[TheSt|G]

Originally Posted by mmurray

Jumping in late one this one - read through the thread, but still unclear - is this a common failure? Sounds like it was an M52/4 issue but just an N52 issue in theory (besides the one guy's run-in with plastic bits)

We are just getting into failure age now, but his wasn't the first I have seen.

Originally Posted by tigermack

In other words, as long as it's still in one piece then it should be fine to remove without having to remove the manifold... thanks!

No. What he is saying is that there are two DISA units. One easily accessible, one on the underside.

[jc_bmw]

So I have my 3 stage intake sitting around waiting to be installed. When I remove the 4 screws holding the DISA valve it seems impossible to pull it out. Any idea how to?

[DickBlisken]

Originally Posted by jc_bmw

So I have my 3 stage intake sitting around waiting to be installed. When I remove the 4 screws holding the DISA valve it seems impossible to pull it out. Any idea how to?

I've got mine here waiting to be installed too. Once you unscrew it, don't be afraid to really pull, it took a bit of effort to get both of mine out.

[jc_bmw]

Ok cool, I had to use two plastic trim pry tool to get it off it was that tight! Didn't have the grip or leverage to just pull it off. Seems to be fine tight as hell. My one has the green gasket not the orange one and this is off of a 2006 530i with the older manifold (with the single port vent hose).

damn it is too cold too install the manifold.... itching to install it and probably get Eurocharged tune for it (local for me).

[tigermack]

Originally Posted by TheSt|G

No. What he is saying is that there are two DISA units. One easily accessible, one on the underside.

Shit, ok. lol

[FlowState]

Wondering how they will ensure the new metal piece won't break off.

Seems like the cause isn't being addressed, just a change of material. (not talking shit, I'm trying to understand what the fix is doing)

I'm looking to do the conversion still, so I can't help but wonder what the fix will do if I'm buying new DISA Adjusters.

[TheSt|G]

Originally Posted by DUI Elite

Wondering how they will ensure the new metal piece won't break off.

Seems like the cause isn't being addressed, just a change of material. (not talking shit, I'm trying to understand what the fix is doing)

I'm looking to do the conversion still, so I can't help but wonder what the fix will do if I'm buying new DISA Adjusters.

The problem historically is that over time the plastic degrades from heat cycles and constant oil contact. It eventually becomes brittle and breaks apart under the strain of intake pressure. Aluminium isn't going to do that on any realistic timeline.

The problem is being addressed if the fix is similar to their last iteration for the M54.

[11b330i]

Mine did the same thing as OP's car. I however figured the engine was toast. Bought a new engine for only 2,000$ (figured the head removal/repair would be just as much) put that engine in. Took this one apart. Same thing. A piece of plastic in the valve. Pulled it out, now I have a spare engine in my garage. I never replaced the flap that fell apart and the car still runs just fine.

[TheSt|G]

Originally Posted by 11b330i

Mine did the same thing as OP's car. I however figured the engine was toast. Bought a new engine for only 2,000$ (figured the head removal/repair would be just as much) put that engine in. Took this one apart. Same thing. A piece of plastic in the valve. Pulled it out, now I have a spare engine in my garage. I never replaced the flap that fell apart and the car still runs just fine.

I expect to see more and more of this as time goes on frankly.

[MarkkyyMan]

Adding more moving parts only increases these chances.

[GTKrockeTT]

if i end up getting the ESS supercharger, going to remove the 3-stage manifold for this reason alone.

[TheSt|G]

Originally Posted by MarkkyyMan

Adding more moving parts only increases these chances.

Yeah, I just fired off a followup email to GAS to see where they are in this. Last I checked they were still working to source a manifold.

[MarkkyyMan]

I sent them a message that I would be interested in a DISA solution.

[Three_thirty_I]

I know that the old M54 type DISA suffered from these failures but in most cases you could fix them when they became noisy (catch it before it totally fails), then there are the upgrade kits as mentioned. With these newer N52 type DISA flaps which are motorised and sealed, fixing is not an option.

