You could just remove the SAI system and live with the DTCs…
Won’t pass emissions here in phx.
I could’ve sworn the A4 guys were able to run a resistor in place of the SAI motor, and still remove everything else. Is that still a thing? …or am I making that up?
If you must reinstall the SAI, I still have all the SAI parts from my RS4 here in the garage.
You dont have to hook everything back up. Just plug in the pump. The pump dosent even need to work. The car just needs to see the pump. As for the rest of the stuff you dont need the combi valves or anything. Just the parts where there is electronic feedback
Hey just want to be sure I understand you right.
If I remove the combi valves and all the vacuum hoses associated with them I won’t get a check engine light?
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Update:
I got the supercharger back on and the front of the motor cleaned up.
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From there I got the flywheel, starter and motor mount back in.
I ordered a new wire harness. The old one was just junk. It was 13 years old and had been hacked to bits. Hard to see in the picture, but with all the hacked bits, broken connectors and broken wires it was just time, and since I’m replacing all this other stuff I mine as well do it right.
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Next up is to finish the other side header. I’m going to have to make a tool to get that one last nut on there. I think if you’ve done the headers before you’d know which one I was talking about, lol.
I’ve got to reinstall the alternator and oil cooler and then bolt back up the trans. I’m hoping to take next Friday and Saturday off to get it shoved back in the car.
Still got a long ways to go but it’s coming along.
Looking good great work. Time to toss that wire mess out. Good idea. Did you get new wire like brand new or just new used.
I feel your pain. I know 100% what your talking about on the bolts. The one bottom bolt and the top middle.
I could be wrong but I would expect to get secondary air injection insufficient flow codes if either the secondary air parts are not hooked up completely or the system isn’t coded out.
Yeah certain nuts and bolts suck with the headers. I struggle with the back header nuts and the upper rearward engine mount bracket bolts. The engine does look good though.
If you got a brand new wiring harness from Audi then that would really hurt.
I figured as much. No biggie. I don’t want to roll around with a CEL, so I’ll just put everything back on.
I did end up getting a brand new harness from Audi. It was the only was to do it right since the harness for the early '04 was different than the later models. There were just so many exposed wires and broken connectors that I would just be asking for trouble if I put it back on.
One issue I found out last night is the fuel injector clips. Whoever installed the VF injectors clips cut it so close to the clip that they can’t be reused. 
So now I have to order new injector clips.
Engine looks great now! Been lurking since you started the thread but glad your motor seems healthy even with the VF blower on. A new harness is gonna feel so nice to put in.
Just thought I’d add a word about the oil cooler. Forgive me if you were already gonna do this but make sure you use some of that nasty black sealant you used for the timing covers on the inlet and outlet of the oil cooler along with the o-ring. I made the mistake a year ago of just trusting the o-rings and have had a slow leak from that spot ever since.
About the SAI cel, it’s probably best you put everything back together so you don’t chance it. When I removed my SAI system, I ran almost exactly a year without the SAI delete option on JHM’s tune. I had a code pop up every 300 miles or so and just cleared it but I believe it was only a code for insufficient flow on bolth banks and I don’t think that a resistor in the sai pump plug would negate that
your deffinitly doing everything right. That is an expensive added cost for the wiire harnuss but its worth it in the end.
Update:
Finally got the tranny back on. That took a little longer than expected so , I didn’t get quite as far as I would have hoped.
Also, got the oil cooler and upgraded Hitachi Alternator on.
At this point, I just need to put the wire harness back on and she’s ready to put back in the car.
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With how hot those blowers car run that oil cooler was a great investment. The project looks great. Keep up the good work
Update:
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Finally got the motor back in. I ran into a couple of delays but once those were sorted and I was finally able to devote this morning to getting motor in. Pain in the ass. Lol. I almost forgot how little room there is for anything. Hahah.
Either way, I’ll spend this next week getting the wire harness plugged back in.
Still have a log ways to go because after looking at my notes I took of all the broken shit, knows the time it has to go back together…properly.
I’m hoping I’m only a few weeks away from starting her up…wish me luck.
Getting there. It’s hard to find the time with work and two kids. But, one step at a time.
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Got the exhaust back on and everything else that I could.
I found a few broken items and broken wires related to the radiator fans and such that I’ve had to order.
Everything is complete and ready at this point just waiting on those couple items to come in to put the front clip back on and hopefully get it started.
3 day weekend coming up next weekend and the timing couldn’t be better. Really thinking I’ll be able to get it running next weekend. Crossing my fingers.
running or at least close. It looks great. Its been a lot of work but you really have taken your time and it look like done everything right. The car would have taken a bigger turn for the worse had you not gotten in and done a lot of the work you did.
Glad to see this car in good hands. You’re doing a killer job man keep it up
Dude, all I can say is WOW!!!, great job and awesome thread, that blacked out covers look killer! You are almost home ;D
It’s getting there. All the parts I ordered to install were delivered after the 3 day weekend, lol. So I to wait until the following weekend. I finally got it started on Friday. I spent the weekend going through some odds and ends. No Chain Rattle!! A few small items to go through and I should be putting it back together and finally start driving it.
Update:…
She’s super close. Got her started and running. I don’t have a Vag Com yet but I do have a scanner. So I was scanning it and noticed something wasn’t right. Plus you can tell it was missing. So I had to spend some time trying to diagnose that.
It turned out to be a dead injector.
To Recap, I sent all of my working injectors to a company to be cleaned out and I get one back dead. GRRRR. That was the whole point of why I sent it out to be cleaned, to make sure I didn’t run into any issues with that. But I digress. I ordered a new injector and it’ll be here on Thursday.
Everything is else seems to be great. Nothing is leaking thankfully. Granted the car has only been idling with no load but still, baby steps. LOL. I’m really hoping to get all back together to take it for a drive this weekend.
As a quick recap on the whole:
New suspension, had everything rebuilt and revalved and springs replaced in the rear with better springs.
New brakes all the way around, that’s where all this started LOL
New supercharger, prior to diagnosing the chain rattle myself I had a shop look at it. They said it was the supercharger making noise. So I pulled it off and sent it to Magnuson to have rebuilt. FAIL, Clearly. You want something done right… you know the rest.
New subframe bushings, Solid mounts
New snub mount with zero space frame, or whatever it’s called from 034
New wire harness, not that it matters but it looks nice.
New Timing components, obviously.
A whole bunch of smaller new things that were replaced while doing this.
I still have a long ways to go though. Still needs new headlights and the number resprayed, just to name an easy expensive item.
Once thats complete, then it’s off to the interior. Again, long ways to go.
I had no idea I was going to be down this long but I’m getting excited so here’s hoping.