Direct Ignition Cassette Testing
Turn the Cassette over and put the plugs in the holes, ground each plug to the negative battery terminal (by use of a wire about 2 feet long and skinned at length of where each plug is) and turn the engine over watching the spark.
If there is a problem with the cassette one of the plugs will have no spark or a very weak spark. Also, when you turn the ignition key off there should be a shower of sparks that runs the length of the plugs several times.
BE CAREFUL! EXTREMELY HIGH VOLTAGE!
There have been occasions when the DI cassettes would test ok when turned upside down but would fail when turned back over to install into the valve cover! Oil leakage from the individual coils of the cassettes has also been a problem. Oil leaks can be identified by noting that there is oil in the spark plug hole!
Direct Ignition Cassette (DI) Engine Buzzing:
Any car that is equipped with a Direct ignition emits what Saab calls a shower of sparks after the ignition switch has been cut off. This usually occurs within 30 seconds of turning off the ignition. The purpose of this shower of sparks is to keep the plugs completely clean for better starts.
Many cars now use Direct Ignition systems with ignition coils integrated into an assembly that connects directly to the spark plugs. Diagnosing problems with Direct Ignition systems can be challenging, but once a faulty Direct Ignition system is diagnosed, it can be replaced very easily.
The most common trouble codes that you will find in OBD II cars are codes 301/302/304/351/358 which indicate a misfire in a single cylinder. These misfires can be caused by many factors including fouled plugs, damaged coils, corroded wire terminals to the DI, contaminated fuel, compression loss, low fuel pressure or burnt valves. Keep in mind that code P0300 (lean/rich mixture code) is likely due to a fuel or vacuum leak issue. Cranks sensor codes are usually code 320/340 or in that range.
BE CAREFUL! EXTREMELY HIGH VOLTAGE!
DIRECT IGNITION CASSETTE SPARK PLUG NOTES:
[95, 93 98-03, 9000, 900 94-98]
Spark plug burn-off is automatically done with a shower of sparks each time the engine is switched off. It is carried out in all cylinders simultaneously and lasts for 5 seconds at a rate of 210 sparks per second and IT CAN BE FATAL!!!!! EXTREME CAUTION!!!!!
When replacing the spark plugs it's important to do the following:
STEP 1: Let the module power down for 30 seconds then remove the electrical plug
STEP2: Use resistor type NGK spark plugs. All Saabs equipped with DI cassettes have been specified with resistor type NGK plugs
STEP 3: Verify the correct gap at the electrode (1.0mm -1.1mm)
STEP 4: Oil leaks from coil assemblies mean that you should replace the cassette
STEP 5: Coat the rubber boots on the cassette with Saab part number 3019312 or supplied brand dielectric grease.
STEP6: Check to be sure that the contact springs can be seen inside the coil towers and replace them if they are damaged or missing Saab part number 9167032
STEP 7: Coat the thread of the spark plugs with Molycote 1000 Saab part number 3020271 or high temperature anti-sieze
STEP 8: Fit the Cassette to the valve cover and torque to 8.1 lbf ft
STEP 9: Install and torque the Spark plugs to 21 lbf ft
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