Few pics

 

few more

 

one more.

 

uh... wait a minute... doesnt my actuators have to be on to close those 2 holes???

 

Ok, I see you have played with removing the ACV. Why dont you get rid of the rest of the rats nest like those four solenoids and the AWS (i believe thats what its called,4th picture, above the oil filter with big hoses coming off of it). The AWS is what is responsible for the cold start shoot up to 3,000rpm for 15 seconds. I would start off by following the guide at rotary resurrection, remove all the junk you don't need since you already went half way, you will just be keeping your BAC and Thermowax and only have probably 1-3 vacuum lines to worry about in the end.

Since you removed your 5/6th port actuators, you need to take out the sleeve inside the lower intake manifold, i am not sure if you have done that. They are a thin metal cylinder that just slips out. Otherwise your ports will be closed and you will lose power. Also since you did remove your 5/6th port actuators why not also wire the auxilary intake ports on the upper intake manifold (i believe this is s5 only though).

Also, I can't tell from the picture but since you already have removed the rest of the emissions you would need to remove the Purge valve that is located right next to the oil filler tube (black disc shaped with hoses). Then you will just need to run a catch can off of that hard line coming off the filler tube.

Well basically like I said, you removed the ACV, alot of that stuff is not working anymore and you still have it plugged in and it is just sitting there doing nothing.

Follow the rotary resurrection guide, except don't block off the coolant lines and don't do the throttle body mod and keep the BAC. If I were you I would keep the EGR blocked off, you already removed the main emission components.

I suspect alot of why the car is running rough is because you have components that use to use the ACV and now that you removed it you still have them running to vacuum when they usually were controlled by the ACV.

At the end of removing everything, on my s5 I only had to run vacuum lines for the fuel injector and oil injector air bleeds, and these were all tee'd into the intake manifold getting FRESH air (NOT VACUUM) through the throttle body gasket hole in the middle (shown on the guide). Also one extra line going to the vacuum for the double throttle diaphram and the other going to the thermowax.

Let us know if you have any questions, you should have everything capped of and will have less things to worry about, even less than you have now.

Here is the link for the s4 n/a:

http://www.rotaryresurrection.com/2n...s_removal.html

Edit: By the way, I am telling you this based off an S5, I was looking at the rotary resurrection guide and he kept the 5/6th port actuators I know on the S4's they are controlled via exhaust gas velocity so you might still be able to keep those, hope someone else can clarify this part....

 

dang I didnt realize I should remove all that stuff. But the thing that bugs me is it was running GREAT before...

 

Your first post says, you were putting the egr back on because it wasn't running right, when did you remove the acv and airpump stuff and did it run right after you did that?

You might want to buy some new vacuum hose, 10feet will be more than enough. Also order/buy a cap kit like this one:

http://cgi.ebay.com/ebaymotors/121-P...QQcmdZViewItem

 

oh yeah the ACV was gone a long time ago.

 

Okay im taking everything apart now. and I noticed that when I put grease on my lower intake manifold gasket there was a little too much. And I dont think I had my aux port sleeves in right. lol but other than that I cannot find anything wrong.

 

So you checked and all unused vacuum lines are blocked off (on the mannifolds)? Did you leave the EGR on or just removed it again and blocked off? On your blockoff plates did you make sure to either use gasket sealer or an actual gasket? All components connected?

 

Yes, all open lines are blocked off. EGR is still on with good gasket and new hose. all new gaskets (LOWER UPPER AND ACV) All components were connected. in my last time taking it apart (yesterday) I realized the 2nd time when I took it apart (last week?) I tore it all down... except I didn't look behind the new lower manifold gasket...

I found the problem. I didn't get ALL the old gasket off the block. So on the forward side of the motor where the mounting bolts hold the manifold onto the motor, there was still some of the old gasket there. I didn't see it because of the vacuum lines from the spider were in the way. But yesterday I looked over EVERYTHING and for me this was a total dumb mistake. I usually pay very close attention to detail and something like this would never go over looked. Needless to say. I got it running. I played with the adjustments after I got it going and decided that my idle at 1000 rpm is good for now. but wow it runs smooth. Next is going to be ATF treatment & oil change... then 3" straight pipe from header =D

I love it when we have 3 paychecks in one month...

LESSON LEARNED. CLEAN ALL REMAINS OF OLD GASKETS AND USE WIRE BRUSH TO GET ALL EXCESS BUILD UP OFF. A little bit of patience will go a LONG way. Thanks for all your guy's help and support.