Lean Fuel Issues after 4k rpm on Revo Stage 2+ Ed30

[MAT ED30]

oh crap mate thats not good what u going to do if it is the block?

[vwrascal]

oh dear, sorry to hear this      must be a v.rare problem if its the block   

[john_o]

 
in what terms is the block a possible issue? leaking past rings? porous in general , or flexing ? etc
On a positive note sounds like an excuse to go the whole BT route inc new block/rods etc 

fingers crossed for you 

[jonnyc]

I dont understand.. How could there be a 'problem' with the block?

The only problem the block could have is that its overheating or its got a big hole in it.. Its neither of those surely? lol..

Did he say any more?

[illyun]

With regards to the above comments, I really have no idea except that the fuel pressure is ok in the fuel pressure rail (although there are odd spikes going to 137/8 bar which might be down to the ECU trying to over compensate the lean fuel issue - its running trim at 25% as it is which is why my mpg was affected adversely), the injectors are flowing correctly so that means that the fuel is getting through to the combustion chamber ok.. its the lambda value that is coming out wrong showing that the afr is too lean at high revs when boost on the revo map is turned up. The higher the boost, the worse the problem.  The o2 sensor has been checked out so logically it the problem has to be with the fuel going through the engine... if not, then then I really haven't a clue.    Still I'm looking at the bright side... I've spared a lot of mileage on the car not having driven it for the past 5 weeks. 

[illyun]

I dont understand.. How could there be a 'problem' with the block?

The only problem the block could have is that its overheating or its got a big hole in it.. Its neither of those surely? lol..

Did he say any more?

I hope you're right Jonny and I hope it isn't the block.  Obviously the next thing is the leak test but to me the engine block is a black box in that I have no idea what it looks like internally or how it works.

[jonnyc]

I dont understand.. How could there be a 'problem' with the block?

The only problem the block could have is that its overheating or its got a big hole in it.. Its neither of those surely? lol..

Did he say any more?

I hope you're right Jonny and I hope it isn't the block.  Obviously the next thing is the leak test but to me the engine block is a black box in that I have no idea what it looks like internally or how it works.

A leak down test would show problems with the piston rings potentially, but the block is a block.. Its either working or, it really isnt..

Hope it goes ok mate! Need to have you at the next RWYB day.. No one else is getting close  hehe..

[illyun]

Can the Piston Rings be replaced separately? 

[Phil Mcavity]

There best next stage would be to remove the cylinder head and check the piston crowns for detonation.Sounds like a melt down on the engine mechanicals.How did your stage 2 + Remap? all gone wrong since that point ?
Sad news nadeem. Hope its not as serious as it sounds.

Good luck.

[chungster]

blimey, so its time to take the head/block apart! Yikes.

feel for ya mate. Soo many K04 engines out there running your set up with no probs. Very very unlucky.

[JKM]

Guys,

I’ve just seen this and need to correct a few things quickly.
We don’t think that the actual engine block itself is defective as there is nothing to suggest this, some confusion here as I merely said that as we have basically tried many routes without any success, an engine leak down test is going to be performed as the next step to see if anything appears abnormal in the combustion chamber. Until the results of the leak down test are taken, analyzed and if need be compared with other engines there is no need or suggestion to need to remove the cylinder head....

I have not been able to get onto the car recently, as we have some members of staff away in our office, so I am assisting with some office duties until they return….

I can appreciate that there is a lot of interest in this cars fault, This is certainly the highest profile fault that I have worked on. We have spent many hours in and out of the workshop (a scary amount to be honest) looking into this fault and trying to comprehend a series of events that could cause this issue to occur.
I have consulted with Tuning and Software companies from both the UK and USA. A certain high profile USA company whom I cannot name, has seen a similar fault but never truly got to the bottom of the issue and this was with a large development team at their disposal. Their solution was far from ideal.

I certainly feel that we now have arguably the biggest correlation of data for ED30 / K04 spec engines in stage 1 and 2 level of tune. Data logging, Dyno Runs and Oscilloscope waveform patterns of various ECU channels, signals, Actuators and sensors etc – all areas are looking correct though which is the headache! Obviously apart from the AFR lean running issue.

I will be trying to write another report shortly for my customer, to explain things in more detail as it is very time consuming to do so for each and every step / test…..

Regards

JKM

[RedRobin]

^^^^
Burning the midnight oil!! You guys continue to impress me with your caring and commitment and that's not even mentioning your knowledge.

I never have any hesitation whatsoever in driving the 2 hour journey each way to JKM.

[WhiteGTI]

I think your attitude, commitment and perseverance in this situation has been exemplary JKM. 

[Phil Mcavity]

^^^2nd that. By far .

[jonnyc]

Guys,

I’ve just seen this and need to correct a few things quickly.
We don’t think that the actual engine block itself is defective as there is nothing to suggest this, some confusion here as I merely said that as we have basically tried many routes without any success, an engine leak down test is going to be performed as the next step to see if anything appears abnormal in the combustion chamber. Until the results of the leak down test are taken, analyzed and if need be compared with other engines there is no need or suggestion to need to remove the cylinder head....

I have not been able to get onto the car recently, as we have some members of staff away in our office, so I am assisting with some office duties until they return….

I can appreciate that there is a lot of interest in this cars fault, This is certainly the highest profile fault that I have worked on. We have spent many hours in and out of the workshop (a scary amount to be honest) looking into this fault and trying to comprehend a series of events that could cause this issue to occur.
I have consulted with Tuning and Software companies from both the UK and USA. A certain high profile USA company whom I cannot name, has seen a similar fault but never truly got to the bottom of the issue and this was with a large development team at their disposal. Their solution was far from ideal.

I certainly feel that we now have arguably the biggest correlation of data for ED30 / K04 spec engines in stage 1 and 2 level of tune. Data logging, Dyno Runs and Oscilloscope waveform patterns of various ECU channels, signals, Actuators and sensors etc – all areas are looking correct though which is the headache! Obviously apart from the AFR lean running issue.

I will be trying to write another report shortly for my customer, to explain things in more detail as it is very time consuming to do so for each and every step / test…..

Regards

JKM

I hope that you didn't feel you had to write that due to my comments etc.. It seems you are exploring all of the potential avenues with the car. Hope that you find the problem soon and thanks for the comment

Jonny