Technical Data-General 010-1 on

-r-(
C
010 Technical Data-General
Technical Data-General 010-1 Lubrication and Maintenance-
Quick Data . . __ .. _.. _ __ 010-2

TECHNICAL DATA-GENERAL

mm in.

Track (rear) 1440 56.7

Wheelbase 2517 99.1

Turning radius 5600 220.5

kg. lb.
f - - - - 9 9 . 1 in.----c..
Curb weight (depending on 1252-1411 2755-3105
< + - - - - - - - - 1 8 4 . 3 i n . - - - - - - -.. equipment)

Gross vehicle weight 1677-1768 3690·3890

(depending on equipment)

Weight distribution
at curb weight 59-62% front
at gross weight 52-55% front

Vehicle capacity weight---ex. 422 930

conv. (five people, 180 lb.
luggage)

89139-SG681
Maximum roof rack load---ex. 100 220
conv.

Maximum trailer weight:

General mm in. trailer with brakes 900 2000
Overall length (sedans, 4680 184.3 trailer without brakes 450 1000
convertibles)
Maximum trailer tongue weight 75 165
Overall length (hatchback) 4687 184.5
Tnunk volume (SAE)
Overall width 1690 66.5 hatchback 14.9 [Link].
Overall height (at curb weight) 1419 55.9 hatchback, parcel shelf reo 19.1 [Link].
moved
Overall height with convertible 2230 87.8 sedan 14.2 [Link].
at highest point
convertible 10.7 [Link].
Road clearance (full load)
SPG models 120 4.7
all other models 137 5.4

Track (front)
alloy wheels 1430 56.4
steel wheels 1437 56.6

TECHNICAL DATA-GENERAL

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010-2 Technical Data-General

Engine Specifications
Model Year Displacement Com pression Horsepower @ Torque Ib-ft @ Fuel system
cc (cu. in.) ratio rpm SAE net rpm SAE net

900/900S/Convertible 1986-1987 1985 (121) 10.1: 1 125 @ 5500 128 @ 3000 Bosch LH 2.2

1988 1985 (121) 10.1: 1 128 @ 6000 128 @ 3000 Bosch LH 2.4

1989-1990 1985 (121) 10.1: 1 128 @ 6000 128 @ 3000 Bosch LH 2.4

1991-1993 2118 (129) 10.1: 1 140 @ 6000 133 @ 2900 Bosch LH 2.4.2

900 TurborTurbo 1985-1988 1985 (121) 9.0:1 160 @ 5500 188 @ 3000 Bosch LH 2.2
Convertible

1989-1993 1985 (121) 9.0:1 160 @ 5500 188 @ 3000 Bosch LH 2.4

900 SPG 1985-1986 1985(121) 9.0:1 160 @ 5500 188 @ 3000 Bosch LH 2.2

1987-1988 1985 (121) [Link] 165 @ 5500 195 @ 3000 Bosch LH 2.2

1989 1985(121) 9.0:1 165 @ 5500 195 @ 3000 Bosch LH 2.4

1990-1991 1985 (121) 9.0:1 175 @ 5500 195 @ 3000 Bosch LH 2.4

LUBRICATION AND MAINTENANCE-

QUICK DATA

Engine Oil Change Spark Plug Applications

Saab recommended engine oil SAE 10W-30, API Service Model Spark Plug
Rating SG or SF/CD
1985-1993 Turbo
Altemate for extremely hot 15W-40, API Service Rating normal driving NGK BCP 7EV
climates SG or SF/CD
altemate NGK BCP 7ES
Engine oil drain plug tightening 29-39 Nm (21-29 ft-Ib) city driving NGK BCP 6EV
torque (13 mm or 19mm
altemate NGK BCP 6ES
wrench size)
Spark plug electrode gap 0.024-0.028 in. (0.6-0.7 mm)
Engine Oil Capacity 4.2 quarts (4.0 liters)
(including filter) Tightening torque-- 25 to 29 Nm (18 to 21 ft-Ib)
sparkplugs

Ignition System Applications Ignition Timing

1985-1992 turbo models basic Hall ignition Distributor vacuum hose
disconnected and plugged,
1986-1992 non-turbo models EZK ignition -Hall-effect with
knock sensor where applicable

