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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > NA Engine (non-turbo) / Drivetrain / Exhaust Modifications > 3 Stage Intake Manifold!



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      08-01-2017, 10:04 PM   #1
MotorenWerkeN52
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3 Stage Intake Manifold!

So I bought a 3 Stage intake manifold after two years of contemplating. I just couldn't justify the cost before but I recently found a used manifold that came with both DISA valves. Came off of a 2010 z4 with 55k (my E90 is a 2011 with about 80k on it).

Only thing I am concerned about is using the old DISA valves. I have heard horror stories of the plastic breaking and going into the cylinder head. Any input? Should I be worried?
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      08-01-2017, 10:29 PM   #2
Biginboca
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Just unscrew the valves from the manifold and look them over. They come right out. If they look good run them!
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      08-01-2017, 10:33 PM   #3
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Take them out and make sure there's no play in them at all, and that they are in good overall condition. There's Youtube videos on other tests you can do.
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      08-02-2017, 08:52 AM   #4
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Quote:
Originally Posted by N52UNED View Post
Take them out and make sure there's no play in them at all, and that they are in good overall condition. There's Youtube videos on other tests you can do.
This, the bushing and shaft the holds the actual flapper valve in place should be tight. I think in the few (really few) cases of a failure, it was caused by these components letting go. Just pull them out as other have already said and inspect. I believe there are some rebuild kits out there if it is indeed loose/sloppy. The rubber seals on the flapper valve are known to fall apart over time, if you see any loose rubber strands I would try and clean them up so they don't get sucked into the intake. Nothing much you can do to repair other than clean up. See this example of my old DISA valve that had a failed seal:

https://drive.google.com/file/d/0B8p...ew?usp=sharing
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      08-02-2017, 01:14 PM   #5
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The 3 stage manifold I bought from a yard was said to be in working order, but the large DISA was broken badly. I ordered a rebuild kit that uses all aluminum and steel parts, a huge increase in quality. You do have to pry the halves apart, replace the pieces, and melt them back together with some acid, but it worked like a charm. Most older manifolds will probably have some issues with the valves. Even as bad as mine was, the valves were still in position, and it didn't look like they were going to break apart and fly into the motor, but they certainly were going to work (at least the larger DISA). The smaller DISA looked basically perfect, but I rebuilt it anyhow since I was already in there.
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      08-02-2017, 01:52 PM   #6
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You really have nothing to worry about. 9 times of 10, the the hex base of the shaft wears away and the flap rotates freely on the shaft. It doesn't break like the older E46 design where the shaft/flap normally fell into the manifold.

The rebuild kit really doesn't help here either. The problem is the flap base, not the shaft base. The kits provide a metal shaft, but a plastic flap. I'd probably recommend epoxying the shaft and base together so they cannot wear away at each other.

You can see in the photos that the hex base on the shaft is perfect. It's the hex base inside the flap that wears. Honestly, I don't know why it's a 2 piece design to begin with.
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      08-02-2017, 07:17 PM   #7
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Thank you for all the information everyone! Very helpful
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      08-03-2017, 08:10 PM   #8
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Quote:
Originally Posted by tom.gnade View Post
The 3 stage manifold I bought from a yard was said to be in working order, but the large DISA was broken badly. I ordered a rebuild kit that uses all aluminum and steel parts, a huge increase in quality. You do have to pry the halves apart, replace the pieces, and melt them back together with some acid, but it worked like a charm. Most older manifolds will probably have some issues with the valves. Even as bad as mine was, the valves were still in position, and it didn't look like they were going to break apart and fly into the motor, but they certainly were going to work (at least the larger DISA). The smaller DISA looked basically perfect, but I rebuilt it anyhow since I was already in there.
Where did you bought rebuild kit ?? I got similar issue to yours
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      08-11-2017, 06:08 AM   #9
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Instead of starting a new thread i'm hijacking yours for a bit. I'm in the thougts of buying a N53 three stage manifold and I've come a cross one that i'm not 100% sure of if it will fit. I have a E90 325i 03/2009 with a N53 engine and the inlet manifold i'm looking at is from a E60 530i 2007 with the N53 engine. The information I got about the manifold is the following:

11618507239
51750610
752036907

And some pictures:



RealOEM is referencing to: 11617593004 for the 330i, but I got a feeling that the manifold from 530i with the same engine will fit. Am I wrong?
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