Engine - Starting Problems In Sub Zero Temperatures
89saab05FILE IN VOL.
S.I. Man. I
SEC. PG.
A-2 213
ISSUE: 02/89-1110
SUBJECT: SERVICE KIT FOR COLD WEATHER STARTING PROBLEMS IN SUB-ZERO WEATHER
APPLICATION: 1988-, 900 MODELS WITH LH 2.4 FUEL SYSTEM
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 kit has no effect under warmer conditions.
If a cold start complaint exists in temperatures above 5~F (-15~ C) the problem exists elsewhere and a service kit must 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: Because the service kit is available only in limited quantities, the District Service Manager must issue a Prior Authorization Code (PAC). The PAC must be noted on the warranty claim.
Cold Start Kit P/N 88 19 070
Kit contents:
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
Banjo seal (qty 2) 83 26 704
Banjo Bolt 83 20 319
Banjo seal (qty 2) 93 28 824
Jumper Lead 85 98 526
Figure 1:
Service Kit Installation Procedure
1. Most 1988 models are equipped with a throttle housing that must be drilled to accept the cold start valve. Late-1988 and 1989 models are pre-drilled. Identify the type you are working with before starting the repair (Figure 1). Start with Step 2 if the housing must be drilled, or remove the blank plate and proceed to Step 5 if it is pre-drilled.
Figure 2:
2. Remove the throttle housing assembly. Cover the open end of the intake manifold with a shop towel.
3. Measure to find the center point between the two bolt holes of the mounting surface for the cold start valve (Figure 2). Drill a 9 mm (11/32 in.) diameter hole at this center point. Clean all drill shavings and deburr the hole after drilling.
Figure 3:
4. Remount the throttle housing assembly on the intake manifold.
5. Fit an O-ring (P/N 81 09 548) to the cold start valve. Install the cold start valve (P/N 74 86 129) on the throttle housing using the two self-tapping screws (P/N 75 07 072). (See Figure 3) Position the valve so the electrical terminal faces the engine.
WARNING
FUEL LINE (P/N 75 37 681) MUST NOT CHAFE ON ANY PART OF THE ENGINE OR WIRING HARNESS.
ALWAYS OBSERVE THE FOLLOWING SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SYSTEM.
^ NO SMOKING!
^ DISCONNECT NEGATIVE LEAD 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.
Figure 4:
6. Disconnect the banjo fitting at the fuel injection rail.
7. Connect the fuel line (P/N 75 37 681) to the fuel injection rail using the longer banjo bolt (P/N 75 81 143) supplied in the kit and three new seals (P/N 83 26 704). (See Figure 4)
8. Connect the other end of the fuel line to the cold start valve using a banjo bolt (P/N 83 20 319) and two seals (P/N 93 28 824).
9. Locate the connector strapped to the vehicle's engine wiring harness. Plug the connector onto the cold start valve.
Figure 5:
10. Remove the right-hand side trim panel to expose the LH fuel injection ECU. Locate the 2-pin connector with green/yellow and grey/white leads coming from the ECU. Connect the jumper lead (P/N 85 98 526) supplied with the kit across the connector. (Figure 5)
11. Replace the trim over the ECU.
12. Start the engine and check for fuel leaks.
Warranty Information:
Claims must have a District Service Manager Prior Authorization Code (PAC) entered.
For warranty claims, use Failure Coding 24220-08-3-01-05. Labor allowance is Operation # 24220 (0.3 hour) to install the service kit, and for early-1988 900 models, Operation # 24610 (0.6 hour) for R & R throttle housing.
SAAB-LINK (DCS) dealers use "Dealer Administration" function on the main SAABLINK (DCS) menu to add 24220 to the Failed Part Table, and 24220 to the Labor Operation Number Table. For Failed Part Code 24220, use the text "Cold Start Kit." For Operation No. 24220, use text "Install Cold Start Kit," "B" for transmission, "1" for engine, 0.3 hour for model 900, "88" for beginning year, and "89" for ending year.