Engine - Cold Weather Starting Kit
89Saab06FILE IN: S.I. Man VOL. I
SEC. B-2 PG. 23
S.I. 09/89-1178
SUBJECT: SERVICE KIT FOR COLD WEATHER STARTING PROBLEMS IN SUB-ZERO WEATHER
APPLICATION: 1988-, 9000 MODELS WITH LH 2.4 FUEL SYSTEM
Two service kits have been developed to improve cold engine starting of 1988- 9000 models with the LH 2.4 fuel injection system. One service kit is for early 1988 9000 models and the other is for late 1988 and 1989 9000 models. The kits are effective when starting a car in temperatures of 5~F (-15~C) or colder, but have no effect under warmer conditions.
If a cold start complaint exists in temperatures above 5~ (-15~C) the problem exists elsewhere and a 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 these kits.
NOTE
Because the service kits are only available in limited quantities, the District Service Manager must issue a Prior Authorization Code (PAC). The PAC must be noted on the warranty claim. The DSM should be contacted prior to ordering a service kit from your Saab Parts Distribution Center.
Service Kit for 1988 (Engine No. J106602-). 1989 Models: Installation Procedure
Cold Start Kit P/N 88 19 773
Kit Contents:
Cold Start Valve 74 86 129
O-ring 81 09 548
Fuel Line 89 81 417
Banjo Fitting 89 81 581
Seal (qty 2) 83 26 704
Banjo Bolt 83 20 319
Seal (qty 2) 89 81 987
Jumper Lead 85 98 526
WARNING
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 1:
Figure 1:
Figure 2:
1. Remove the cover plate and existing gasket from the intake manifold (Figure 1).
2. Fit the O-ring onto the cold start valve (Figure 2). Install the valve on the intake manifold and secure using the existing screws.
3. Remove the existing banjo bolt from the fuel injection rail.
Figure 3:
4. Install the new banjo fitting and two seals (P/N 83 26 704) onto the fuel rail. Connect the cold start valve fuel line to the top of the new banjo fitting (Figure 3).
5. Connect the fuel line to the cold start valve using the banjo bolt and two Seals (P/N 89 81 987) (Figure 3).
6. Unclip the electrical connector for the cold start valve from the engine wiring harness on the fuel rail. Plug the connector onto the cold start valve.
Figure 4:
7. Uncover the LH fuel injection electronic control unit (ECU) by removing the anti-lock braking system (ABS) cover and ECU.
8. Locate the two-pin connector with green/yellow and grey/white leads at the LH fuel injection ECU. Connect the jumper lead provided in the kit across the connector (Figure 4).
9. Reinstall the ABS ECU and cover over the LH fuel injection ECU.
10. Start the engine and check for fuel leaks.
Service Kit for early 1988 Models (Engine No. -J106601): Installation Procedure
This procedure involves relocating the automatic idle control (AIC) valve closer to the throttle housing and installing a cold start valve at the old AIC valve location.
Cold Start Kit P/N 88 19 088
Kit Contents:
Cold Start Valve 74 86 129
O-ring 81 09 548
Fuel Line 89 81 417
Banjo Fitting 89 81 581
Seal (qty 2) 83 26 704
Banjo Bolt 83 20 319
Seal (qty 2) 89 81 987
Jumper Lead 85 98 526
Bracket 91 14 984
Hose (qty 2) 74 86 624
Hose (qty 2) 75 60 345
Hose Clamp (qty 4) 79 63 531
Adaptor 75 80 301
Self Tapping Screw (qty 2) 75 07 072
WARNING
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 1:
1. Disconnect the crankcase breather hoses from between the camshaft cover and the throttle housing (Figure 1).
2. Remove the air mass meter assembly complete with hoses. Remove the top clamp for the dipstick tube to obtain better access to the engine.
Figure 2:
3. Remove the automatic idle control (AIC) valve complete with clamps, rubber ring and hoses from the intake manifold and throttle housing (Figure 2).
Figure 3:
4. Remove the right hand wiring harness clamp on the fuel injection rail (Figure 3).
Figure 4:
5. Carefully cut open the wiring harness sheath as far as the left hand clamp and remove the leads for the AIC valve (Figure 4).
6. Protect the leads for the AIC valve and repair the slit in the wiring harness sheath using black electrical tape.
7. Reinstall the right hand clamp on the fuel injection rail (Figure 4).
Figure 5:
8. Install the hose bracket on the camshaft cover. Secure it with the left rear camshaft cover bolt and the intake manifold bolt (Figure 5).
Figure 6:
9. Fit the O-ring onto the cold-start valve. Install the valve in the adaptor and secure with two selftapping screws. Note position as shown in Figure 6.
Figure 7:
10. Fit the cold start valve with two hoses (P/N 75 60 345) and four hose clamps between the intake manifold and the hose bracket (Figure 7).
Figure 8:
11. Reinstall the AIC valve in its new location with two hoses (P/N 74 86 624) and the existing hose clamps between the hose bracket and throttle housing (Figure 8).
NOTE
Leave some slack in the wiring harness when connecting the AIC valve.
12. Plug the connector onto the AIC valve (Figure 8).
13. Remove the existing banjo bolt from the fuel injection rail.
Figure 9:
14. Install the banjo fitting and two seals (P/N 83 26 7041 onto the fuel rail as shown in (Figure 9). Connect the new cold start valve fuel line to the banjo fitting.
15. Loosen the hose clamps on the hose between the cold start valve and the pipe on the new bracket. Adjust the cold start valve to ensure that the fuel line is not stretched or kinked (Figure 9).
16. Connect the fuel line to the cold start valve using the banjo bolt and two seals (P/N 89 81 987) as shown in (Figure 9).
17. Unclip the electrical connector for the cold start valve from the engine wiring harness on the fuel rail. Plug the connector onto the cold start valve (Figure 9).
18. Reinstall the air mass meter with hoses and the crankcase breather hoses. Reinstall the clamp for the dipstick tube.
19. Remove the anti-lock braking system (ABS) cover and electronic control unit (ECU) over the LH fuel injection ECU.
Figure 10:
20. Locate the two-pin connector with green/yellow and grey/white leads at the LH fuel injection ECU. Connect the jumper lead across the connector (Figure 10).
21. Reinstall the ABS ECU and cover over the LH fuel injection ECU.
22. Start the car 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 24220-08-0-01-05. Labor Allowance is Operation # 24220 (0.4 hour) to install the service kit, (P/N 88 19 773).
For service kit, P/N 88 19 088, installation, add 0.5 hour in straight time.
SAAB-LINK (DCS) Dealers:
Use the "Dealer Administration" function on the main SAAB-LINK (DCS) menu to update your Labor Operation Table:
^ For 9000 hours, use: "0.4"
^ Beginning year: "88"
^ Ending year: "89"