The Problem:
The DISA valve, otherwise known as the “Intake Manifold Adjuster Unit”, is located on the side of the intake manifold and is a common failure on the M54 BMW engines. The failure is caused by the type of materials used in the manufacture of two of the three key DISA valve components.
During normal engine operation, vibrations from pressure pulses inside the intake manifold cause the bell crank lever and flapper valve to vibrate against each other where the hex shaped portions contact each other. These vibrations start a wear process which will cause the tiny glass fibers in the flapper valve to become exposed. Once the fibers become exposed they start to erode away the male hex portion of the weaker bell crank lever. As soon as the erosion starts it’s all down hill from there until the hex is completely worn away. The symptoms of a worn DISA valve include rough idle, lean engine codes and lack of low to mid rpm power.
If you disassemble a worn out DISA valve and look at the bell crank lever it’s common to not even recognize that it once had a hex shape on the protrusion. Once the hex is shape is worn off the lever, the flapper valve no longer opens and closes in a controlled manner by the rotation of the bell crank lever. The brittle flapper valve becomes free to slap around uncontrolled within the DISA support framework. This uncontrolled movement can lead to complete destruction of the flapper valve. The broken pieces of valve have no where else to go except through the intake manifold runners and through the motor, sometimes resulting in severe engine damage. Even a small piece of plastic broken off the flapper valve can hold an intake valve open, resulting in bent valves or much worse.
Since the only parts on the DISA valve that typically fail are the flapper valve, bell crank lever and housing seal, why replace the entire unit. Replace the failed internal parts with our upgraded parts and have a much more reliable DISA for 1/3 the cost. At German Auto Solutions we thoroughly analyzed the DISA valve and engineered a solution that addresses all the weak points of the original design.
OEM BMW DISA Valve
The Solution:
The German Auto Solutions DISA repair kit features the following improvements over the original design:
- The plastic flapper valve has been replaced with a black anodized & stress relieved 6061-T6 aluminum flapper valve that is twice as strong and many times less brittle than the stock part it replaces.
- The plastic crank lever has been replaced with a black anodized 6061-T6 aluminum bell crank lever that is four times stronger than the stock part it replaces.
- The flapper valve and lever lock together on a precision machined hex shaped taper & are screwed together, instead of just snapped together like the original design. Locking the parts together prevents any possible movement and wear between the two pieces, the #1 cause of failure in the stock design.
- The parts are securely locked together by a custom, light weight, custom pivot screw that’s held captive from outside the housing. The custom pivot screw also replaces the stock steel pin of the original design. Since the pin is part of the pivot screw, and the pivot screw is held captive from outside the DISA housing, there is no longer a possibility of a steel pin coming loose and getting sucked into the engine.
- OEM running clearances are reduced to minimize vibrations.
- All parts are precision CNC machined to very close tolerances in the U.S.A.
- The kit is installable by anyone with basic mechanical skills, using basic hand tools. Very detailed step by step instructions are provided using the link below.
- The kit is priced at about 1/6 the retail cost of a new DISA valve from a BMW dealer. Remember, a new stock DISA can still fail prematurely.
- The kit includes all parts and hardware, plus a new main DISA housing O-ring seal, proper spec’ed tube of threadlock compound, tube of synthetic grease, cotton swabs applicators & a twist tie to aid with the installation process
G.A.S. M54 DISA Repair Kit
$69.95
G.A.S. M54 DISA Valve Repair Kit
BMW has increased the price of the OEM DISA Valve from the original price of $239.00 to a current retail price of over $400.00. The G.A.S. DISA repair kit is a $330.00 or more savings over the cost of a new BMW replacement DISA Valve.
NOTE – OUR REPAIR KIT ONLY FITS OEM BMW DISA VALVES!
THE KIT IS NOT COMPATIBLE WITH DORMAN, VAICO, REIN OR URO BRAND DISA VALVES!
$69.95
See What Our Customers Have to Say About the G.A.S. DISA Repair Kit
24 Reviews for GAS M54 3.0L DISA Repair and Upgrade Kit for 'OEM BMW' DISA
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Peace of mind and confidence.