Turbo models 16°BTDC @ 850 rpm

Normally aspirated models 14°BTDC @ 850 rpm

Spark Plug Applications

Model Spark Plug

Cooling System
1986-1988 Normally aspirated NGK BCP 6ES

altemate Capacity (50/50 mixture anti- 10.5 quarts (10 liters)

NGK BCP 6EV
freeze and water)
1989-1993 Normally-aspirated NGK BCP 5ES

LUBRICA nON AND MAINTENANCE-QUICK DATA

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 Technical Data-General 010-3

Engine Drive Belt Tensions Automatic Transmission

(measure using special belt tensioning gauge)
ATF Ford Specification M2C-33F
Drive belt tension N (Ib) (alternate: Ford Specification G)

Altemator ATF capacity 8.5 quarts (8.0 liters)

checking (minimum) AJT final drive grade of oil SAE EP 80 or 75 API-GL-4 or
one belt 200 (45) API-GL-5
two belts 420 (95) Altemate grade of oil 10W-30 engine oil
adjusting, used belts
AJT final drive capacity 1.3 quarts (1.25 liters)
one belt 310±20 (70±5)
two belts 645±20 (145±5) ATF drain plug tightening 5-8 Nm (48-72 in-Ib)
adjusting, new belts torque
one belt 535±45 (120±10) AJT final drive drain or filler 39-59 Nm (28-44 ft-Ib)
plug tightening torque
AlC compressor
checking (minimum) 245 (55)
adjusting, used belt 355±20 (80±5) Brake System
adjusting, new belt 535±45 (120±10)
Brake Fluid Grade SAE Dot 4
Power steering
Brake Pad Wear Limit
checking (minimum) 220 (50)
adjusting, used belt 310±20 (70±5) 1985-1987 models 1.0 mm (0.04 in.)
adjusting, new belt 445±45 (100±10) 1988 and later models 4.0 mm (0.16 in.)

Manual Transmission WARNING

Grade of oil SAE 10W-30 SF/CC, SF/CD, Do not use SAE DOT 5 brake fluid. Brake system failure may
SG result.

Alternate grade of oil SAE EP 75 API-GL-4 or API-

GL-5
Steering and Wheel Alignment
Oil capacity 3.1 quarts (3.0 liters)
Power Steering Fluid GM Power Steering Fluid (GM
9985010), Texaco TL4634 or
equivalent

LUBRICAnON AND MAINTENANCE-QUICK DA TA

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 022 Engine-Technical Data
Engine-Technical Data 022-1
I
Engine Tightening Torques 022-1 Crankshaft 022-6

Connecting Rods and Piston Pins 022-2 Lubrication System 022-6

Piston Rings 022-3 LH Fuel Injection 022-7

Pistons 022-3 Cooling System 022-8

Cylinder Head and Valve Turbocharger 022-8

Mechanism 022-4

ENGINE TIGHTENING TORQUES

Tightening Torques Nm ft·rb (in-Ib)

Cylinder block end plate to 20 15

engine (flywheel end)

Cylinder head to cylinder block

stage 1 60 44
stage 2 80 plus and 59 plus and
additional additional 90 0
90° (1/4 (1/4 tum)
tum)

Engine to transmission
automatic transmission 33--39 24-29
manual transmission 25±3 18±2.2

Engine oil cooler line to oil filter 7-10 (62-89 in-Ib)

housing

Engine oil drain plug to case 29--39 21-29

EGR valve to cylinder head 8 (71 in-Ib)

Tightening Torques Nm ft·lb (in-I b)
Exhaust manifold to cylinder
Camshaft sprocket to camshaft 63 46 head
Camshaft bearing caps to 15 11 turbo models 25 18
cylinder head normally aspirated models 20 15
Camshaft timing chain 63 46 Flywheel to crankshaft (17 mm 60 44
tensioner to timing case bolt head)
Clutch slave cylinder to 6-14 (53-124 in-Ib) FlyWheel to crankshaft (19 mm 85 63
transmission case bolt head)
Coolant drain plug to engine 15 11 Fuel pump to fuel tank 55 41
block (threaded collar)-1990 and
later
Coolant temperature sensor 20 15
(LH sensor) Ignition distributor to cylinder 20 15
head
Connecting rod cap to 55 41
connecting rod Intake manifold to cylinder 22 16
head
Crankshaft pulley to crankshaft
1985-1990 190 140 continued on next page
1991 and later 175 129

continued

ENGINE TIGHTENING TORQUES

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 -
022-2 Engine-Technical Data

