Klaus,

While cleaning the TB on my 96 850 Turbo I did not find a hole int TB connected to the AIC. However, from your description I followed the AIC output hose and it dumps air via ~3/4" dia hose directly into the intake manifold via the top of a vacuum port/tree just beside the throttle pulley and cable. It looks like Volvo agreed with your assessment and moved the air inlet to the top of the manifold!

I inspected the AIC inlet and outlet hoses for blockage. I found there was a film of oil on the inside surfaces of the inlet hoses right back to where they enter the top of the rad ... I assume as part of the inter-cooler piping. The insides of the AIC itself looked pretty dirty as well. I am speculating here but --- it is possible when it is very cold outside the dirt build up & oil film does not let the AIC valve open or otherwise allow enough air in for a cold start. So carefully using the throttle body cleaner and air I cleaned up the valve - taking care not to let fluid seep into the motor - a lot of dirt did come out and the valve seemed to move much more freely. I also checked the resistance specs across the terminals and they were withing spec.

The car started right up after the fix -- about 5 hours in the cold ... but this is not a good test. Tomorrow I will try to start the car as if it were normal!

Cheers,

David