SAI Delete DIY Guide Almost complete

[2003gtivr62.8liter]

Disclaimer: I am not a ase certified technician and do not take any responsibility if things don't go right.

Ok here is some of it. I bought the block off plate from INEngineering. You can probably do this without taking off the bumper beam & lock carrier, but I did just because.

First I located the SAI pump motor which is right behind the radiator. After locating that I then traced all the lines/hoses and found out where they all went.

Second I took out the Bracket holding pump motor. It has 2 bolts in the oil pan and 1 bolt in the cylinder block. They are right under the oil filter housing. You will have to disconnect the Harness connector on the pump.

Disconnect half of the pressure hose on the side of the engine so you have less hose to remove from the bottom. These hoses are disconnected by pushing in and pulling. Remove pump from the bottom thru and around radiator hoses.

Next, take out your intake tubing to gain better access to the Combi-valve. It is kind of a pain in the ass but not to bad.

Now you can gain access to the Combi-valve you have a radiator hose that needs to be disconnected. It might be a pain, but keep at it and take your time to take it off as you will still need it. There are 3 bolts one is on top, one is on bottom and the other is in the middle of the radiator hose and the Fitting Flange on the Combi-Valve. The one in the middle was the real only pain.

You will have to disconnect the ground wire and relocate it. I relocated mine right on top of the Valve cover. (hopefully that works) (Any ideas on where else it could be moved to are welcome).

Install the block off plate and the hose.

The only thing that I have left to do is the vaccum plug leading into the SAI Solenoid Valve(N112). Has anyone done this before? Can I just delete that whole solenoid valve or just plug it?


Where the bracket is located.


Combi-valve.


SAI Pump motor. You can disconnect the hose in the middle to make removal easier.


Side view of the lines afterwards.


What it looks like with the combi-valve.


Better pic of Block off Plate with hose connected.


SAI Solenoid Valve on the left. Can I just take that compeletly off or just plug that hole?

[madonion]

Remove the whole plastic box with both solenoid under the intake. Cut the 2 connectors and put 300omhs 10W resistors instead. Make sure you don't cut the connector too short so you can weld them back if you need to. Keep everything in a box in case you need to reinstall everything. Once the plastic box and the solenoids have been removed you'll have to figure out the vacuum lines but this part is quite easy, make sure you reconnect the FPR vacuum line and that there's no vacuum leaks anywhere.

[2003gtivr62.8liter]

Sounds good. Man I hate to mess with electrical ****

[2003gtivr62.8liter]

So what you are saying is to completely remove these solenoids correct?

Another question is since I already have the Unitronic Stage 2 will I still throw a CEL?

[madonion]

Yes these and the black plastic box. Take a look at the 1.8T sai delete DIY it's really similar. Resistors "should" prevent from trowing codes. But I can't guarantee it will. In my case, I get N112 circuit open error code I need to check if something as gone wrong with the connection to the resistor.

You could remove the black plastic box and vacuum lines and leave the solenoids connected and tuck them somewhere.

[2003gtivr62.8liter]

Now I was looking in the Bentley and there is a relay for the sai. Should I get rid of that also? Considering I am taking I out.

[madonion]

Personally I wouldn't remove the relay, but you could do it if you make sure it's not used for anything else than the pump. Just make sure you find a way to insulate the SAI pump connector. I used a big piece of eat shrink with glue in it.

[anthony3vdublove]

You can remove the SAI relay. Chip tuning along with resistoring is need to keep the CEL off and fuel trims adapting.

[jaso028]

Nice!!
glad to see someone making a nice DIY on this..

removing that SAI frees up some nice space...

[GRN6IX]

The other solenoid is for your intake changeover valve, don't remove that one.

[jaso028]

dont some tunes allow you not to use the solenoids?

[2003gtivr62.8liter]

^. That's what I thought. Could have sworn unitronic does it with the stage 2 software.

[jaso028]

Meant to say resistors, but I think you knew what I meant.. lol
I remeber something with the UM tune I have saying it eliminates the SAI, but I always here it run. So I dont think it did..

[madonion]

The other solenoid is for your intake changeover valve, don't remove that one.

