Engine - Cold Weather Starting Problems
89saab08FILE IN VOL.
S.I. Man. I
SEC. PG.
A-2 220
S.I. 10/89-1179
SUBJECT: SERVICE KIT FOR COLD WEATHER STARTING PROBLEMS
APPLICATION: 1985-88 900 MODELS WITH LH 2.2 FUEL SYSTEM
A service kit, P/N 88 18 338, is available to improve cold engine starting of 1985-88 900 models with the LH 2.2 fuel injection system. This kit is effective when starting a car in temperatures of 20~F (-7~C) or colder, but it will have no effect under warmer conditions.
If a cold start complaint exists in temperatures above 20~F (-7~C) the problem exists elsewhere and this 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 and specification should be verified before determining the necessity of installing this kit.
NOTE
Because this service kit is available only in limited quantities, the District Aftersales Managers must issue a Prior Authorization Code (PAC). The PAC must be noted on a warranty claim. The DASM should be contacted prior to ordering this service kit from your Saab Parts Distribution Center.
Parts Required:
Cold Start Kit 88 18 338
Kit contents:
Hose 75 17 915
Hose Clamp 79 75 543
Hose Clamp (qty. 2) 79 63 531
Cold Start Valve 93 12 471
O-ring 81 09 548
Self-tapping screws (qty. 2) 75 07 072
Fuel Line 75 37 681
Banjo Fitting 75 81 143
Seals (qty. 3) 83 26 704
Banjo Fitting 83 20 319
Seals (qty. 2) 93 28 824
Wiring Harness 74 78 159
Relay 95 19 224
Thermostatic Switch 78 81 212
Seal 81 24 141
Tube 83 69 365
Plug 22 36 487
Spade terminals (female) 85 71 804
Cable Ties (qty. 10) 79 71 872
Connector 85 93 915
Also Required: Two-part epoxy locally sourced
Figure 1:
1. Release the pressure from the cooling system and drain the system.
2. Disconnect all hoses and the throttle cable from the throttle housing assembly and remove the assembly from the manifold.
3. Locate the center of the recessed area in the mounting plate by carefully measuring the halfway point between the centers of the two screw holes. Mark the location and center punch it (Figure 1).
Figure 2:
4. Drill a 9 mm dia. (11/32") hole through the center of the mounting plate for the cold start valve as shown in Figure 2.
NOTE
Remove any burrs and carefully clean the throttle housing of all metal fragments before proceeding.
NOTE
Steps 5 through 10 are applicable only to early production variants with the Automatic Idle Control (AIC) valve connected to a fitting on the inlet manifold. If the AIC hose is connected to the throttle housing, refit the throttle housing and proceed to step 11.
Figure 3:
5. Remove the seal plug from the side of the throttle housing (Figure 3). Drill a hole in the plug and use a slide hammer equipped with a self tapping screw attachment to remove the plug.
NOTE
Carefully clean the throttle housing of all metal fragments before proceeding.
Figure 4 - Install Tube 83 69 365.:
6. Insert tube 83 69 365 in the throttle housing casting as shown in Figure 4 and cement it in position using an epoxy adhesive. Follow the manufacturer's directions for preparation, application and curing time.
Figure 5 - Remove The AIC Hose.:
7. Refit the throttle housing assembly.
8. Remove the hose from between the AIC valve and the fitting on the inlet manifold (Figure 5).
Figure 6 - Install Hose.:
9. Slide hose clamps 79 75 543 and 79 63 531 onto the new hose contained in the kit (P/N 75 17 915). Connect the hose between the AIC valve and the tube just installed in the throttle housing and tighten the clamps (Figure 6).
Figure 7 - Install Plug:
10. Fit plug 22 36 487 onto the fitting to which the previously-removed AIC hose was connected. Secure with clamp 79 63 549 (Figure 7).
Figure 8 - Install Cold Start Valve:
11. Fit O-ring 81 09 548 onto the cold start injector valve and install the valve onto the throttle housing using the two self-tapping screws (P/N 75 07 072) as shown in Figure 8.
Figure 9:
12. Remove the banjo bolt on the fuel injection rail.
13. Connect fuel line 75 37 681, using banjo bolt 75 81 143 and the three seals (P/N 83 26 704) to the fuel injection rail and original fuel line.
Connect the other end of the fuel line to the cold start valve using banjo bolt 83 20 319 and the two seals (P/N 93 28 824) as shown in Figure 9.
Figure 10.:
14. Remove the small bottom drain plug from the fitting located on the RH side of the block (viewed from the rear). Fit thermostatic switch 78 81 212 complete with seal 81 24 141 in place of the plug (Figure 10).
15. Refill and bleed the cooling system.
Figure 11.:
16. Install the wiring harness (P/N 74 78 159) as follows:
a. Fit relay 95 19 224 on the upper inner fender edge behind the expansion tank.
b. Connect the wiring harness to the relay and lay out the harness following the existing harness across the firewall. secure loosely with the tie straps (Figures 11, 13, and 14) .
Run the branch harness for the NTC sensor and the cold start valve, along the coolant hose running from the block to the heater box. Loosely secure the harness to the hose with tie straps. Do not tighten the tie straps at this time.
c. Unplug the connector from the NTC sensor, peel back the rubber cover and snip off the leads as close to the old plug as possible.
Figure 12:
d. Push the leads from the new harness through the rubber cover from the rear. Connect together the leads from the new and existing wiring harness in pairs (yellow to yellow; green to black). Use the special Saab crimping tool to install terminal 85 71 804 on each of the new wire pairs. Fit them inside the new connector, P/N 85 93 915, (yellow to pin 1; black/green to pin. Plug the connector onto the NTC sensor. Slide the rubber cover back over the connector (Figure 12).
Figure 13:
e. Connect the ground lead to the ground point at the lifting eye on the engine.
f. Connect the lead for the cold start valve to the valve.
g. Connect the red lead to the spare pin (15a) on the starter motor. Run the lead along the positive feed from the battery and loosely secure it with tie straps. Do not tighten the tie straps at this time.
h. Connect the thermostatic switch, running the lead along the existing wiring harness across the firewall and down to the thermostatic switch (Figure 13).
NOTE
Tie strap the wiring harness to the engine mount to prevent contact with the drive shaft.
Figure 14:
i. Inspect to ensure that the wiring harness is secured with tie straps at the points shown in Figure 14.
Be careful to route the harness away from the AC compressor. Tie strap the "Y" of the harness to the heater hose to achieve this.
j. Once the harness is properly routed and connected, tighten all tie straps securely but do not overtighten them. Pay particular attention to the tie straps used to secure the harness to the heater hose. These straps should be snug but not tight to avoid potential damage to the wires when the heater hose expands.
Warranty Information:
Claims must have a District Service Manager Prior Authorization Code (PAC) entered.
For warranty claims, use Failure Coding 24220-08-1-01-05. Labor allowance is operation # 24220 (0.3 hour) to install the service kit and 1.2 hours in straight time.