Wednesday, October 9, 2024
I purchased two DISA repair and upgrade kits for the OEM BMW DISA (a 2.5L & 3.0L) and found the components to be very well made, precise / exact fit and easy to install. Turns out that my DISA valves were in good condition but I wanted to ensure that I won’t have a future failure and the kit(s) gives you the peace of mind and confidence that these parts can’t fail! Plus, thank you for such great instructions!
Thank you German Auto Solutions -
High quality kit and better engineered than original.
Saturday, October 5, 2024
I couldn’t recommend this upgrade more! Not only a better design and higher quality than original, but a fraction of the price of buying oem replacement. Also it is a great peace of mind not having to worry about a pin falling out and destroying your engine.
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Repeat happy customer
Thursday, September 12, 2024
I bought this same kit 8 1/2 years ago and removed that DISA to swap into my "new" E39 with an utterly failed flap mechanism. It is still tight as a drum. This order was shipped and arrived quickly. I'm confident it will work as well as the first This new kit looks as well made as my first - no "thrifting" with reduced quality.
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Quality-Brilliance and a money saver in one Kit! Bravo
Wednesday, September 4, 2024
This is as good as on Anything that can save your M54! Well maybe a quart of oil when needed. This repair and a drilled oil pump nut. May save you from walking home some day. Thanks! GAS two thumbs up
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Superb Product
Friday, March 22, 2024
Order Number: 16215
Original OEM DISA gasket was worn and resulted in a vacuum leak. I was impressed with the GAS repair and upgrade kit as it was well engineered and constructed of superior materials; better than the original design and materials. The instructions were well written and included relevant pictures, and included functional checks of the DISA. Highly recommend. -
A simple, robust solution to protect your engine. 2002 530i
Wednesday, January 31, 2024
As a BMW tech who first trained on the M54, I've lost count of the number of DISA valve swaps I've done over the years. Not to mention the number of engines I've had to replace, because it swallowed the broken pin after the valve failed (including my own car). I first encountered the G.A.S. upgrade as I was doing a complete reseal of a customer's intake manifold, when I pulled the valve to swap the O-ring. The minute I laid eyes on this thing, I was sold; quality parts, had been in the car for years, and was still in better-than-new shape. First reseal I ever did without having to replace the valve! One of the other techs recognized it and I was able to find the website and place an order before I even put my customer's valve back in. (Order ID 15996)
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Great upgrade. 2005 BMW 330Ci
Monday, November 20, 2023
I successfully upgraded my OEM DISA valve with this kit. The only thing I would recommend to upgrade the lever extractor, it is short to pull out the lever out. I had to buy a long screw hook from Walmart, it helped successfully extract the lever.
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Excellent quality and instructions, 2005 330i
Tuesday, October 31, 2023
So happy with my purchase. The instructions were very detailed and thorough which gave me the confidence to do this job. The quality of materials is excellent as well.
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Great - 2002 330Ci
Wednesday, July 5, 2023
Great price compared to a replacement DISA. Fantastic instructions, very thorough and easy to follow.
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Very Pleased with Product and Installation Instructions.
Tuesday, May 9, 2023
Ditto: This product is outstanding. The instructions on the website were incredibly detailed, and installation was a breeze. The parts arrived early, were incredibly well made and vastly superior to the stock item, I do not have enough positive things to say about this product or the company who made it, very pleased.
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Great upgrade - 03 Z4 3.0i
Sunday, March 5, 2023
Amazingly engineered solution to DISA valve issue. Great quality of product and instructions.
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Simple fix
Saturday, February 18, 2023
This was a simple overhaul (except for cleaning the old gasket off, that took a while). Instructions online were clear, and everything fit as expected.
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2002 330ci
Tuesday, November 29, 2022
Quality kit. Was able to rebuild my worn out, original 209k DISA valve back to better than new condition.
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Fantastic—2002 330xi
Wednesday, November 2, 2022
(Brian Mattson Order No.13983)
I really, really didn’t want to buy a cheap Chinese DISA replacement, but I also find a BMW OEM replacement hard on the budget. So… repair my original with upgraded parts? Yes, please!
What a tremendous service, G.A.S! Instructions were clear and easy, and I had the new and improved DISA installed in half an hour. Couldn’t be more pleased! Many thanks.
