What are N52 DISA valves?

The 3 stage intake manifold (3sim) or "330i conversion" is a popular OEM upgrade amongst N52 enthusiasts worldwide. The manifold utilizes small electric actuating valves called "DISA" valves to close off sections of the manifold to change the length of air travel to the intake runners. Optimizing airflow for different engine speeds to increase horsepower, torque and efficiency. This intake manifold is also standard equipment for N51 SULEV engines. Unfortunately, it is common for 3 stage manifold users to experience DISA valve failure. This causes reduced power output and sometimes results in the DISA valves separating into multiple pieces inside of the intake. Debris from the broken DISAs can get pulled into the engine and could potentially lead to complete engine failure.

After researching and testing the OEM-style design, I identified its main flaws and narrowed down the three most common failure points. I then reached out to Chris from Printables Auto to create a model based on my proposed solution with additional help from Nick at TortSport. The result is the "Lifetime DISA"

The OEM Problem and the "Lifetime" Solution

The most catastrophic DISA valve failures are related to the gear "pin" that dictate the "flap" orientation. The OEM pin is a thin, hollow plastic piece with a small allen hex shaped key that slots into the flap to hold it in the open or closed position. The short duration hex shape experiences all of the torque on a small area, and is prone to rounding out over time. Which prevents the flap from rotating, or staying open or closed. Being made out of thin hollow plastic, the pin is prone to snapping after years of continuous use and heat cycles. Some DISAs feature a shorter plastic pin and a small metal top dowel, but experience the same failures which result in even more pieces loose inside the intake.

The LIFETIME DISAs feature an all metal TORX PLUS keyed pin that slots firmly through the entire duration of the flap. The improved driver and grab duration eliminate the possibility of rounding out, and the all metal corrosion resistant 6061-t6 aluminum eliminates the chance of the pin snapping. The pin was also designed as a single piece so there is no possibility of any small components loosening up and becoming free within the intake. The design is overengineered to never experience failure.

The Lifetime DISA flap is 3D printed from PAHT-CF which is a composite of PA12 and carbon fiber. This filament has excellent strength and heat resistance with a heat deflection temperature of around 381F (194C) as well as excellent chemical resistance against oils and grease. The flap maintains the OEM waffle style grid for structural support, and increased turbulence for the midrange. The key slot is modified to accommodate the torx plus shape of the pin. The material is highly durable and is resistant to cracking or rounding of the axis.

The Lifetime DISA valves are installed with upgraded shaft seals made from 95a TPU and also feature a 3mm capped drain plug at the low point of the cases to monitor if oil surpassed the seal. Consider opening drain plugs every once in a while to ensure a long lifespan of the motor.

PREORDER INFO

The Lifetime DISA Set is currently a preorder item. After the preorder window has closed (12/16/25) the manufacturing order will be placed. Please anticipate approximately 1 to 1.5 months for manufacturing and assembly before the items are shipped. You will receive a confirmation when your order has been shipped. Prices after preorder window are potentially subject to change. 

2 Year Service Warranty

Being that this is a newly designed product, it is possible that small issues can occur. We believe all the bases are covered, but if an issue occurs from normal use scenarios within 2 years of purchase date, the item can be mailed back to InlineV6 at buyers expense for a free repair or replacement. It is still highly recommended to run an oil catch can and keep your PCV/CCV in good working order in conjunction with this product. If any issues occur, please email Ultimatebimmerexperience@gmail.com so the problem can be addressed.

Features:       

Single Piece Billet Aluminum Rotating Pins with Torx shaped key

3D Printed PAHT-CF High Temperature Resistant Flaps

Torx shaped axis slotted through entire flap. Impossible to round out! 

OEM style Flap turbulence grid

Upgraded 95a TPU Shaft Seal

3mm drain plug in the event of oil intrusion

Fully assembled using Aftermarket DISA electronics / shells

Hand assembled with high temperature resistant lubricant and sealing 

2 year Service Warranty (for normal and recommended use cases)

Flaps manufactured by Printables Auto

Pins manufactured by Tort Sport

Assembled in the USA by InlineV6

Disclaimer: Product photos are not fully assembled prototype variants. Final product might differ slightly.