Tightening Torques Nm ft-Ib (in-Ib) CONNECTING RODSAND PISTON PINS

Main bearing caps to cylinder 110 81
block

Oil filter to oil filter housing 10 7.4

Oil pressure switch to oil filter
housing
small (1/4"-18 NPTF) 10 (89 in-Ib)
large (M 14X1.5) 30 22

Oil pump to timing chain cover 8 (71 in-Ib)

Oxygen sensor 40 30

Spark plugs to cylinder head 28 21

Thermostat housing to cylinder 18 13 89082

head

Timing chain cover to engine 20 15

block and cylinder head
Connecting rods mm in.
Timing chain tensioner to 63 46
cylinder head Diameter of big end 56.000-56.019 2.2047-2.2055
(bearing shells
Valve cover to cylinder head 15 11 removed)

All other fasteners Diameter of small end 24.005-24.010 0.9451-0.9453

M5 bolt 5 (44 in-Ib) (bushing installed)
M6 bolt 10 (89 in-Ib) Big-end clearance 0.026-0.062 0.0010-0.0024
M8 bolt 20 15
Maximum permissible 9 g (0.32 oz.)
M10 bolt 40 30 weight variation per set

Piston pins mm in.

Piston pin diameter 23.996-24.000 0.9447-0.9449

Piston pin to connecting rod clearance

B202 engine 0.005-0.014 0.0002-0.0006
B212 engine 0.002-0.011 0.00008-0.0004

CONNECTING RODS AND PISTON PINS

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 Engine-Technical Data 022-3

PISTON RINGS

Piston Ring Top compression ring Second compression ring Oil scraper ring

End gap 0.35-0.55 mm 0.0138-0.0217 in. 0.30-0.45 mm 0.0118-0.0177 in. 0.38-1.40 mm 0.0150-0.0551 in:

Width (thickness) 1.73-1.75 mm 0.0681-0.0689 in. 1.98-1.99 mm 0.0780-0.0783 in. 2.63-2.73 mm 0.1035-0.1075 in'"

Side clearance in piston 0.05-0.09 mm 0.0020-0.0035 in. 0.04-0.07 mm 0.0016-0.0028 in.

groove

•Applies to segment part of ring

"Oil scraper ring segment width (thickness) 0.58-0.64 mm 0.0028-0.02552 in

PISTONS Piston diameter mm in.

Turbo engine with Mahle pistons (cont'd)

first oversize 90.460-90.475 3.5614-3.5620
(0.5mm)
second oversize 90.960-89.975 3.5811-3.5817
Piston and Cylinder (1.0mm)
Classification Codes
Normally aspirated engine with Mahle or KS pistons
(ex. 8212 engine)
standard A 89.978-89.988 3.5424-3.5428
standard A8 89.988-89.996 3.5428-3.5431
AA standard 8 89.996-90.004 3.5431-3.5435
standard C 90.004-90.020 3.5435-3.5441
first oversize 90.482-90.497 3.5623-3.5629
(0.5mm)
second oversize 90.982-89.997 3.5820-3.5826
(1.0 mm)

Normally aspirated engine with Hepolite pistons

(ex. 8212 engine)
69084-S2l1102
standard A 89.977-89.985 3.5424-3.5427
standardA8 89.985-=89.991 3.5427-3.5430
standard 8 89.991-89.999 3.5430-3.5433
standard C 89.999-90.015 3.5433-3.5439
Piston diameter mm in.
Normally aspirated engine with Hepolite pistons
Turbo engine with Mahle pistons (ex. 8212 engine)
standard A 89.960-89.970 3.5417-3.5421 first oversize 90.477-90.492 3.5621-3.5627
standard A8 89.970-89.978 3.5421-3.5424 (0.5 mm)
standard 8 89.978-89.986 3.5424-3.5427 second oversize 90.977-89.992 3.5818-3.5824
standard C 89.986-90.002 3.5427-3.5434 (1.0 mm)

continued continued on next page

PISTONS

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022-4 Engine-Technical Data

Piston diameter mm in. CYLINDER HEAD AND VALVE

B212 engine (2.1 liter engine) MECHANISM
standard A 92.982-92.992 3.6607-3.6611
standard B 92.993-93.002 3.6611-3.6615
standard B 93.003-93.012 3.6615-3.6619
first oversize 93.482-93.492 3.6804-3.6808
(0.5 mm)
second oversize 93.982-93.992 3.7001-3.7005
(1.0mm)
nominal piston 0.009-0.035 0.00035-0.00137
clearance

