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Re: Rebuilding a DI cassette Posted by Ari [Email] ![]() ![]() In Reply to: Rebuilding a DI cassette, Sean, Tue, 30 Nov 2004 06:57:08 Members do not see ads below this line. - Help Keep This Site Online - Signup |
The springs are on top of the coils, and make connection between the coil and the spark plug.
As to 'rebuilding' the cassette - there are two different basic failure modes. In one case, one or more coils loose oil, and they overheat and short out. In the early years of DI, the coils were individually replaceable, so theoretically you could swap out the offending coil. Saab went away from this design, because the connection between the replaceable coil and the rest of the cassette represented another failure location.
The other mode is that one or more components in the DI itself fail. This is usually due to dielectric breakdown, where a part arcs over and burns out. Again, theoretically you could dig it out and replace the part.
The problem with this approach is that the failures are due to heat and high-voltage arcing. You may find the offending part by looking for the component burned to a cinder. However, a bunch of other parts were stressed by the arc, and the rest are just plain old. So you can do all that work and it still may not function - worse, it could fail again in a week.
If there was just one or two weak points in the DI, I'd say you could rebuild it by replacing those parts. But the DI is filled with weak spots. Replace one or two, and you still have parts just waiting to fail.
I wouldn't trust a repaired DI - unless you've replaced all the parts, you're just waiting for the next one to fail. And replacing all the parts isn't rebuilding - it's replacing.
posted by 192.249....
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