piston The jag to be turned forward
Piston
and connecting rod must not be separated. Therefore, only piston with connecting
rod mounted is available as a spore port.
Oct. 1975
020-1

020-2
lower
s 1267
Upper compression ring:
Thickness
Width
ThicKness
Width
Piston ring
in position
Oil control ring ltrinnr-til:,.,\.
Thickness
Width
Piston
Bore diameter in the big-end
control
1.978-1.990 mm
0.15 in. max. (max. 3.76 mm)
0.0394-0.077 mm
0.250--0.500 mm
2.978-2.990 mm
0.15 in. max. (max. 3.76 mm)
0.040--0.078 mm
0.250--0.500 mm
AS FROM ENGINE
NUMBER 59835
(USA CARS AS
FROM NO. 53921)
4.839-4.991 mm 3.824-3.974 mm
3.430-3.580 mm
0.026--0.203 mm 0.026-0.196 mm
0.380-1.400 mm
red 56.820-56.830 mm
blue 56.830-56.840 mm
Vertical inner diameter of fitted con-rod bearing inserts:
standard blue 54.004-54.034 mm
red 54.014-54.044 mm
undersize 0,25 53.760-53.800 mm
0,50 53.506-53.546 mm
0,75 53.252-53.292 mm
1 ,00 52.998-53.038 mm
Diameter of cranK"' pins: standard blue 53.99 ~53.98 mm
red 54.00 -53.99 mm
undersize 0,25 53.746-53.736 mm
10,50 53.492-53.482
mm
0,75 53.238-53.228 mm
1,00 52.984-52.974 mm
Clearance between bearing insert and crank pin: standard 0.014-0.054 mm
undersize 0.014-0.064 mm
Crankshaft
Crank pin diameter
Number of main bearings
Main bearing journal diameter
see above
3
standard red 57.Q00-56.990 mm
blue 56.99G-56.980 mm
undersize 0,25 56.746-56.736 mm
0,50 56.492-56.482 mm
0,75 56.238-56.228 mm
1,00 55.984-55.974 mm
Oct. 1975