Piston-to-Cylinder Clearance (mm)

piston! non-turbo turbo non-turbo

cylinder (KS) (Hepolite)
classification

B202 engine (2.0 L)

AlA 0.012-0.032 0.030-0.050 0.015-0.033
ABIA 0.004-0.022 0.022-0.040 0.009-0.025
AB/B 0.014-0.032 0.032-0.050 0.019-0.035
B/A 0.014-0.032 0.001-0.019
BIB 0.006-0.024 0.024-0.042 0.011-0.029
CIB 0.008-0.034

B212 engine (2.1 L)

AlA 0.008-0.028
BIB 0.009-0.027
BIB 0.009-0.027

Cylinder head "'eight mm in.

(dimension A)

New 140.5±0.1 5.533±0.004

After machining 140.1±0.05 5.516±O.004

Machining limit 0.4 0.0016

CYLINDER HEAD AND VALVE MECHANISM

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 Engine-Technical Data 022-5

Exhaust valve

44.5"

6.955-6.980 mm

29.0 mm
t
I ,
(0.2738-0.2748 in.)
1.5mm
(0.06 in.)
approx.
JI--
(1.14 in.)

Intake valve

6.960"6.975 mm 1.5mm
t (0.2740-0.2746 in.)
(0.06 in.)

32.0 mm
I J %
,,--
approx.

(1.26 in.)

I
89088

Valves mm in.

Valve clearance non-adjustable

Valve guides
valve guide wear
(clearance between
valve guide and valve
stem)
maximum pennissible 0.5 0.02
length 49.00 1.929
outside diameter 12.039-12.050 0.4740-{).4744
B9087 I

bore for valve guide in 12.000-12.018 0.4724-{).4731

cylinder head

Valve Springs Camshaft mm in.

out-of-square (maxi- 1.75 0.07 Bearing diameter 28.922-28.935 1.1387-1.1392
mum)
Axial play (maximum 0.08-{).35 0.0031-{).0138
free height 45.0±1.5 1.77±O.06
pe nn issible)
installed height 37.0 1.46
height when com- 28.4 1.12
pressed with pressure
of 131-141 Ibs. Cam followers mm in.

Diameter 32.96-32.98 1.2976-1 .2984

Height 26 1.02

Bore for cam followers 33.000-33.016 1.2992-1 .2998

in camshaft bridge

CYLINDER HEAD AND VALVE MECHANISM

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022-6 Engine-Technical Data

CRANKSHAFT LUBRICATION SYSTEM

Crankshaft mm in.

Maximum variation in 0.10 0.004

straightness (runout)

Axial play (end float) 0.08-0.28 0.003-0.011

Maximum out-of-round 0.05 0.002

of journals

Radius of main journal 2.2-2.5 0.09--Q.10

fillet

Main bearing oil 0.020-0.062 0.0008-0.0024

clearance
Lubrication System
Big-end bearing oil 0.026-0.062 0.0010-0.0024
clearance Oil pressure at 2000 at least 2.7 bar (39 psi)
rpm, engine temp. 80 D C
Crankpin diameter (176 D F)
standard 51.981-52.000 2.0465-2.0472
Oil pressure relief valve 3.6-5.3 bar (52-77 psi)
first undersize 51.731-51.750 2.0367-2.0374
opening pressure
second undersize 51.481-51.500 2.0268-2.0276
Waming light on below 0.3--0.5 (4.4-7.3 psi)
third undersize 51.237-51.250 2.0172-2.0177
pressure bar
fourth undersize 50.987-51.000 2.0074-2.0079
Oil pump end noat 0.03--0.08 mm (0.0012-D.0031
Main journal diameter in.)
standard 57.981-58.000 2.2827-2.2835
first undersize 57.731-57.750 2.2729-2.2736
second undersize 57.481-57.500 2.2630-2.2638
third undersize 57.237-57.250 2.2534-2.2539
fourth undersize 56.987-57.000 2.2436-2.2441

Color markings, main and big-end bearing shells

standard first oversize second oversize

thin-red thin-yellow thin-white
thick-blue thick-green thick-brown

LUBRICA nON SYSTEM

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 Engine-Technical Data 022-7

