Boost Proofing the DISA
These instructions will go in conjuction with rebuilding your DISA with the German Auto Solutions rebuild kit.
The DISA is so big because the housing itself is a vacuum reservoir. It's used to actuate DISA when there is no vacuum in the intake plenum. You can switch DISA up to 3 times when there is no vacuum.
Using a soldering iron or plastic welder, plug the hole that feeds to DISA air. You should be able to shut the hole without any filler material needed. However, to be safe you use can any PA6-GF30 donor piece of plastic.
Carefully drill a hole into the side of the DISA with 5/16" drill bit (ideally you want to use an "R" drill bit) and then tap with 1/8" NPT. Once finished, be sure to clean out all plastic shavings that fell into the housing. Shake out as much as you can then blow out the rest with compressed air.
Thread in your 1/8" NPT to 1/8" barb fitting. Make sure to use the thread sealant you purchased mentioned in part 1. You will utilize the existing port on the back of the intake manifold that was used for the secondary air pump. You can remove the solenoid as it will serve no purpose for us but you will keep the check valve. Simply connect from the back of the manifold, to the check valve, to the DISA and you're all done.
1 and 2 will be used or capped depending on what accessories you choose to have (boost gauge, BOV, FPR). 3 will be removed and 4 will be kept. The line running to the solenoid (3) that gets removed is what will now go to the DISA.
This is another example provided by somebody who did the modifications listed above.
The DISA is so big because the housing itself is a vacuum reservoir. It's used to actuate DISA when there is no vacuum in the intake plenum. You can switch DISA up to 3 times when there is no vacuum.
Using a soldering iron or plastic welder, plug the hole that feeds to DISA air. You should be able to shut the hole without any filler material needed. However, to be safe you use can any PA6-GF30 donor piece of plastic.
Carefully drill a hole into the side of the DISA with 5/16" drill bit (ideally you want to use an "R" drill bit) and then tap with 1/8" NPT. Once finished, be sure to clean out all plastic shavings that fell into the housing. Shake out as much as you can then blow out the rest with compressed air.
Thread in your 1/8" NPT to 1/8" barb fitting. Make sure to use the thread sealant you purchased mentioned in part 1. You will utilize the existing port on the back of the intake manifold that was used for the secondary air pump. You can remove the solenoid as it will serve no purpose for us but you will keep the check valve. Simply connect from the back of the manifold, to the check valve, to the DISA and you're all done.
1 and 2 will be used or capped depending on what accessories you choose to have (boost gauge, BOV, FPR). 3 will be removed and 4 will be kept. The line running to the solenoid (3) that gets removed is what will now go to the DISA.
This is another example provided by somebody who did the modifications listed above.
