Engine - Hard Cold Weather Starting
90saab08Subject: Service Kit for Cold Weather Starting
Problems in Extremely Cold Weather
Application: 1988-91 900 models with LH 2.4 1991-900 models with LH 2.4.2
CATEGORY Engine
SECTION PAGE
2 8
ISSUE CODE
12/90-0073 242
Supersedes SI 02/89-1110
A service kit, P/N 88 19 070, has been developed to correct cold starting complaints under extremely cold conditions. The kit is effective when starting in temperatures of 5~F (-15~C) or colder.
The cold start kit will not remedy complaints of cold starting problems above 5~F (-15~C). If a complaint occurs above this temperature, the problem exists elsewhere and the service kit should not be installed.
A winter grade of engine oil (5W-30) must be used in frigid temperatures to help avoid possible cold start complaints. Correct oil viscosity and proper spark plug condition should be verified before determining the necessity of installing this kit. Note
Aerosol cold-starting fluids must never be used on Saab vehicles with LH Fuel Injection because of the risk of backfiring which can damage the air mass meter.
Parts Required:
Cold Start Kit 88 19 070
^ Cold start valve 74 86 129
^ O-ring 81 09 548
^ Self-tapping screws 75 07 072
^ Fuel line 75 37 681
^ Banjo bolt 75 81 143
^ Sealing washer (3) 83 26 704
^ Banjo bolt 83 20 319
^ Sealing washer (2) 93 28 824
^ Jumper lead 85 98 526
Figure 1:
Installation Procedure:
1. Identify the type of throttle housing fitted on the car (Figure 1). Late-1988 and later models have throttle housings that are pre-drilled to accept the cold start valve and are fitted with a cover plate. Remove the plate and proceed to step 5. If the throttle housing is not pre-drilled, proceed to step 2.
Figure 2:
2. Remove the throttle housing from the intake manifold. Cover the open end of the manifold with a shop towel.
3. Find and mark the center of the mounting flange for the cold start valve (Figure 2). Drill a pilot hole at the center and then a 9 mm (11/32") diameter hole. Clean all shavings and deburr the hole after drilling.
4. Remove the shop towel from the intake manifold and refit the throttle housing. Ensure that the throttle housing o-ring is properly fitted before tightening the nuts. Torque: 18 N-m (13.5 lb.ft.).
Figure 3:
5. Fit o-ring 81 09 548 to cold start valve 74 86 129. Mount the valve, with the electrical connector facing the engine, to the throttle housing using selftapping screws 75 07 072 (Figure 3).
WARNING
ALWAYS OBSERVE THE FOLLOWING SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SYSTEM.
^ NO SMOKING!
^ DISCONNECT THE GROUND CABLE FROM THE BATTERY AND COVER THE TERMINAL POST
^ HAVE A FIRE EXTINGUISHER NEARBY.
^ WEAR EYE PROTECTION
^ WORK IN A WELL VENTILATED AREA (USE VAPOR EXTRACTION EQUIPMENT IF AVAILABLE).
^ AVOID PROLONGED SKIN CONTACT WITH FUEL AND WEAR SUITABLE GLOVES.
6. Disconnect the banjo fitting for the fuel supply hose at the front end of the fuel injection rail.
Figure 4:
7. Connect the fuel line for the cold start valve, P/N 75 37 681, to the fuel rail using the longer banjo bolt, P/N 75 81 143, and three new sealing washers, P/N 83 26 704, supplied in the kit (Figure 4).
Figure 5:
8. Connect the fuel line to the cold start valve using banjo bolt 83 20 319 and sealing washers 93 28 824.
WARNING
FUEL LINE 75 37 681 MUST NOT CHAFE ON ANY PART OF THE ENGINE OR WIRING HARNESS.
9. Locate and cut the tie-strap securing the connector for the cold start valve to the engine wiring harness. Plug the connector onto the valve.
10. For models with LH 2.4 injection only:
(1988-90 Naturally aspirated and 1989-91 Turbo models)
Loosen the right-side carpet to expose the LH ECU. Locate the 2-pole connector containing GN/YL and GR/WH wires coming from the ECU. Install jumper lead 85 98 526 supplied in the kit to the connector (Figure 5). Refit the carpet.
11. Start the engine and check for fuel leaks.
Warranty Information:
For Warranty Claims use Failure Coding 24220-08-3-01-10. Time allowance is Labor Operation No. 24220 for 0.3 hour. Change the ending model year in your DCS Labor Operation Table for operation No. 24220 to "99." Cars requiring removal of the throttle housing for drilling may add Labor Op. No. 24610 for 0.6 hour.