A m o u d i

Hi guys,
This is some information about my car C6 2005 A4 full bolt-ons with stock engine not opened before or during the project. No issue for the last two and half years.
Car mileage before starting the project 65,625

Note:The date format in this thread is dd/mm/yyyy = day/month/year
Project Info:
Start Date:5\11\2011
End Date:5\3\2012
Project duration: 122 days = 4 months and 1 day
expected RWHP 480 - 520

Project mods:
e-force part#1594(3.5 pulley) with z06 fuel pump


b & m trans cooler


mt 305 35 tires


innovate afr kit, boost and fuel pressure gauges





Dewitts radiator


This is my last three dyno runs pics:
First run (click on the picture to enlarge)


Second Run


Third Run


After the third run the tuner make tune more safer without additional dyno run or street test.

Next day 6\3\2012 I was happy to try my first street full throttle with new mods. I went full throttle (1st gear) directly my 5th piston gets broken as shown below:





What do you think the causes of my engine failure ?????

Tainted

iTrader: (9)

3.5 pulley im guessing is 3-4psi?

JRENIGAR

iTrader: (37)

How much boost? Timming @ WOT? Max RPM's? Id also check the spray pattern on the injector from that cyl just incase.In 1st graph AFR is dangerously lean, better in 3rd but Id shoot for 11.3-11.5 to be safe-errr... Damn, that sucks...

Hank Peabody

iTrader: (2)

That one graph shows it was 14.15 afr at 6000rpm, super lean under boost, the hp drops off as the afr goes lean on the graph.

Johnnystock

iTrader: (6)

Tell your tuner he sucks and ask him to rebuild your engine haha

redtan

iTrader: (5)

Shitty tune basically.

_GTO_

I'm really sorry for you brother, after all the efforts and time you ended up with this.

I'm absolutely sure that it was the tuner fault.

Wish you all the best.

ctd

iTrader: (1)

Were you there listening during the dyno runs?

My guess would be during a couple of those runs you may have heard a pop thru the exhaust.

A m o u d i

Sorry guys I'm not familiar with tuning staff.
the feedback I received from the tuner "my car was safe but the RWTQ was too high for a stock engine which might cause this failure. I was not sure by his answer. So I post here to get inputs form experience tuners/car builders in this forum.

Thanks to all of you for your concern and inputs.

A m o u d i

Yes, I were there. But the exhaust sound (corsa sport) was too loud I couldn't here any thing i was closing my ears.

Alpha

I'm the LAST one to blame a tuner. But. Either you had a tune issue, fuel issue or the wideband came out the exhaust stream. At around 5500rpm you can see it severely lean out.

A m o u d i

Brother I'm a customer. I paid for all new mods + labor and that's what I got. No one take the responsibility of that failure. Just I'm seeking for a decent answer form experts guys like you or others.

NHRAFORMULA00

iTrader: (2)

This is what happened. When the top of the piston breaks off like this, is becuse it got too hot. When that happens the ring gap closes up and stickes in the cylinder bore,breaking off the top of the piston,where it is beeing pinched. You more than likely have a broken block with a crack in the cylinder. The only way to prevent this from happening is to disassemble the motor with the pistons out and file the rings end gap bigger so that it has more clearance.

gectek

iTrader: (2)

Maybe you should read the rest of the thread?

A m o u d i

5-7 psi

Slowhawk

iTrader: (12)

That is a real clean break. Looks like it got weakened when it was NA and the boost just finished it.

The edelbrock kit is well known to have a real shitty fuel delivery through the rails. They should be modified with a dual feed to keep certain cylinders from running lean -ie-#5.

The runs above look lean but I have no idea what the timing is and the maggie style blower can be run leaner. The last graph looked alot better.

I would suggest to beaf up the fuel system and do some forged pistons. Maybe add a methenol system too.

venom ws7

iTrader: (13)

Very sorry about this bro..

LS2 engines are very strong it will not break easily 1st , 2nd dyno runs were extremely lean (if the sensor didnt fell from the exhaust) 3rd run was alittle better but still mid 12s A/F ratio after 6400rpm with our crappy fuel and hot weather I recommend 11:1 - 11:5 A/F.

What size injectors did you run? why did it take 4 months for a very simple setup?

Good luck man I think it's time for forged setup, fuel system and more boost BUT WITH better tuner..

A m o u d i

Hi Bro,
Check my answers in blue color.

Alpha

I hear you. I've tuned A LOT of cars. I can tell you without doubt. Either fuel issue, tuner should have let out, or the tune up was the issue. You can see it in the powerband. Look at the air:fuel as it begins to lean out and look at the hp/tq.

venom ws7

iTrader: (13)

Did u dyno the car before the supercharger?
Was there any problems before the install?