1) car seems to level off after 4000 rpm, like my secondarys arent working, is there anything else it could be
2)car runs pig rich at idle, and i think it leans out under load
3)idle ajustment screw does absolutly nothing. i dont have a tps, is that it?
4)when i brake the idle drops
5)strait fuel lines, only getting 60 psi from pump
6) smokes on start up, and needs throddle to start
7)hesitation at 3800 but my pressuer sensors blocked so my secondarys should open up at 3500, and i have wired open ports.

note there is no emmissions on it but the cats
what do you all think?

 

get a TPS!!!
and run your aux ports stock off of back pressure

 

1) if secondaries were working, i'd say you had the ports wired SHUT, not open.... in an S5 motor... the actuators rotate differently than an S4.... you sure you hooked that stuff up right in the transition (s4 actuators pull IN, s5's push OUT)????

2) if you've removed the air pump and other emissions junk, the cats are most likely clogged to hell and back by now.... might as well rip them off too...

3) Yes.... you need a TPS... without the TPS to tell the car its at 0 throttle, it will never idle right...... been a while since i dicked with an s4 TPS, but, i thik the TPS will cause problems with the secondaries as well.... like if its not there the ECU is going to see a fault and anything set to the TPS signal is going to go apeshit.... Basically, i'm still trying to figure out why the hell you don't have one and how the hell the cars running wihtout it.......

4) chargins system problem or giant VAC leak

5) straight fuel ines????? no FPR???????????

6) see #3 and #2

7) See #2