The installation of the German Auto Solutions DISA repair & upgrade kit does not require any special tools, nor a high level of mechanical ability. The instruction presented here are very detailed and should allow anyone with basic mechanical skills to install the kit properly. We apologize to anyone with extensive mechanical experience who may think that these instructions are overdone to the point of explaining the obvious, but in order to be assured that someone with minor ‘Do it Yourself’ experience would have no trouble installing the kit we have gone overboard with detail and pictures
Please read the entire procedure through to the end to familiarize yourself with the process. It may seem like a lot of steps, but that’s only because there is so much detail provided. With the exception of cleaning your old DISA housing and removing the molded in housing seal, the entire procedure can be completed in about 15 minutes. If you cannot have a computer near by during the installation, please print off the PDF version of the instructions for reference before you begin.
Important!
This kit is NOT compatible with aftermarket DISA valves. Please verify that you have an OEM DISA valve before you begin the installation of this kit. An OEM BMW DISA valve will have one of the following part numbers on the main body of the unit – 7544806 or 7502269 for 2.5L versions, or 7544805 or 7502275 for 3.0L versions. It will also have the BMW logo just to the left of the part number.
Important!
Please check the parts list and make sure you have received everything with your kit. We go to great effort to make sure everything is packaged in the kit, but our shipping staff is human and can make a mistake. You don’t want to be half way through the install and find out that there is a problem.
Important!
Once you have removed the DISA valve from the vehicle, check the flapper valve that you received in the kit to make sure that it is physically the same size and shape as the one in your DISA. We have found several instances of 2.5L DISA valves having been installed into 3.0L vehicles by previous owners. If the size does not match, DO NOT start the kit installation. If the flapper valves are not the same size and shape you either have the wrong DISA valve in your vehicle or you may have ordered the wrong kit version. If you live in California and ordered a kit for a 2.5L vehicle and the new flapper is too small, you probably have the Ultra Low Emissions M56 engine which uses the 3.0L DISA Valve.
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