Oops... good thing you mentioned this. I deleted mine thinking it wasn't used. I wonder how the change over was acting while it was plugged directly on a vacuum line with no solenoid, no check valve. I will reinstall it tonight.

[2003gtivr62.8liter]

So it sounds like I should not delete the IMT just relocate it

[jaso028]

so did you end up putting the resistors on yet? if so you have pics of that and how that works?

[2003gtivr62.8liter]

No not yet. I have been busy with work and school. Hope to get back at it tomorrow.

[jaso028]

are you getting a CEL without them????

[2003gtivr62.8liter]

Don't know haven't had a chance to do anything with the car

[jaso028]

Oh lol

[madonion]

Anyone else as red and brown wires going to the n112 solenoid ? Diagrams show it should be blue/yellow, brown/yellow.

[2003gtivr62.8liter]

Ok so I have called every place I can think of except the VW dealer. Where can I get the 330 ohm resistors from? Right now I am thinking of just disconnecting it and just tucking it somewhere out of the way. This is the last thing before it will be complete.

[2003gtivr62.8liter]

Anyone else as red and brown wires going to the n112 solenoid ? Diagrams show it should be blue/yellow, brown/yellow.

I will check my wires when I get home after work and let u know.

[madonion]

Never mind, diagrams are correct. I had the wrong connector.

[GRN6IX]

Ok so I have called every place I can think of except the VW dealer. Where can I get the 330 ohm resistors from? Right now I am thinking of just disconnecting it and just tucking it somewhere out of the way. This is the last thing before it will be complete.

http://lmgtfy.com/?q=330+ohm+resistors

[03_uni-B]

i am watching all this very close. i am ready to do it to mine.

[madonion]

Just to keep this thread alive, here's what I wrote to 2003gtivr62.8liter in private.

I had done the delete but since I followed 1.8T DIY I got some things wrong. I fixed it yesterday. Yesterday I reinstalled the black box under the intake and reinstalled the solenoids. On the n112 I installed a vacuum hose between the in and out of the solenoid, just to keep dust out of the solenoid. I removed the resistors I had installed in the past and just kept the solenoid plugged in. Like someone else said in the thread it's important to keep the N156 solenoid for the intake change over. Most people recommend 330ohm 10 watts resistor but I believe it is not required for the SAI pump it self, and I have doubt about 330ohm 10 watts being the ideal resistor to get for everything. I measured the N80 @25ohms and N112 at 55ohms. I believe if you let the n112 and the n80 plugged in you won't have to purchase any resistors. I believe you should keep the black vacuum box under the intake since it provide the reserve of vacuum to feed the N156 (intake change over).

At the time I bought the resistor from integrated engineering. I need to clear the codes in my ECU and make sure everything runs like it should. But everything seems fine now.

[secfodubbin]

Im attempting this also and have some questions, I'm pretty new to vw but I get the hang of things... I took the combi valve off and the pump and all, installed the block off plate.. Now I'm wondering what my next step is... Where should I put the ground wire, and where exactly are the solenoids located?

[2003gtivr62.8liter]

I put the ground wire on the stud top right. As for the solenoid it is in front of the head. I left mine in but took off both vacuum lines from the SAI solenoid. Pluged both of them and the IMT solenoid. Everything runs good. Driven the car around 200 miles. Going to get it flashed by um and get launch control for ****s and giggles Monday. I will let u guys know that night how everything is.

[03_uni-B]

what did you use to plug the vac lines?

[2003gtivr62.8liter]

I went to autozone and bought the vacu-tite value pack lol. Vacuum cap assortment. I went yesterday and got the car flashed by UM and it is all good and then some.

[jaso028]

so with the flash are you running the resistors?

[2003gtivr62.8liter]

Nope. No resistors. I just plugged the vacuum lines and that was that.

[MachtSchnell]

Nope. No resistors. I just plugged the vacuum lines and that was that.

Ditto, I removed the pump and valve and plugged the vacuum line. Screw buying a block off plate for what $50? I bought aluminum flat stock at HomeDepot (<$10) to make my Macgyver plate to take the place of the valve. UM tune, no resistors and it has no CEL!

[jaso028]

Ok good to know with the UM tune I am able to not run resistors.. I know what I am ordering next week!
Thanks for the good updates and good write up!!