May have solved both problems although more work likely needed.

Discovered a 1-2 inch crack in the air filter housing box, covered it with duct tape.

Jiggled the connecting wires to bank 2 O2 sensor (these were butt connections previously repaired from heat damage). Will check for continuity and suspect connection later.

First startup the Check engine light never reappeared. 70 miles today, nothing.

A little surprised that the air filter box might create a vacuum leak but maybe I guess?


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Replies to others- I’ll check the air pump, I seem to recall there is a small vacuum line to it that I pulled loose while working on the O2 wiring once. Maybe again or compromised hose.

My DISA passes the simple “holds vacuum” test but there is another test that requires a vacuum being applied and injecting 12v to the connector causing the motor to activate and close the DISA flap. Mine failed that but so did a replacement DISA so good chance I did the test wrong.

Thanks to all for the help.


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If the first test works then applying power to the solenoid should let the flap open when closed(activated with vaccuum and no power.) Your DISA is likely fine.
Butt connectors are likely a big part of your problem.