DISA Nightmares

[TECN1K]

Well - I wish I never read about the catastrophic damage a failed DISA valve can cause - it's like a silent killer...

A bad DISA valve can cause a variety of issues, from a loud racket in the engine bay, hesitation at low rpm and a rough idle with lean codes.
If the valve is making a loud noise, we recommend replacing it as soon as possible. It is possible for the pin holding the flap to be sucked into the motor causing serious damage.
Very easy to replace, just need to undo the 4 bolts holding it to the intake manifold.

With that being said, I'm replacing mine if it needs it now or not - ordered a Vaico (OEM) kit from ECS, on sale to boot - and it looks like a brainless replacement... except

How the hell does the electrical connector come off

*Edit - You push in the metal clip on the inside facing the DISA. You do not pull it. Repeat - do not pull.

This thing is filthy - but the pin is still intact, and it still has spring to the flap. It may not be bad, but considering the headache they'll cause, it's worth replacing. It has traces of silicone sealant, so the previous guy was chasing an air leak due to the collapsed O-Ring.

[cn90]

I use the rebuild kit from German Auto Solutions.
It cost me about $85.

[g300d]

Yeah, caught mine chasing a whistling sound at idle.

It was about to fall apart when I pulled it.

As mentioned the rebuild kit is a good proven option if you catch yours in time and the flap actuator is still working as it should.

[Kristophe]

I too used the G.A.S DISA kit. Very good improvement.

[tmv]

Another G.A.S kit user, on my old 3.0i

[Ricky Bobby]

^x3, gives you a much better O-ring on the kit as well, rebuild your OEM one for half the cost of that new aftermarket unit and no pin to ever fall out

[TECN1K]

Looks like I'm getting good at having spare parts to tinker with. Ordered the replacement - so I'll have the original unit to install the kit on. Hit up my hardware store and they had 60MM nitrile orings, so I'm back in business for a few days until the new one comes.

I'll look into that kit!

[TECN1K]

New part in - low end power has noticeably increased.

DISA was defiantly on it's way out.