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Old 01-17-2012, 08:37 PM
gary@germanautosolutions's Avatar
gary@germanautosolutions gary@germanautosolutions is offline
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Location: Grand Rapids, Michigan
Join Date: Jul 2010
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Mein Auto: E39 528i, E60 M5
Oops, I forgot a couple of things. These are the instructions for the replacement seal.

The M54 has the main seal molded into the framework which is why BMW don't offer a replacement O-ring.

The molded in seal needs to be scaped out with small flat blade screwdriver or similar Non-sharp tool that will fit into the groove. After scraping the molded silicone out, you can use a fine-wire stainless steel or brass brush (Harbor Freight) to remove the little remnants. The groove should look like this when you're finished. Be careful not to scratch or gouge the groove. If you are retrofitting a new DISA you can skip this step and keep the new O-ring in stock for a future failure.

Once the groove is cleaned you can install the new O-ring. I squeeze some of the supplied grease onto my fingers, then work the grease onto the surface of the O-ring before installation. This not only helps ease the reinstallation of the DISA into the intake manifold, but also aids in sealing.

"I'm a little rascal on my Little Rascal"
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