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I fixed the problem. It was none of the fears I mentioned above; it was the damn DISA valve.
I ordered the G.A.S. DISA repair kit and installed it - haven't thrown ANY CODES AT ALL. Well, here's what happened - my DISA flap LEVER broke in half. What I didn't realize was that the lever is hollow (has a hole running through it from outside the manifold to inside the flap. Well, this means that when you remove the DISA flap, the lever effectively becomes a hole on the side of the intake manifold (i.e. a vacuum leak). It was this that was throwing all the codes in my car; the DISA itself was the vacuum leak that I was trying to chase around.
Problem solved. So, the next time one of you have any sort of lean/rich, misfire, or 02 sensor codes and a rough idle, check your DISA valve first; especially because it's the quickest and easiest thing to check. If the DISA is broken, it's more than likely the reason your car is throwing those codes.
I am so impressed with the build quality and obvious durability of the G.A.S. kit that I'm ordering two more kits; one for each of my other M54 cars. Brilliant.
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10-07-2012, 07:44 PM
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