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Simply Outstanding - 2006 BMW X3
Monday, May 30, 2022
Individual parts and all needed supplies included in the kit. Straightforward instructions...very easy to follow. Kit is well made and will surely last a long time. Highly recommended!!!
Order #13396. -
Excellent Quality - 2001 BMW X5
Saturday, May 21, 2022
Order ID: 13335
Top Notch attention to detail and quality. An obvious improvement over stock design. My stock valve with 165k miles on it had completely failed. Bell crank was rounded and non-functional, pin in bottom slid right out when I removed the valve... Kit includes name brand thread lock and grease, and all pats necessary for installation. Install guide is straightforward and easy once you have the parts in front of you. -
Love the fact that it's US made!
Sunday, July 14, 2019
Kit came the next day, the instructions are great, everything needed for the install was included, E46 runs great now, very happy.
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Better than buying an OEM part
Saturday, June 15, 2019
Yes,Better than buying an OEM part for 350.00 or cheap one for 120.00
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Very Happy
Friday, May 10, 2019
Company was quick to reply and solve my issue! Great service!
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works perfectly
Thursday, May 2, 2019
Item arrived as represented. It was installed and works perfectly.
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Very Happy
Friday, April 19, 2019
The material on the valve was perfect. Easy instructions and a great way to prevent your motor from potentially blowing up
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works great!
Thursday, March 7, 2019
works great!
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Definitely recommend
Thursday, February 28, 2019
Delivered before estimated delivery date and item is exactly as described. Definitely recommend.
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This product is outstanding!
Monday, January 28, 2019
I don't normally leave reviews, but this product is outstanding, the instructions on the website were incredibly detailed, and install was a breeze. The parts arrived early, they were incredibly well made and vastly superior to the stock item, I do not have enough positive things to say about this product or the company who made it, very pleased.
10 Reviews for GAS M54 2.5L DISA Repair and Upgrade Kit for 'OEM BMW' DISA
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Top quality product
Tuesday, April 23, 2024
Michael Werths
Truly anupgrade over -
Excellent Kit for 2004 325xi
Thursday, April 11, 2024
Easy to install, very high quality, instructions were clear and concise, great price fast shipping. This kit gives you piece of mind for the OEM ticking time bomb that could ruin eng. Matthew Boudreaux
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Fast shipping high quality- 2003 BMW 325i
Wednesday, March 27, 2024
My dad was having issues with his BMW cold idle and stumbling off the line and after diagnosing the issues he was having and reading a few forums, I traced it to a broken factory DISA . The shipping was extremely fast, and my dad said it was very high quality and I didn't realize it was aluminum until he told me! Very pleased with GAS, if I need more parts in the future I will definitely purchase from them again!
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Mystery Unsolved 03 BMW 330i
Friday, June 9, 2023
So I bought a 2003 BMW 330i and went through GAS for Disa upgrade kit. Went to install flapper and did not work. After looking at the Disa Valve I saw part number 7544806 which is a 2.5l. In did not know the engine swapped before purchase was the 2.5l. GAS customer service helped me figure it out. Returned other kit and purchased right one. Works without any issues. Order from here!
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Well designed upgrade
Friday, February 24, 2023
Installation was very straightforward and much better designed than original
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Solid product e46 330i
Thursday, November 24, 2022
Jonathan carrasco
Hands down the best you can buy. Solid engineering and you can tell it will definitely last a life time. Have 2 kits installed on both my bmws -
Awesome Kit! - E46 325i
Wednesday, August 14, 2019
Your DISA rebuilding kit was part of an overhaul of the CCV system in my 325i.
I worked with a friend who is a Senior Engineer for Pratt & Whitney aircraft engine company. Between the two of us we have over 80 years experience of working on cars. Neither one of us has ever come across such an incredibly highly engineered repair kit for an auto part. You have thought of and included virtually everything necessary to rebuild and install the valve. -
Love the fact that it's US made!
Sunday, July 14, 2019
Kit came the next day, the instructions are great, everything needed for the install was included, E46 runs great now, very happy.
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Better than OEM
Saturday, June 15, 2019
Yes,Better than buying an OEM part for 350.00 or cheap one for 120.00
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worked out good
Friday, May 31, 2019
worked out good, high quality kit
