Saab 99 1982 Manuel utilisateur

Contents

Engine

1982—

Saab-Scania

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)

(100

hp)/5.200

r.p.m.

Max.

torque,

DIN 162

(120

ft.lb.,

16.5

kpm)

3.500

r.p.m.

Compression

ratio

9.5:1

Cylinder

bore

3.543

(90.0

mm)

Stroke

3.071

(78.0

mm)

Cylinder

volume

121.0

cu.in.

(1985

)

Firing

order

1-3-4-2

Engine

idlinq

speed (warm engine

and

headlamps

low

beam)

850

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

(Sweden

spec.)

RON

(Europe

spec.)

022—1

p.3

Engine

Number

20 C

tiC

01 C

000001

“B’

Petrol

engine—

Cylinder

volume

dl-

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.

main

bearings

Cylinder

bore:

Standard

(A)

Standard

(B)

1st

oversize

2nd

oversize

Cylinder

head

Specially alloyed

casL

iron

90.000-90.010

90.010-90.020

90.500

91.000

Max.

grinding

facing

cylinder

head

surface

Distance

from

cylinder

head

gasket

valve

cover

gasket

surface,

new

cylinder

head

Material

No.

rings

per

piston

Width

ring

grooves:

Top

Second

Scraper

Piston

diameter

perpendicular

gudgeon

(“MAHLE”

measu

red

from

lower edge

piston

“KARL SCHMIDT”

measured

from

lower edge

piston)

Standard

(not

spare

part)

Standard

(not

spare

part)

Standard

(C)

1st

oversize

(0.5

mm)

2nd

oversize

(1.0)

Piston

clearance

Withdrawal

piston

Piston

orientation

diameter

Fit

92.75

0.05

“MAHLE”

“KARL

SCHMIDT”

Pistons

different

makes

must

not

fitted

the

same engine.

Light

metal

alloy

compression

rings

1.79-1.81

2.03-2.05

4.01-4.03

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

block

Croove

top

should

facing

the

transmission

end

engine

23.996-24.000

0.005-0.014

Sliding

fit

under

gentle

pressure

with

thumb

rn/s

5000

r/min

0.4 mm

Pistons

Make

Piston

speed

(average

speed)

022—4

Piston

rings

Top

compression

ring:

Thickness

Gap,

fitted

new

cylinder

Piston

ring

play

groove

Second

compression

ring:

Thick

ness

Gap,

fitted

new

cylinder

Piston

ring

play

groove

Oil

scraper:

Thickness

(segment)

Gap

fitted

new

cylinder

(segment)

Thickness,

middle

ring

Connecting

rods

ate

Diameter

drilling

big-end

Small-end

bush

installed

Max.

permissible

weight

varia

tion

per

set

Crankshaft

[vi

Surface

treatment

Journal

hardness

No.

main

bearings

Crank

diameter:

1.73-1.75

0.35-0.55

0.050-0.082

1.98-1.99

0.30-0.45

0.040-0.072

0.58-0.64

0.38-1.40

2.63-2.73

Forged

steel

56.000-56.019

24.005-24.010

0.2

oz.

F-

orged

steel

Tenni

fer-coa

ted

800

approx.

Standard

1st

undersize

2nd

undersize

3rd

undersize

4th

undersize

Main

journal

diameter:

Standard

1st

undersize

2nd

undersize

3rd

undersize

4th

undersize

Radius

journal

end

Max.

ovality

journals

(out—

—

otin

Max.

conicity

journals

(taper)

E3earing

material

Crankshaft

end

float

Main

bearing

clearance

E3ig-ericl

bearincj

clearance

51.981-52.000

51.731-51.750

51.481-51-500

51.237-51.250

50.987-51.000

57.981-58.000

57.731-57.750

57.481-57.500

57.237-57.250

56.987-57.000

2.2-2.5

0.005

Lead

bronze

0.08-0.28

0.020-0.062

0.026-0.062

Colour

marking,

main

arid

connecting

rod

beaririq

shells:

Standard

1st

undersize

2nd

undersize

110w

White

Thick

Blue

Green

Brown

022—5

Camshaft

Number

bearings

Bearing

diameter

Camshaft

end

float

Cam

lift

(at

valve

clearance):

Inlet

Exhaust

Valve

timing (at

valve

clearance):

Inlet

opens

closes

Exhaust

opens

closes

Valve

mechanism

Valve

face

angle,

inlet

and

exhaust

Valve

seat

angle

cylinder

head,

inlet.

and

exhaust

Valve

seat

width,

inlet

and

exhaust

Valve

stem

diameter:

28.94

0.08-0.25

Inlet

Exhaust

Stem

guide

clearance

Valve

head

diameter:

Inlet

Exhaust

7.960-7.975

7.955-7.980

0.5

Measured

valve

head

raised

above

seating

42.0

34.5 mm

Valve

guides:

Length

Outer

diameter

Bore

for

valve guides

cylinder

head,

diameter

Valve

springs:

Installed

length

Free

length

Length

full

elevation

Load

full

elevation

Valve

depressors:

Diameter

Height

Bore

cylinder

head

for

valve

depressors

(camshaft

bearing

assy.)

diameter

46.65

13.040-J3.051

13.000-13.018

39.5 mm

43.1

29.5

755-815

(170-183

Ib,

77-1]

kg)

37.87-37.98

38.000-38.016

10.8

11.0

10°

BTDC

540

ABDC

46°

BBDC

18° ATDC

4450

450

1-2 mm

022—6

Pallets

for

valve

adjust-

men

Diameter

Thickness

Exhaust

valves

Inlet

valve

Valve

guides

Valve

seats

Valve

clearances,

cold

engine

(30

minutes

after

driving

the

engine

warm:

Inspection

tolerance

zone:

Exhaust

Adjustment

tolerance

15.5mm

1.77-2.89

There

are

pallets

different

thicknesses

intervals

0.50

Stellited

steel

Steel

(Valve

stems

are chromium

plated)

Cast

iron

Sintered metal

0.006-0.012

(0.15-0.30

mm)

0.014-0.020

(0.35-0.50

mm)

zone:

Inlet

Exhaust

Lubrication

system

0.008-0.010

(0.20-0.25

mm)

0.016-0.018

(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

Oil

pressure

warning

light

comes

Oil

pressure

2.000

r/min

(oil

SAE

1767°C

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

inlet

manifold.

Valve

cover

connected

atmospheric

pressure

via

the

air

cleaner.

SAt

30,

40,

30.

oil

meeting these

speci

fications

available,

oil

with

viscosity

SAE

may

used.

The

use of

additives

not

recommended.

Service

API-system

rord

spec.

ESE-M2C-IO1C

Imp.

pints

(3.5

litres)

3.6-5.2

bar

(kg/cm

51-74

lb/in

)

0.3-0.5

bar

(kg/cm

4.2-7.1

lb/in

)

Mm.

3.0

bar

(kg/cm

lb/in

)

Materials

022—7

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