Guide for Direct Ignition cassette and spark plug service - all DI-equipped vehicles

Using non-resistor spark plugs could cause several different types of fault symptoms and driveability problems in the car. The DI uses the spark plugs to monitor the combustion process.
An incorrect spark plug gap (excessive wear) can also lead to driveability problems. Use of non-resistor spark plugs could also destroy the DI cassette.

! - Spark plug burn-off - !

Automatic spark plug burn-off is carried out with a burst of sparks each time the engine is switched off. Burn-off is carried out in all cylinders simultaneously and lasts for 5 seconds at a rate of 210 sparks per second.
! -This Is Lethal Current Use Extreme Caution- !

Therefore, it is very important to adhere to the following guidelines :

When replacing the spark plugs it's important to check following:

• First Allow 30 seconds for the module to power down then remove the electrical plug to ensure your safety.
• Always use resistor type NGK spark plugs. All Saabs equipped with DI cassettes have been specified with resistor type NGK plugs
• Verify the correct gap at the electrode (1.0mm -1.1mm)
• Check For oil leakage from coil assemblies. This would indicate a failed DI assembly.

Before installation of the DI cassette:

• Coat the rubber boots on the cassette with Krytox (P/N 30 19 312) or a name brand dielectric grease.
• Check to be sure that the contact springs can be seen inside the coil towers and replace them if they are damaged or missing ( P/N 91 67 032)
• Coat the thread of the spark plugs with Molycote 1000 (P/N 30 20 271) or high temperature anti-sieze.

Torque:

• Install and torque the Spark plugs to 21 lbf ft
• Fit the Cassette to the valve cover and torque to 8.1 lbf ft. Use Loctite removable threadlocker.

Recommended spark plugs for DI-equipped cars: 1990->

NGK BCPR7ES	91 12 541 NGK 1095	900 B204 TURBO (94-98) 9000 B202 TURBO with DI 9000 B234 TURBO 9-3 B204 TURBO 185 HP (1999) TUNED Stg 1-3+ B207L / B207R .9-1.0mm 9-3 SS B205R 9-3/9-5 B235R 9-3/9-5
NGK BKR8EiX	NGK 2668	Output 400-500whp Gap .8mm These Modern Iridium Plugs are tougher and resist fouling on short trips, a problem with cold plugs.
NGK BKR9EiX	NGK 2669	Even Colder High Output 500whp-700whp+ .8mm Gap
NGK BCR8ES		These non Projected tip are not the best option anymore for high output cars. Gap 1.0-.9mm
NGK BCPR6ES - 11	91 17 565 NGK 6779	9000 B234 Nat. Asp. with DI 9-5 B235 TURBO
NGK BKR7ES -11	91 71 307	9-5 B308 V6
NGK PFR7H - 10	91 88 681	Discontinued > Use NGKPFR6H - 10 Hard Use only. Prone to cold fouling on short trips. (HOT T7 cars) 9-3 B205 TURBO 185 HP (2000>) 9-3 B205 TURBO 205 HP 9-3 B235 TURBO 230 HP VIGGEN 9-5 B235 TURBO AERO
NGK PFR6T-10G		B207E / B207L .9-1.0mm 9-3 SS
NGK PFR6H - 10	93 99 866 NGK 6290	9-3 B204 TURBO 200 HP (1999) 9-3 B205 TURBO 185 HP (2000>) 9-3 B205 TURBO 205 HP 9-3 B235 TURBO 230 HP VIGGEN 9-5 B235 TURBO AERO
	*NOTE	"7" series spark plugs have a colder heat range than "6" series and are, therefore, commonly used as an alternative plug on cars consistently run at high speeds or under heavy loads. Running too cold of plug for short trips will lead to fouling. This is more of a problem in the winter. "R" in the NGK plug designation signifies resistor type this is very important. "P" in the NGK plug designation signifies Platinum electrodes. These are more expensive but last a bit longer. It is ok to run copper "C" plugs in the application that originaly had platinums as a cost savings but they will requre more frequent sevice.

If you have any questions please contact via email: parts at GenuineSaab.com
When Contacting us Include the Complete VIN if possible.