Following is a step by step to replace the DISA crank, flap and pin. This particular unit is from a 325, but the process is the same for a 330. This will not cover the removal of the DISA unit from the car.
X8R refresh kit, purchased on Amazon. The process should be similar for other kits, but there is one specific quirk of this kit. See step 6.
Step 1: Remove crank cover from front of unit. Gently pry up with a screwdriver.
Step 2: Remove lock washer. Use a screwdriver to pry it off, or pliers. The washer will not be reused with this kit.
Step 3: Gently pull the actuator arm up off the crank. Secure the arm in the retracted position with wire.
Step 4: Pull the crank out with pliers, it may take a small amount of effort. Do not have the actuator arm in the position shown in the photo!! Make sure not to break the actuator arm while removing the crank (why you wired it out of the way)
Excessive wear of the OEM crank.
Step 5:Use a thin blade, pick or screw driver to pry the pin out of the opposite end of the flap.
SPECIFIC QUIRK WITH THE X8R KIT
The X8R flap is cast aluminum. While a very nice looking piece, there is a problem with it. The outside of the main shaft casting is square the entire length of the flap. This prevents the flap from closing fully. The corners of casting must be ground down to allow the flap to fully close.
Step 6: Remove the old flap, fit new flap and identify where the flap needs to be trimmed. Mark the area.
Step 7: Grind the corners of the casting in the two locations, remove as little material as possible to allow the flap to close fully.
Step 8: Place flap in the DISA in the closed position. Liberally grease the crank and insert it. With the flap closed the crank should be in the retracted position.
Step 9: Apply loctite to the threads of the pin. Grease the pin journal in the back of the unit. Insert pin and tighten to hand tight plus a wee bit.
Step 10: Place actuator arm back on the crank pin. Install new lock washer. Install cover.
Step 11: Remove old silicone seal with a blade and pick. Lube the new o-ring and install (large orange o-ring in below photo).
DISA done, put it back on the car and enjoy.
X8R refresh kit, purchased on Amazon. The process should be similar for other kits, but there is one specific quirk of this kit. See step 6.
Step 1: Remove crank cover from front of unit. Gently pry up with a screwdriver.
Step 2: Remove lock washer. Use a screwdriver to pry it off, or pliers. The washer will not be reused with this kit.
Step 3: Gently pull the actuator arm up off the crank. Secure the arm in the retracted position with wire.
Step 4: Pull the crank out with pliers, it may take a small amount of effort. Do not have the actuator arm in the position shown in the photo!! Make sure not to break the actuator arm while removing the crank (why you wired it out of the way)
Excessive wear of the OEM crank.
Step 5:Use a thin blade, pick or screw driver to pry the pin out of the opposite end of the flap.
SPECIFIC QUIRK WITH THE X8R KIT
The X8R flap is cast aluminum. While a very nice looking piece, there is a problem with it. The outside of the main shaft casting is square the entire length of the flap. This prevents the flap from closing fully. The corners of casting must be ground down to allow the flap to fully close.
Step 6: Remove the old flap, fit new flap and identify where the flap needs to be trimmed. Mark the area.
Step 7: Grind the corners of the casting in the two locations, remove as little material as possible to allow the flap to close fully.
Step 8: Place flap in the DISA in the closed position. Liberally grease the crank and insert it. With the flap closed the crank should be in the retracted position.
Step 9: Apply loctite to the threads of the pin. Grease the pin journal in the back of the unit. Insert pin and tighten to hand tight plus a wee bit.
Step 10: Place actuator arm back on the crank pin. Install new lock washer. Install cover.
Step 11: Remove old silicone seal with a blade and pick. Lube the new o-ring and install (large orange o-ring in below photo).
DISA done, put it back on the car and enjoy.
DIY: DISA flap repair (X8R kit specific extra step)
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