[kolopn]

Hi!

NOTE: I know that this topic will not be completely DIY, but I wanted to share my experience with DISA valves and how I resolved shaft issue in DISA valves.

I had many issues flaps that were sucked inside engine (thankfully nothing more happened). I had enough of it, so I started to disassemble both small and big disa valves - Basically both units are the same in topic of electronic and gearing. Only difference is length of the big shaft.

Solution: I decided to go for reverse engineering, and I made two shafts from stainless steel. I tried several concepts - gear from plastic, gear and part of the shaft from plastic but rest from steel, but nothing was really robust, so I pick option to made everything from stainless steel.

Now I am after driving for 40 000km, and everything is working fine. I disassembled disa units to check if there is anything abnormal in case of this "double" gear that is made from plastic (factory part), but there is no additional wear at all.

Also worth noticing is the seal that is preventing oil from intake coming inside disa valve itself. Size is: 10x14x3 (millimeters).

Machined shaft itself designed by me:




Assembled shaft inside DISA with factory plastic "double gear" - Original Mahle double gear is very robust




Housing glued together, and secured with a few screws



If you have any questions feel free to ask!

Cheers!

[ChristianMoller]

Good work.
That looks very nice.
What module/pitch on the teeth?

merry christmas
Christian