LH FUEL INJECTION

89092

Fuel Injection

LH Coolant Temperature Sensor Resistance

89091 Tem peratu re Resistance (Ohms, ±10%)

1. Fuel tank 7. Fuel injector 14,000
2. Fuel pump 8. Coolant temperature sensor
3. Fuel filter 9. Throttle plate 9,000
4. Fuel distribution 10, Th rottle switch
5,800
5. Pressure regulator 11. AIC valve
6, LH control unit 12. Air mass meter 3,800

3,000

System YearlModel Identification 2,600

LH 2.2 1985-1988 tu rbo Three wire AIC idle valve, 2,000

1986-1987 metal air mass meter with
sealed mixture adjustment 1,700
normally aspirated
screw 320
LH 2.4 1989 and later Two wire AIC idle valve,
turbo plastic air mass meter
1988-1990 without mixture adjustment
normally aspirated

LH 2.4.2 1991 and later Three wire AIC idle valve,

normally aspirated si milar plastic ai r mass meter
without mixture adjustment

Fuel Pump

Fuel Pump Delivery Volume 900 ml (30 oz.) in 30 seconds

(minimum)

Fuel system pressure - fuel pump running, engine off

normally aspirated models 3.0 bar (43.5 psi)
turbo models 2.5±0.05 bar (36.3±0.7 psi)
Fuel system pressure - engine idling
normally aspirated models 2.4 bar (34.8 psi)
turbo models 1.9 bar (27.6 psi)
Residual fuel pressure
all models 0.1-0.2 bar (1.5-3.0 psi)
below system pressure,
minimum after 10 minutes

LH FUEL INJECTION

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 -
022-8 Engine-Technical Data

COOLING SYSTEM

'-'

89093-S2I1591

89094-S5207
Fuel Injection

Fuel injector resistance

Cooling System
Oxygen Sensor Specifications
Oxygen sensor voltage 0.4-1 volt Cooling system capacity 10 liters (10.5 qts,)
at idle (engine wann)
Pennissible coolant leakage 1 qt. over 60,000 miles (1
Oxygen sensor approx. 4 Ohms Iiter/lOO,OOO km)
preheater resistance
Coolant thennoswitch closing
AIC Valve Resistance temperature
Fuel System Test tenninals Resistance
(Ohms) Coolant thermoswitch opening
temperatu re
LH 2.2 1 and 2 20±2
2 and 3 20±2 Coolant type Phosphate-free 50% mixture
anti-freeze 50% water
1 and 3 40±4
LH 2.4 1 and 2 812 Coolant temperature sender 51 .2±4.3 Ohms at 90°C
resistance (194 C F)
LH 2.4.2 1 and 2 10-15
2 and 3 10-15 Cooling system test pressure 1,2 bar (17.4 psi.)
(maximum)
Idle speed (adjustable 850±50 rpm
only on LH 2.2 injection)

Idle %CO (adjustable only on LH 2.2 injection)

nonnally aspirated 0.5-1.5% TURBOCHARGER
turbo 0.9-1,6%

Dashpot Adjustment speed at which dash pot rod touches

Specifications (LH 2,2) throttle lever
nonnallyaspirated 2500±100 rpm
turbo 2600±100 rpm

89095-S5865 I

Turbocharger basic boost bar psi

pressure
All except 1987 and later SPG 0.3510,03 5.010.4
models

1987 and later SPG models 0.4010.03 5.810.4

TURBOCHARGER

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 Electrical System-Technical Data 023-1

023 Electrical System-Technical Data

Electrical System 023-1

ELECTRICAL SYSTEM

i
[
I
II

II
I
!

' - - - 1

Charging System
J
TIghtening Torques Nm ft-Ib (in-I b) Alternator

Ignition distributor hold- 15 11 rated speed 1900 rpm

down bolt
minimum brush length 5 mm (0.2 in.)
Knock sensor to engine 20 15
block Output test values

Solenoid to starter 4.5-5.5 (40-49 in-Ib) 36 amps @ 1500 rpm

54 amps @ 1900 rpm
Starter field winding strap 7-9 (62--80 in-Ib)
and battery cable to 80 amps @ 6000 rpm
solenoid

all other fasteners

M5 bolt 5 (44 in-Ib)
M6 bolt 10 (89 in-Ib) Ignition System
M8 bolt 20 15
Ignition system type
M10 bolt 40 30

