It won't Start! But before I get to that an update on progress. Cooling hoses are connected up enough for testing. Here is a pic I took when it was mostly done.
After the cooling lines were all connected I powered up the electrical system and put the key in and it won't engage the starter. Bad deal. The cluster now says the steering lock is defective and red steering wheel lights up on the dash. That s a new and bad error. We have stripped a ton of wires from the harness but I've checked and all the ones for the steering lock are intact and look good. Using VCDS it surprisingly shows the immobilizer is happy. The steering steering lock is in the unlocked position. The steering lock quit locking on earlier engine starts due to some of the modules I removed.
I'm a bit frustrated with it. Not sure if the steering lock module is now broken, something else is broken, some wire to something else is missing causing it to think it's broken or if the no start is something unrelated. It may be time to remove the IMMO but if the issue is something else that's be kind of a waste and might not fix it. Already spent many hours looking over wiring diagrams and checking things. Fixed a couple wires that were mistakenly removed but so far still no starter action.
I've taken the steering lock apart and checked it to see if it just failed but it appears good. I expect it is likely a wiring problem from us removing gobs of wires or man handling the wires but where? My guess at the moment is either the J393 module or J519 module. Checked over the J393 module connections last night and none of the removed wires appear significant. Did find out that unplugging the J393 module allowed things to power up (T15) and NO steering defective error on the dash (no errors in the text window and and just a few lights). Strange. Oh with J393 plugged in and the steering lock unplugged or the steering wheel module unplugged nothing powers up. Or if the Steering lock is in the locked position (and everything plugged in) nothing powers up (it currently set to the unlocked position.)
Things I changed before the steering lock error went off. I found a ground wire not grounded. However this wire was simply a diode to ground from one of the power leads in the fuse box. Grounding the wire didn't appear to change anything. Recoded the comfort module (J393) back to Auto trans along with the steering wheel electronics back to Auto trans. Then the steering lock error (red steering wheel) went off and the steering lock started actuating again. The engine allowed to start field in VCDS is now showing as Yes.
The cluster still says "depress clutch", odd as I can't find anything that is not coded to auto trans with the exception of the gateway, which I've unchecked the auto trans as that module isn't there. On J519 there is a wire that ran to the P/N switch and looks like may go to the clutch switch on manual trans cars. When grounding that wire (T16g/7) the J519 module sees the P/N switch as activated. With that wire grounded pressing the key all the way in now activates the starter relay. Now I just need a better battery and some fuel and it should run again!
Got a new battery and the car started then died. No new errors. Seemed a bit fuel starved. Ran the pump a bunch of times hoping to get the air out but the engine would fire up, fun a bit and die. The fuel lines were connected the exact same way as the first time. So seemed like it should work. Looking at the fuel pump assembly I noticed a large amount of fuel coming out the extra line, I thought it was just for the 4motion version. The tube I had that would attach there inside the 4motion tank was quite restrictive so I just plugged it (see picture) and the car started and ran just fine. Ran the engine for about 5 min. and shut it down. So success there. The wiring and modules seem happy again.
Below is a picture of the bin holding the wiring and a few electronics boxes we have extracted so far from the wire harness. And that's not even all of it.
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