DISA Upgrade Kit (Video)
- Thread starter StarSedz
- Start date
I did the DISA repair today using the i6 Automotive kit. Just a couple of tips that may be of interest -
The 'O ring' isn't really an O ring. It's a soft moulded seal which is made of the same material that is bonded to the inside of the recess for the DISA flap to seal to. Removing it is best done by scoring it around its circumference each side with a sharp craft knife or Stanley blade. The seal can then be picked out rather labouriously. I found the serrated edge of a trim removal tool ideal for this and speeded up the process no end. The supplied O ring can then be fitted.
I also recommend brake cleaner or carb cleaner and a small brush to clean the whole dirty side of the DISA assembly.
The centre bolt is supplied with a spring washer so Loctite may not really be needed. I did use it. The i6 kit doesn't come with any.
When it comes to pressing the E clip back on to the pivot arm the easiest way to do this is to press it on with a 7mm socket.
I used a smear of silicone grease on the pivot arm, the new O ring and the inner edge of the intake manifold. When pressing the DISA assembly back into the manifold you need to take care to push it squarely and firmly to avoid pinching the O ring.
The 'O ring' isn't really an O ring. It's a soft moulded seal which is made of the same material that is bonded to the inside of the recess for the DISA flap to seal to. Removing it is best done by scoring it around its circumference each side with a sharp craft knife or Stanley blade. The seal can then be picked out rather labouriously. I found the serrated edge of a trim removal tool ideal for this and speeded up the process no end. The supplied O ring can then be fitted.
I also recommend brake cleaner or carb cleaner and a small brush to clean the whole dirty side of the DISA assembly.
The centre bolt is supplied with a spring washer so Loctite may not really be needed. I did use it. The i6 kit doesn't come with any.
When it comes to pressing the E clip back on to the pivot arm the easiest way to do this is to press it on with a 7mm socket.
I used a smear of silicone grease on the pivot arm, the new O ring and the inner edge of the intake manifold. When pressing the DISA assembly back into the manifold you need to take care to push it squarely and firmly to avoid pinching the O ring.
Thanks for taking the time and effort in doing a vid 
Great vid! What time do the disa's tend to fall to pieces? I'm currently on about 32.5k miles and the cars ten years old in September. Probably not a bad shout to do it sooner rather than pay the price later?