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all about DI's and failures (long)
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Posted by Dean (more from Dean) on Thu, 8 Aug 2002 12:02:19 Share Post by Email
In Reply to: Need Cables w/ the DI Cassette?, Brett, Thu, 8 Aug 2002 11:29:44
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The DI is used on the turbo engines. It sits on the plugs and there are no cable or rotor etc. Hence Direct Ignition.

The DI converts 12VDC to 400V and fires the small coils with the 400V. The DI also senses knocking condtions via the ionic resistance across the spark plug gaps. That is one reason why spark plugs are so important with the DI.

The DI's get cooked with endine heat and get lots of vibration. For vehicles with higher miles they seem to fail mostly in a band of 100000 miles to 120000 miles. But older vehicles with lower miles and lots of city driving hours are been seen where the DI's start to act poorly around 60-80000 miles. With higher miles the DIs' characteristically fail totally and suddenly. With lower miles they seem to lead to running and starting problems more than sudden death. Pinpointing the DI is not easy, but we are recognizing this as an event that is becoming quite frequent in the fleet. So it is suggested that if DI failure is unavoidable, to go get a new one and worse case you have a spare when the day comes.

The DI electonics are potted into the aluminum casting and the whole unit gets replaced. There are screws which you can remove and have a look see, but there is nothing that you can repair.

The 4 torx screws which secure the DI do get loose. Don't try to secure them by over tighenting them. Get some loctite blue and use that and tighten moderately with the torx driver in the trunk.

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