Charging System

Alternator

rated output 14 volts

ELECTRICAL SYSTEM

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023-2 Electrical System-Technical Data

L Ignition System
1985 and later, turbo basic Hall ignition
1986 and later, non-turbo EZK ignition-Hall-effect with
knock sensor

Ignition firing order 1-3-4-2 (no. 1 cylinder next to

firewall)

Ignition timing (vacuum hose

discon nected)
Turbo 16°BTDC @ 850 rpm

Non-turbo 14°BTDC @ 850 rpm

Ignition coil
primary winding resistance* 0.5-<:>.9 Ohms

secondary winding resis- 7200-8200 Ohms

tance*

Spark plug wires and rotor

ignition rotor resistance 1000 Ohms

coil high tension lead 500-1500 Ohms

resistance (complete with
end connectors)

spark plug lead resistance 2000-4000 Ohms

(complete with end
connectors)

'Measure with all wires disconnected from call. See 340 Ignition System for testing
information

ELECTRICAL SYSTEM

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 ....:..... ;........•...
Transmission-Technical Data 024-1
·11111
024 Transmission-Technical Data
Transmission 024-1

TRANSMISSION

Tightening Torques Nm ft-Ib (in-Ib) Tightening Torques Nm ft·lb (in-Ib)

ATF pressure tap (automatic 5-7 (44--62 in-Ib) Shift rod clamp bolt 30---35 22-26
transmission) (manual transmission)

ATF sump pan bolts 8-12 (71-106 in-Ib) All other fasteners
(automatic transmission) M5 bolt 5 (44 in-Ib)
ATF sump pan drain plug 5-8 (44-71 in-Ib) M6 bolt 10 (89 in-Ib)
(automatic transmission) M8 bolt 20 15
ATF cooler connection nut 13-16 10-12 M10 bolt 40 30
(automatic transmission)

Clutch slave cylinder mounting 6-14 (53-124 in-Ib)

screws

Gearbox drain plug (manual 39-59 29-44

transmission)

Selector cable setscrew 2.5 (22 in-Ib)

tightening torque
(automatic transmission)

TRANSMISSION

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024-2 Transmission-Technical Data

4 65
1. Torque convertor 5. Rearband
2. Front clutch 6. One way clutch
3. Rearclutch 7. Govemor
4. Front band

Automatic Transmission

Type Borg Wamer 37

ATF volume (transmission) 8.0 I (8.5 U.S. qts.)

ATF Ford specification M2C-33F

89100-S6605 (alternate Ford specification G)

6. Slave cylinder AfT final drive capacity 125 I (1.3 U,S. qts.)
1. Pressure plate
2. Housing 7. Master cylinder AfT final drive grade of oil SAE EP800r75API-GL-40rAP
3. Diaphragm spring 8. Clutch pedal I-GL5
4. Pivot rings 9. Clutch fluid reservoir Alternate grade SAE 10W·30 engine oil
5. Release bearing
General stall speed (APC 2250-2700 rpm
solenoid unplugged)
Manual Transmission Line pressure at idle 4.2-4.9 bar
(gear selector in D) (61-71 psi)
Clutch type Fichtel & Sachs

Clutch diameter
non-turbo 204 mm (8 in,)
turbo 216 mm (8.5 in,)

Clutch adjustment automatic

(non-adjustable)

Manual transmission oil 3.0 I (3.5 U.S. qts.)

capacity

Grade of oil SAE 10W-30 SF/CC, SF/CD, SG

Altemate grade of oil SAE EP 75 API-GL-4 or API GL·5

Clutch/brake master DOT 4 brake fluid

cylinder fluid

TRANSMISSION

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 Brakes-Technical Data 025-1

025 Brakes-Technical Data

Brakes 025-1

BRAKES

Front Brake Disc Applications

Model year and Model Disc type

1985 through 1987900 Solid

1985 and 1986 900s Solid

1985 Turbo Solid

1987900s Ventilated

1986 through 1987 Turbo, Ventilated

including convertible

1988 and later All Ventilated

Front Brake Solid disc Ventilated Ventilated

Disc disc disc (1988
(1986·1987) and later)
89102
Thickness 12.7 mm 20mm 23.5 mm
(new) (0.50 in.) (0.787 in.) (0.93 in.)
Tightening Torques Nm ft-Ib (in-Ib)
Thickness 11.2 mm 18mm 21.5mm
ABS hydraulic unit to bulkhead 26±4 19±3 (wear limit) (0.441 in.) (0.709 in.) (0.85 in.)

