1994-2002 [Subscribe to Daily Digest] |
Without any signs or warning, my 1999 9-3 (with only 40,000) failed to start. It seemed that all system were go, the starter cranked but the engine didn't fire. After an extensive search of the internet, followed by several calls to Saab service mechanics (no one else even knows what a DI cassette is, it seemed likely the DI cassette (direct ingnition cassette) had failed. By the way, the DI cassette is the red flat-topped gizmo (about 16" by 4") sitting on the top of the engine block hiding the spark plugs and replaces the conventional rooter/distributor/capacitor mechanism. This was news to me. But how to be sure this was faulty before buying an expensive replacement (and electrical parts can nnot be returned). The authorized Saab service center in my area is lame and did not stock the DI cassette, nor did they have one for diagnostics (or any other real substitute). Not wanting to pay for a tow and partial diagnosis (and long wait while the so-call Saab service guys waited days for a snail shipment), I learned the best procedure to help confirm the DI cassette failure. First, I made sure there wasn't a problem with my key and is access chip. The prblem also occurred with my second key...I also cleaned the key, and clean and vacuumed the keyhole. Next, I checked that all fuses (e.g. fuel pump) were good. Next, I removed the cassette and spark plugs. (I smelled fuel in the plug openings and on the plug tips, helping to eliminate fuel delivery possibilities. I also confirmed that the correct plugs were installed (resistor-type) and reset the worn gaps (to 1mm). (I put everything back together and tried again, but still failed, to start the engine. I took the stuff apart again and fitted the spark plugs firmly into the cassette, grounded them (with alligator clips on the metal gasket) to the negative pole of the battery. I turned off the lights in the garage and had my son turn the ignition key. The starter cranked but no sparks were seen. All other electrical seemed fine, but I needed to be sure electricity was being delivery to the cassette. I disconnected the wiring plug into the cassette (by pulling out the red plastic retaining clip/fork). I attached an ohmeter to the terminal pins (with long thin probe clips). I wasn't at all sure what to do here (which pins, what meter setting) but I prevented the clips from touching anything (shorting), set the meter to DC and stood back. My son cranked the engine briefly and the meter jerked, so at least some current was being delivered (so I guess the coil was at least functioning). Okay, it now seemed worth the risk of buying a replacement cassette. The Saab dealer quoted $385 plus tax and shipping. eEuroparts listed a new one (Saab part #9178955, found on the old cassette itself) for $275 and a rebuilt on (one of those blue cassettes) for $170 (and no tax). Great, I felt even better about doing this myself for less than half the prce of the service center and ordered the rebuilt one (tauted to be as good as a new one). I ordered new plugs (BCPR7ES) at the same time. The online order was processed immediately and the parts were in FedEx's hands within hours (tracked at FedEx's website initiated by the confirmation email from eEuroparts). The package arrived and I installed the plugs in the engine (after checking the gap was 1 mm), mounted the blue DI cassette, talked nicely to my faithful charriot, and turned the key. Bingo!! Problem solved. She's running even better than before (may be my imagination or just the new plugs). Either way, I am happy, proud, relieved and wanted to post this to help anyone else in this simple but uncertain situation.
posted by 24.136.38...
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