I replaced both DISA flaps on my 330i in late 2012 in the process of trying to sort out my car's pinging rattle sound (was told by a specialist that it was the DISA flaps "fluttering") and the only concern that I had was that small portions of the green rubber gasket on the smaller of the two units had come off and no doubt been "consumed" by the engine! I am hoping that they simply vaporised during the combustion process and being as small as they no doubt were, simply passed through the open valves. Of course, these new parts made no difference to my problem, but glad that I did replace them ultimately. They have just become super expensive locally since then!

Inspecting the smaller unit is a PITA since the intake manifold has to come off in order to get to it, and you have to then replace the 6 intake gaskets and don't forget the green throttle body gasket. Then care has to be taken so that no dust or grit that typically gathers around the 6 intake gaskets find their way into the intake ports.

Now is when all sorts of random and not so random failures will occur, so hopefully third party suppliers are taking note and coming up with solutions that are better and hopefully more affordable than the OEM parts.

[TheSt|G]

Originally Posted by Three_thirty_I

I know that the old M54 type DISA suffered from these failures but in most cases you could fix them when they became noisy (catch it before it totally fails), then there are the upgrade kits as mentioned. With these newer N52 type DISA flaps which are motorised and sealed, fixing is not an option.

I replaced both DISA flaps on my 330i in late 2012 in the process of trying to sort out my car's pinging rattle sound (was told by a specialist that it was the DISA flaps "fluttering") and the only concern that I had was that small portions of the green rubber gasket on the smaller of the two units had come off and no doubt been "consumed" by the engine! I am hoping that they simply vaporised during the combustion process and being as small as they no doubt were, simply passed through the open valves. Of course, these new parts made no difference to my problem, but glad that I did replace them ultimately. They have just become super expensive locally since then!

Inspecting the smaller unit is a PITA since the intake manifold has to come off in order to get to it, and you have to then replace the 6 intake gaskets and don't forget the green throttle body gasket. Then care has to be taken so that no dust or grit that typically gathers around the 6 intake gaskets find their way into the intake ports.

Now is when all sorts of random and not so random failures will occur, so hopefully third party suppliers are taking note and coming up with solutions that are better and hopefully more affordable than the OEM parts.

Spot on.

I've actually offered my N52 DISA manifold to GAS for R&D. Hopefully they will take me up on it and we can get a lockdown rolling before someone grenades an engine.

[FlowState]

^I have 2 brand new DISA adjusters that I have not installed because I've been waiting to hear the news on this lol. Wondering if I should offer them up for R&D on this.

[TheSt|G]

Originally Posted by DUI Elite

^I have 2 brand new DISA adjusters that I have not installed because I've been waiting to hear the news on this lol. Wondering if I should offer them up for R&D on this.

Please do. And mention mine as well just to keep it on their mind.

[TheSt|G]

Looks like GAS has sourced a manifold on their own, so progress should begin soon I'd imagine.

[MarkkyyMan]

Originally Posted by TheSt|G

Looks like GAS has sourced a manifold on their own, so progress should begin soon I'd imagine.

[andrey_gta]

Originally Posted by TheSt|G

Looks like GAS has sourced a manifold on their own, so progress should begin soon I'd imagine.

Excellent. Their e46 solution is awesome

[TheSt|G]

Just spoke with GAS again. Their evaluation after opening up the adjuster is that the DISA unit on the N52 is even worse from a design standpoint than the failure prone units from the M54. The good news is they feel confident that they can fix them in a permanent fashion, but the downside is that the project is quite a bit more complicated than the M54 version and likely will require people to send in their DISA units.

Either way, I'm personally on board. DISA failures on the early cars are becoming more and more common, and seeing as many of us who retrofitted our manifolds did so from early model cars, the risk is widespread. And to be clear, I don't see this as limited to '06-'07, but rather that they are simply the oldest and first to fail.

[andrey_gta]

Originally Posted by TheSt|G

Their evaluation after opening up the adjuster is that the DISA unit on the N52 is even worse from a design standpoint than the failure prone units from the M54.

Unbelievable
I guess the Pivot point at the top of the flap is weaker than the metal pin of e46 days...