I ended up taking mine out and inspecting it. I saw nothing broken, flap seems to function fine and didn't fall out even when I took out the metal pivot pin. Not sure if the flap just moves around or there is some tension?

So I just cleaned up all the gunk on it and snapped some photos for your visual inspection. I put the DISA back in. There are "3" Torx screws and not 2. I believe it's a T40 and I thought the picture would show the number on there but it didn't. I cleared all the codes and did a road test to include a short freeway drive. Nothing so far. I will let my wife know to tell me if the Service Engine Light comes back. Keeping my fingers crossed.

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2004 Gray/Gray 3.0 X5