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It was "fun" trying to help you with that problem. I only wish the first suggestion I would have made was the plugs. However because the F5DP0R plugs were quite new, I did not suspect them as the ultimate problem. I think I did say check the plugs but I was thinking that maybe they weren't tight in the head. Oh well, fixed now.
Question: Is this the 16V 4 cylinder VW/Audi engine distributor Hall sender that you used as your "Tuna Can" AAN G40 cam sender:
Some updates. Got major misfiring issue right after fitting 7A cover. While fitting the cover, fixed all intake leaks by replacing all hoses with silicone, turbo finally blows where it should. Right after that the car started misfiring horribly, and very violently. Was battling with it for 3 weeks until found out the cause. In the process we swapped everything that is possible to swap, to no avail. At the last moment when nothing was left to swap I decided to my old spark plugs in. All problems were miraculously gone the moment I took out F5DP0R's. Big thanks to Dave for holding with me during this time.
Spent 2 days trying to choose spark plugs. Chose FR5DTC, but not Bosch, don't want to drive with Bosch plugs. I picked NGK alternative - BCPR7ET. Running good so far.
Got a new G40, G28 and G4 sensors in the process of debugging the misfire. All FACET made.
Started tidying the engine bay after that. Last of the silicone arrived, final hose replaced.
Gonna hunt missing plastic bits from the engine bay - Airbox/MAF cover, firewall connection cap.
Some wastegate porn. Replaced the old and worn out studs with these 6 strenghtened allen heads. Resprayed the WG cap with thermal matte black color.
Next in the list:
1. another set of headlights, mine are in pretty bad shape. I'm going to get a set of lights in good shape from S6 and swap my glass in.
2. rear sway bar assembly. I do not have it and want to get it. I'll get poly crossmember bushes from Apikol before installing it.
3. gauges. Already installed turbo boost gauge, still need fuel pressure and air/fuel ratio gauge.
There's nothing to it. Get a V8 S6 C4 dashboard and just swap it in. Only things that need to be done are diagnostics connection to dash, ABS light workaround & recode the dash to 5-cyl turbo. Consumption works straight away, all the pins are present. Gotta love Audi for universality (or laziness to make another set of wiring ).
Might have to try at some point I know it can save loads on fuel when you see "current fuel consumption"
More info on this? I would much rather have that over boost gauge.
There's nothing to it. Get a V8 S6 C4 dashboard and just swap it in. Only things that need to be done are diagnostics connection to dash, ABS light workaround & recode the dash to 5-cyl turbo. Consumption works straight away, all the pins are present. Gotta love Audi for universality (or laziness to make another set of wiring ).
So, my ignition lock broke. Key just went full circle without any life signs. Pretty standard issue on these cars. So I took the lock off and started it with a screwdriver. After some of those starts (It's my daily car, I need it) the ignition contactswitch jammed in starter position and burned down my starter. Epic fail for me.
So I started fixing it. Got starter from 2.3 AAR, and since the ignition lock only can be put from non-adjustable steering column, I thought f*ck it, I'm swapping the adjustable column in. And everything that goes with it. Since I'm changing my key, I swapped all locks as well.
So what was done:
- New locks all around (front doors, trunk)
- Adjustable steering column assembled with ignition lock.
- S6 C4 V8 dash installed (dash modified - clock removed, oil pressure in place)
- All attributes around steering column from A6, S6 air bag steering wheel.
Some considerable mods had to be done to do all that.
Steering wheel switch clamps had to be adjusted and some pins swapped to different spots, switches from S6 cannot be connected to 100/UrS4 clamps.
Installed oil pressure gauge from my old UrS4 dash. Pretty straight forward.
Relay trick to stop the annoying ABS error.
Phase 1 of interior changes complete. Everything works. Got a consumption gauge instead of boost gauge just as I wanted. Dashboard recoded to 5-cyl turbo. Gotta do something with dashboard illumination, it's too dark, and oil pressure gauge does not match color with the rest, it's orange. Even check engine light works.
I have a 6-speed box from a similar S4 withing my grasp and I'm thinking is it a straight swap? I have a 5-speed CBD, and that one is 6-speed CBL. Has anyone done this before? What about linkage and shifter?
Besides plugs, did some prop shaft restoration work. My propshaft was ringing when standing and revving more than 3500 rpm. Got the parts described in multiple threads here - Ford Scorpio CV joints (LPR KAR801) and BMW central bearing. Unfortunately the bearing was a no go, looks like it can only be put on S2's. But examining the original bearing I found a part number - 4A0521113A. Checking that number in parts stores I found a single bearing - TED-GUM 00054970. Dunno what Ted Gum is, but better a new bearing than a broken one. Mine was kinda OK, so we decided to leave it for now.
New joint in place. Joints were perfect for the shaft, no unnecessary movement when assembled. The old front one was completely broken, it was rattling and moving from side to side.
Also changed gearbox's tail gasket, between propshaft and differential.
The old f5dpor was good but I have seen and heard lots or stories about them breaking up and damaging engines. The newer batches seem to be weaker. Use caution is all I'm saying...
The old f5dpor was good but I have seen and heard lots or stories about them breaking up and damaging engines. The newer batches seem to be weaker. Use caution is all I'm saying...
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I only wish the first suggestion I would have made was the plugs. However because the F5DP0R plugs were quite new, I did not suspect them as the ultimate problem. I think I did say check the plugs but I was thinking that maybe they weren't tight in the head. Oh well, fixed now. 
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