AWR-fix: repair DISA for 20¢
 

Wife's car went into engine limp mode today. Indications were MAF or big intake leak.

I unplugged MAF and idle went from hell to useful and car drove ok except a transmission error kicked on (that was MAF error related)

Shifts were horrible. Slam shifting but I drove a bit then decided I'd rather have crap idle and good shifts so plugged MAF back in and drive home to a garage ..with MAF cleaner I picked up.

Put a glove on the air intake and blew and I could hear the air just venting like crazy

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(No smoke needed I could hear it just whizzing out)

Took off disa valve because it's a common leak and I've not rebuilt hers yet and it's way overdue.

Disa was blown. But rather than use the $230 part.or the $75 repair kit I used 18¢ worth of nuts and bolt

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6-32 1" screw with a #6 lock washer to help snug the screw head.

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(3) 6-32 nuts. Aligned while snugging tight and with thread lock to keep them in place. (unfortunately the mechanism twists in the direction that loosens the nuts).

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Some heat shrink tubing. The dimensions of the nut were about 0.3mm smaller than the inside of the flap. This was perfect. Tight fit I had to press in with force, no wobble whatsoever.

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Since the pin side also was wobbly, I drilled out the now conical holes to be nice and sharp cylinders and put some shrink wrap around the pin to make it fit perfectly. I intentionally didn't drill all the way so it was very snug at the end and is held tight in the flap and rotates on the disa frame.

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Measured the diameter of the disa valve seal and it was about 0.4mm smaller than the opening so I wrapped with 4 wraps of teflon. Made a perfectly tight seal

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You can test the valve function by sucking on the little vent hole. If you use a tiny tube it tastes better.

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Mid suck.

Oh: you need to of course fine tune the twist of the nuts (ouch) until the flap is 90° open with no vacuum applied and closed tight with vacuum applied.

So there, approximately 1/1400th the price of new part and 1/400th the price of the badass aluminum and titanium repair kit I used on mine.

MacGyver ain’t got nothing on you!

Man, and I just bought a brand new oem Disa and Maf.

MacGyver or "The Cleaner" have been my nickname at times. I already knew from the excellent $75 kit what it's supposed to look like. There was literally nothing left of the hex part of the shaft.

“The Cleaner” makes me a bit nervous. LoL..

Nice repair! I am honestly Blessed that I have not lost the pin in my engine.

Nice work on making problems go away. Not even needing metric fasteners.

https://www.youtube.com/watch?v=-BBfxHZ8Xag

AWR-fix: repair DISA for 20¢
 

I looked at metric and sae. Sae was what fit. I actually started with a #10 self tapping screw, the head fit great but I didn't have a good way to secure the screw. Awesome find on the Seinfeld take on the cleaner.