<center><img src="http://pictureposter.audiworld.com/3953/cylinderdamage.jpg"></center><p>
I've been out of town for a while so I haven't actually seen my motor after it has been torn apart, but my friends took some pictures the other day which show how extensive the damage is.
For those that don't remember, I was running PES's t28 kit and software and was having serious issues with misfiring among other things. Anyhow, this is the damage done to the cylinder walls in cylinder #1.

<center><img src="http://pictureposter.audiworld.com/3953/burntpiston.jpg"></center><p>

<center><img src="http://pictureposter.audiworld.com/3953/burntpistons.jpg"></center><p>

<center><img src="http://pictureposter.audiworld.com/3953/headdamage.jpg"></center><p>Its hard to see, but parts of the pistons put some indentations into the cylinder head. I'm not too sure how this happened...

<center><img src="http://pictureposter.audiworld.com/3953/pistonpieces.jpg"></center><p>I didn't get to see the car in the shop so I don't know exactly where it is but my friends were told that these are pieces of the pistons...

running with a chip from Russ's (1-bar's) 2000 that was dyno tuned on 91 octane at GIAC.

I knew my rings were getting bad because my compression was dropping in 2 of the cylinders.

what are your plans otherwise....sticking with the kit? Going to port out the head a bit while it's out?

I'm going to stick with the kit, but I'm planning on running a 91 octane chip, less boost and maybe some toluene or c16 in ever tank for safety. As for porting the head, I simply can't afford it at this point and there are some mods I would do before it at this point. The only changes are going to be forged pistons and a slight overbore.

if not I would reccomend it.

Looks like cali 91 craptane strikes again ;)

I would probably do it the old fashion way...with a timing light. But first you need to mark up a pulley (preferably the crank) with respect to TDC and 2 degree increments up to 40 degrees BTDC. White finger nail polish works good. Next find out what the stock total advance should be and check it against your marked up pulley. If it's too high (usually more than 4 degrees above stock), you need to have your chip reprogrammed.

too rough on the engine with the T28 turbo kit?
I have a K04 turbo, 1.4bar software, larger injectors, ported cylinder head, exhaust manifold, schrick cams, exhaust, downpipe, intake, dv. that's about it. will i be ok, or too risky for the engine?
and probaly in the summer, I am getting a custom intake manifold for my car as well.

after all these mods, do you guys think it's very unsafe for the egine???? thanks for all inputs, don't flame me please.

before saying it's the kit's fault. I dont know how much mileage your car has but mine is pretty old so I have to recheck just about everything (vac hoses, valves, sensors, etc).

but since the kit DOES run well in alot of cars, it gives me hope that it's my car and not the kit

best of luck.

regards,
Liam

it's not detonating at idle, probably just under WOT, in which case you need to watch VAG-COM to see how much timing it's pulling.

I agree, I am hoping it is my car and not the kit, but everything I tried only made problems worse. I am having all of my vac lines replaced, new plugs and other small odds and ends cleaned up when my new motor is put in to hopefully make trouble shooting easier, let me know if you have any luck.

I actually monitored my knock sensors at idle and they were pretty much off of the charts in two cylinders (the ones with the burnt pistons). This was pretty close to the end of the motors life though and it may have just been because the motor was in that bad of shape. Any thoughts?

I'd also take a look at your PCV system. If oil enters the chambers, it can cause detonation

There are a few products out there that can retard the timing as boost/MAF/etc increases, although I think you might be better off just doing some VAG-COM datalogging.

Start with 1 bar of boost, log timing and cyl retard, then slowly increase the boost and see how the timing reacts. You could probably have your chip altered to provide the correct timing.

and too much total advance will put holes in the top of your pistons and crack your rings....Racing Experience (2000 Daytona 24 Hrs..Car #40)

...but I don't think it's ever caused me to have misfires on my S4.

It has at least a couple degrees of slop in it, so you'd have to align the crank pulley to the TDC mark first.

It wouldn't surprise me if the ECU compares the cam position sensor to the crank sensor to keep base timing in check.

What is the difference with reformulate gas?

never heard any of them whine about their 93 let alone have it cause engine damage.

Just messing with ya :)

I heard APR ships in free barrels of 100 with 104 for weekends ;)

Ok so you can check it. Now what?

...difference down the front straight at either Texas World or Texas Motor Speedways. It's oxygenated with MTBE to burn cleaner in older vehicles in the reformulated varieties in Houston and D/FW.