My 5th Piston Gets Broken (dyno pics inside)
#1
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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![Sad](https://ls1tech.com/forums/images/smilies/LS1Tech/gr_sad.gif)
expected RWHP 480 - 520
Project mods:
e-force part#1594(3.5 pulley) with z06 fuel pump
![](http://i1085.photobucket.com/albums/j421/dfd9111/E111594.jpg)
b & m trans cooler
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111024-WA0007.jpg)
mt 305 35 tires
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111026-WA0000.jpg)
innovate afr kit, boost and fuel pressure gauges
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111024-WA0008.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/3a439cafb4279fdf2b2a468b4037f099image200x200.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/fuel.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/holder.jpg)
Dewitts radiator
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111121-WA0008.jpg)
This is my last three dyno runs pics:
First run (click on the picture to enlarge)
![](http://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05203526.jpg)
Second Run
![](http://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05204155.jpg)
Third Run
![](http://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05204748.jpg)
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:
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG_1749.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG_1748.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG_1747.jpg)
What do you think the causes of my engine failure ?????
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
![Sad](https://ls1tech.com/forums/images/smilies/LS1Tech/gr_sad.gif)
expected RWHP 480 - 520
Project mods:
e-force part#1594(3.5 pulley) with z06 fuel pump
![](http://i1085.photobucket.com/albums/j421/dfd9111/E111594.jpg)
b & m trans cooler
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111024-WA0007.jpg)
mt 305 35 tires
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111026-WA0000.jpg)
innovate afr kit, boost and fuel pressure gauges
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111024-WA0008.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/3a439cafb4279fdf2b2a468b4037f099image200x200.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/fuel.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/holder.jpg)
Dewitts radiator
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG-20111121-WA0008.jpg)
This is my last three dyno runs pics:
First run (click on the picture to enlarge)
![](http://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05203526.jpg)
Second Run
![](http://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05204155.jpg)
Third Run
![](http://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05204748.jpg)
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:
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG_1749.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG_1748.jpg)
![](http://i1085.photobucket.com/albums/j421/dfd9111/IMG_1747.jpg)
What do you think the causes of my engine failure ?????
![Sad](https://ls1tech.com/forums/images/smilies/LS1Tech/gr_sad.gif)
Last edited by A m o u d i; 04-06-2012 at 09:12 AM. Reason: Adding the date format The date format dd/mm/yyyy = day/month/year
#7
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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.
I'm absolutely sure that it was the tuner fault.
Wish you all the best.
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#9
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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.
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.
#10
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#11
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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.
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.
![](https://i1085.photobucket.com/albums/j421/dfd9111/2012-03-05204155.jpg)
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.
#12
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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.
Last edited by A m o u d i; 04-06-2012 at 06:17 PM.
#13
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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.
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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.
Maybe you should read the rest of the thread?
#16
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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.
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.
#17
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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..
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..
#18
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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?
Fuel Injectors (52 lb/hr)
why did it take 4 months for a very simple setup?
Simply no commitment.
Good luck man I think it's time for forged setup, fuel system and more boost BUT WITH better tuner..
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?
Fuel Injectors (52 lb/hr)
why did it take 4 months for a very simple setup?
Simply no commitment.
Good luck man I think it's time for forged setup, fuel system and more boost BUT WITH better tuner..
Check my answers in blue color.
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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.