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DI Cassette Failure
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Posted by Bill N (more from Bill N) on Thu, 4 Sep 2003 20:08:07 Share Post by Email
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The Direct Ignition Cassette failed on my wife's '99 9-5 last week with no apparent warning. After replacing it, I disassembled the old unit (it comes apart easily). What I observed was that two of the ignition units displayed significant discoloration. A burned spot in the epoxy(?) encapsulation for the electronics was located next to the ignition unit closest to the connector (#1 cylinder?), which was also the most discolored. The discoloration appears to include of some gummy material and small dribbles, some of which apparently seeped through the plastic and/or dribbled down from the encapsulating epoxy.

It seems likely that the discoloration and dribbles were produced over a period of time as the ignition units gradually deteriorated. Failure probably occurred when things got bad enough and something in the electronics shorted to ground, burning the epoxy and killing the unit.

If this is correct, it means that periodic inspection of the DI cassettes to look for discoloration on the four ignition modules may reveal that a unit is going bad and should be replaced. Given that DI cassette failure can leave you stranded and may pose a significant safety issue if it dies in traffic, having a way to identify a unit that's on its way out would be nice.

I note that the new DI cassette had what looked like dielectric grease where the unit slides over the spark plugs, but the old unit did not. Perhaps the life of older units can be extended by applying dielectric grease to the contacts leading to the spark plugs both inside and out.

Does anyone else have experience with inspecting DI cassettes before/after failure and the use of the dielectric grease (if that's what it is) on the contacts?





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