Ignition Distributor - Overhaul Procedure
87saab01FILE IN S.I. Man VOL. I
SEC. B-3 PG. 9
Service Information
SUBJECT: IGNITION DISTRIBUTOR OVERHAUL ISSUE: 10/87-1010
APPLICATION: All 9000 1986-
The following overhaul procedures are for the ignition distributor installed on 16- valve and 16-valve Turbo engines. Overhauling ignition distributors requires the use of a special slotted rotor puller (P/N 02-75-123) and installation of Saab distributor rebuild kits. Also, warranty policy requires that whenever possible this distributor repair procedure be followed rather than replace the entire distributor assembly.
Overhaul Of The Distributor For The 16- Valve And 16-Valve Turbo Engine
Tools: Puller P/N 02-75-123 Soft jaws or wood blocks for the vise Loctite 601 or equivalent
FIGURE 1 - TYPICAL DISTRIBUTOR FOR THE 16- VALVE AND 16-VALVE TURBO ENGINES.:
Distributor Disassembly
1. Remove the ignition distributor from the engine as shown in the Service Manual.
NOTE
All the following steps apply to Figure 1 unless otherwise noted.
2. Remove the seal ring from the distributor body.
CAUTION
IF THE DISTRIBUTOR IS MOUNTED IN A VISE WITHOUT SOFT JAWS OR WOOD BLOCKS, THE DISTRIBUTOR BODY WILL BE DAMAGED.
3. Mount the distributor in a vise with soft jaws or wood blocks. Be careful not to damage the distributor body.
NOTE
Make sure that no fragments of the crushed rotor get into the distributor.
4. Remove the rotor. If the rotor is secured to the shaft with Loctite, carefully crush it with a pair of pliers. Remove the rotor from the distributor.
5. Remove the dust protection cover.
6. Remove the c-clip and corrugated washer (if applicable) located on top of the slotted rotor.
FIGURE 2 - USING THE PULLER TO REMOVE THE SLOTTED ROTOR.:
7. Install the puller on the distributor and slotted rotor as shown in Figure 2. Be sure that the puller is centered on the distributor shaft and correctly installed on the slotted rotor.
8. Remove the slotted rotor with the puller (Figure 2) and remove the straight pin from the distributor.
9. On the 16-valve Turbo distributor only, remove the screws securing the vacuum control unit, spring clips and Hall sensor.
Remove the clips then unhook and remove the vacuum control unit.
10. On the 16-valve, remove the screws securing the spring clips and the Hall sensor.
11. Remove the plastic holding pin or screw securing the socket. Pull the socket up and out of the distributor body.
12. Remove the small c-clip directly over the Hall sensor on the distributor shaft.
13. Remove the plastic cover (if applicable) with the Hall sensor.
14. While the distributor is apart check for:
a. Shaft bushing wear.
b. Any signs of metal deterioration.
c. Mechanical advance mechanism operation (if applicable).
Distributor Reassembly
CAUTION
NEVER BRING ANY METAL TOOLS INTO CONTACT WITH THE HALL SENSOR. TO MOVE IT, USE EITHER A FINGER OR A SUITABLE PLASTIC TOOL, AND ALWAYS EXERCISE GREAT CARE.
FIGURE 1 - TYPICAL DISTRIBUTOR FOR THE 16- VALVE AND 16-VALVE TURBO ENGINES.:
1. Select the appropriate distributor rebuilding kit from the Distributor Rebuilding Kit Application Chart.
NOTE
All the following steps apply to Figure 1 unless otherwise noted.
2. Install the Hall sensor with the plastic cover. Be sure to correctly position the sensor in the distributor body.
3. Install the small c-clip into the retaining groove on the distributor shaft over the Hall sensor.
4. Secure the socket for the Hall sensor to the distributor body with the plastic holding pin or screw.
5. On the 16-valve Turbo distributor only, install the lone spring clip and secure it and the Hall sensor with the appropriate screws.
Distributor Rebuilding Kits Application Chart
PART NUMBER APPLICATION SUPERSEDES TO
75-88-312 Rebuilding Kit 1986-, 16-Valve Turbo For distributor Bosch P/N 0237507007
75-88-304 Rebuilding Kit 1986-87, 16-Valve For distributor Bosch P/N 0237506009
74-84-892 Rebuilding Kit 1988-, 16-Valve For distributor Bosch P/N 0237481385
Hook the vacuum control unit on its pin. Secure it and the other spring clip with the appropriate screws.
6. On the 16-valve distributor only, install the spring clips and secure them and the Hall sensor with the appropriate screws.
FIGURE 3 - POSITIONING THE STRAIGHT PIN.:
7. Place the slotted rotor on the distributor shaft. Align the cutout in the rotor for the straight pin with the cutout for the pin in the shaft. Place the straight pin in the cutout with a pair of needle nose pliers as shown in Figure 3.
FIGURE 4 - INSTALLING THE STRAIGHT PIN.:
8. Use a drift and hammer to tap the pin into place (Figure 4).
9. Install the c-clip and corrugated washer (if applicable) to secure the slotted rotor.
10. Install the dust protection cover.
NOTE
The new rotor must be locked to the distributor shaft with Loctite 601 or equivalent.
11. Apply Loctite 601 to the distributor shaft and install the rotor.
12. Install the new seal ring on the distributor body.
13. Install the ignition distributor on the engine as shown in the Service Manual.
Warranty Information
Warranty policy requires that whenever possible the above distributor repair procedure be followed rather than replace the entire distributor assembly. For claims use Failure Coding 34272-60- 0__-01. Labor allowance is Operation No. 34272 (1.6 hours).