Front caliper mounting bolt to 30-35 22-26 Brake surface 0.1 mm 0.1 mm 0.08 mm
guide pin (1988 models and lateral runout (0.004 in.) (0.004 in.) (0.003 in.)
later) (maximum)

Front caliper to steering 110-130 81-96

member (1985 to 1987)
Rear Brake Disc
Front pad carrier to steering 70-110 52--81
member (1988 models and Thickness (new) 9.0 mm (0.354 in.)
later)
Thickness (wear limit) 7.0 mm (0.276 in.)
Rear caliper to axle (1985 to 70-90 52--86
1987) Brake surface lateral runout 0.1 mm (0.004 in.)
(maXimum)
Rear caliper to pad carrier 25-30 18-22
(pins) (1988 models and later)

Rear pad carrierto axle (1988 40-54 30--40 ABS Specification

models and later)
ABS wheel speed sensor air 0.65 mm (0.026 in.)
All other fasteners gap
M5 bolt 5 (44 in-Ib)
M6 bolt 10 (89 in-Ib)
M8 bolt 20 15
Ml0 bolt 40 30

BRAKES

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 Steering and Wheel Alignment-Technical Data 026-1

026 Steering and Wheel Alignment-

Technical Data
Steering and Wheel Alignment 026-1

STEERING AND WHEEL ALIGNMENT Tightening Torques Nm ft-Ib (in-I b)

Lower control arm bearing bracket

(front or rear) to body
M12 dry joint 70-95 52-70
M121ubricaled joint (waxed nut) 45-55 33-41
Lower control arm bracket to body 18-26

Power steering rack to body 60-80 44-59

Road wheel to wheel hub

lug nuts 90-110 66-81
lug bolts 105-125 77-92

Steering column to steering rack 20-27 15-20

(clamping bolt, self-locking nut)

Steering column to body 20-27 15-20

(bolts, use with Loctite)

Steering wheel to steering column 25-28 18-21

(self-locking nut)

Universal joint to pinion shaft 18-25

(clamping bolt and self-locking nut)

Power steering hose fittings 15-25

Tie rod end to tie rod 60-80 44-59

Upper control arm bearing bracket 40-55 30-41

(front or rear) to body
All olher fasteners
M5 bolt 5 (44 in-Ib)
M6 bolt 10 (89 in-Ib)
Tightening Torques Nm ft-Ib (in-Ib) M8 bolt 20 15
M10 bolt 40 30
Ball joinl to control arm (upper or 40-55 29-41
lower)
Ball joint to control arm bolts (self- 40-55 29-41 Steering and Wheel Alignment Specifications
locking nuls)
Chassis Ride Height
Ball joint to steering swivel member 35-50 (measured between top of wheel rim and fender/hood gap)
(self-locking nut)
Except sport chassis 243 mm (9.56 in.)
Bearing bracket to control arm
(locknut and lock washer) Sport chassis
lower control arm bracket to 75-90 55-66 with 15 in. wheel 230 mm (9.06 in.)
control arm with 16 in. wheel 217 mm (8.54 in.)
upper control arm bracket to 55-70 41-52
control arm

Coil spring seat to control arm 55-110 41-81

STEERING AND WHEEL ALIGNMENT

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026-2 Steering and Wheel Alignment-Technical Data

Wheel Alignment Specifications

Measurement Model

except sport sport chassis

chassis

Front
caster 2°±0.5 2°±0.25
camber 0.5°±0.5 0.25°±0.25
toe-in 2±1 mm 1.5±0.5 mm
(0.08±0.04 in.) (0.06±0.02 in)

Swivel pin inclination 11.5°±1 11.5°±1

Steering angle-outer 20° 20°
wheel

Steering angle-inner 20.75°±0.50 20.75°±0.50

wheel

Rear wheels (non-

adjustable)
toe-in 4±1 mm 4±1 mm
(0.16±0.04 in.) (0.16±0.04 in.)
camber -0.5°±0.25 -0.5°±0.25

Ball joint wear limit

maximum radial play 1 mm 0.040 in.
maximum axial play 2mm 0.078 in.

