Why the German Auto Solutions BMW M54 DISA Repair and Ugrade Kit costs more - and is Worth it!
We have examined most of the cheap import kits currently on the market, and discovered that most of them get several critical dimensions wrong. German Auto Solutions designed and started manufacturing the first all metal DISA repair kits back in 2011. Since then, a number of other companies across the world have copied our design. The problem is that most of them failed to reverse engineer our product correctly. Couple that with the typically poor manufacturing accuracy and quality control of these import kits, and you end up with an inferior product that can actually cost you more money in the end.
You probably purchased a BMW vehicle for it’s engineering and build quality. Wouldn’t you want the repair parts that you purchase to maintain that same level of quality? Continue reading to find out why the G.A.S. DISA Repair kit is the absolute highest quality kit on the market! Continue reading to find out why.
The DISA CNC Machined Bellcrank Lever
A – This diameter is critical. If too small, the housing seal could leak, especially when coupled with a typical amount of wear of the housings Teflon bearing. If it’s too large, it can cause too much friction against the housing seal, resulting in binding.
B – Almost every other kit on the market gets this very critical dimension wrong. This section of the bellcrank lever actually has a very small taper. It’s not even visable to the naked eye. It’s needs to have this taper, because the Teflon bearing that it pivots in, has a taper! Without this taper on the bellcrank lever, the lever will either bind in the Teflon bearing, or only contact the bearing surface at it’s smallest diameter, resulting in rapid bearing wear and bearing failure.
C – Both the size, and shape, of this tapered hexagonal area are critical. It has to mate perfectly with the matching pocket in the flapper valve. See the next section for an explanation.
The Flapper Valve and Bellcrank Lever Critical Fit
The pocket in the bottom of the DISA kit flapper valve has to be a perfect match to the hexagonal protrusion on the mating bellcrank lever. We designed the flapper and bellcrank lever that way to ensure that once the two parts are assembled together, and the pivot screw is tightened, they become securely locked to each other.
D – If properly manufactured, there will be a small gap between the DISA flapper valve and bellcrank lever as shown at point “D”, once the parts are assembled. If the male taper on the bellcrank lever is too small, or the female pocket in the DISA valve is too large, The two tapers will never be able to lock together.
We have seen two different failures here with the import kits. 1) – Some kits don’t even use a taper here. The bellcrank lever hex just slides into the flapper valve and cannot lock the two parts together. 2) – Some kits are manufactured as explained in the previous paragraph above. The bellcrank lever bottoms out on it’s shoulder, and is not able to lock on the taper. Either of these can result in premature failure. If the kit you purchase doesn’t have a gap at point “D” once assembled, I wouldn’t install it into my BMW.
The Stainless Steel Pivot Screw-Pin
E – This section of the pivot screw replaces the steel pin of BMW’s original design. If this diameter is tool large, it can push out the bushing that it rides in during installation of the screw. If it’s too small, it will result in a loose fit, and rattling of the kit parts during engine operation. We hold a plus or minus 0.001 inch tolerance on this pin section, and we measure 100% of the screws we machine.
F – In our design, we reduce the diameter of this middle section of the screw. We do this to reduce the resonate mass of the kit components. Many of the import kits do not take the extra effort to do this.
We include things in our kit that others don't!
The German Auto Solutions DISA repair kit includes EVERYTHING you need to install the kit and repair your DISA valve, except the few tools required.
What’s not included in most of the import kits:
- Cotton swaps to apply lubricant and Loctite
- Coarse thread lag screw to remove stock bellcrank lever from DISA assembly
- Lubricant packet to lube bellcrank bearing and housing O-ring
- Twist tie to aid in repair kit installation procedure
- Threadlock for the pivot screw. If they do include this, it’s not a top quality brand like “Loctite”
The bottom line is…. the German Auto Solutions DISA Repair and Upgrade Kkit is100% designed and manufactured in the United States, using the highest quality materials, with strict quality control over critical dimensions, and includes items that many other kits do not. The old saying, you get what you pay for, stands true. The German Auto Solutions kit is worth every penny!