Power Steering Fluid

GM power steering 75 cl 0.8 qt
fluid (GM 9985010),
Texaco TL4634 or
equivalent

STEERING AND WHEEL ALIGNMENT

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Suspension-Technical Data 027-1

027 Suspension-Technical Data

Suspension 027-1

SUSPENSION

Tightening Torques Nm ft·lb (in-I b)

Panhard rod to body or rear 40-70 30-52

axle

Torque ann to body or rear

axle
lubricated bushings 21-35 15-26
dry bushings 40-70 30-52

Wheel hubs to drive axle 290-310 214-229

(locking nut)

Wheel lug bolts 105-125 77-92

Wheel lug nuts 90-110 66-81

All other fasteners

M5 bolt 5 (44 in-Ib)
M6 bolt 10 (89 in-I b)
M8 bolt 20 15
M10 bolt 40 30

Front Coil Spring Specifications

Spring color codes Spring free length

1. Upper control ann 5. Shock absorber Standard chassis

2. Spring seat 6. Lower ball joint green, light green, black, or 373mm 14.7 in.
3. Coil spring 7. Lower control ann white
4. Bump stop 8. Upper ball joint yellow or red 380 mm 15.0 in.
pink or brown 388mm 15.3 in.
blue or light blue 372mm 14.6 in.
Tightening Torques Nm ft·lb (in·lb) Sport chassis
Front shock absorber to lower 90-100 66-74 silver or bronze 301 mm 11,8 in.
control ann

Front suspension coil spring 55-110 41--81

seat to control ann Rear Coil Spring Specifications

Anti-roll bar bracket to lower 40-55 30--41 Spring color codes Spring free length
control ann Standard chassis
Power steering rack to body 60-80 44-59 black or white (left spring) 311 mm 12.24 in.
green or light green (right 308mm 12.12 in.
Spring link front mount to body 70-90 52-66
spring)

Sport chassis
silver or bronze 293 mm 11.5 in.

SUSPENSION

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 Body-Technical Data 028-1

028 Body-Technical Data

Body 028-1

BODY

Tightening Torques Nm ft-Ib (in-Ib) Tightening Torques Nm ft-Ib (in-Ib)

AlC system tightening torques All other fasteners

AlCcompressor-to-evaporator M8 bolt 20 15
hose M10 bolt 40 30
connection at compressor 22-27 16-20
(pad-type)
hose fitting at evaporator 28-39 21-29
Body Specifications
AlC compressor-to-condensor
hose Convertible pump hydraulic Aeroshell
fluid Fluid 4/Shell
connection at compressor 22-27 16-20 Code 60 421
(pad-type) (Saab part no.
hose fitting at condensor 21-28 15-21 3018694

AlC condensor-to- Convertible top hydraulic 25 bar 365 psi

receiver/dryer hose pump minimum working
hose fitting at condensor 14-20 10-15 pressure
hose fitting at receiver/dryer 14-20 10-15

AlC evaporator-to- Ale System Specifications

receiver/dryer hose
Refrigerant oil capacity 1.75 dl 4.9 oz.
hose fitting at evaporator 14-20 10-15
(compressor replacement)
hose fitting at receiver/dryer 14-20 10-15
Refrigerant oil capacity per
AlC expansion valve to 21-27 15-20 component (due to sudden
evaporator leakage)
AlC expansion valve pressure 7-10 (62--89 in-lb) evaporator 0.5 di 1.4 oz.
equalization fitting to receiver/dryer 0.2 c!i 0.57 oz.
evaporator condenser 0.2 dl 0.57 oz.
Oil fill plug to AlC compressor 8-12 (71-106 in- hose 0.2 dl 0.57 oz.
Ib)
AlC refrigerant pressure
Convertible top hydraulic hose 5.1-6.2 (45-55 in-Ib) switch (low gas pressure)
fittings opening pressure 2.9 bar 41 psi
Seatbelt guide bolt to body 24-40 18-30 AlC Coolant temperature
(convertible models) switch
All other seat belt mounting 45±10 33±7 opening temperature 115°C 239°F
bolts
AlC Anti-frost switch
All other fasteners switch closed 4.0-6.2°C 39.2-43.1 of
M5 bolt 5 (44 in-!b) switch open 0.4-2.6°C 33-36.6°F
M6 bolt 10 (89 in-Ib)
continued

BODY

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