Right heads explode after high FI - Need help!!! - Toyota GR86, 86, FR-S and Subaru BRZ Forum & Owners Community

EdiVip · 05-09-2016, 05:22 AM

Hello everyone! I have big problem with my new engine setup and I need advice/solution...

First what i've done in my car:

Stage 1

- AVO Turbo kit Stage 1:

- AVO BOV:

- Death Werks - 700cc

- Walbro - 485

- Perrin - Oil Cooler Kit

~300HP/300NM

Stage 2

- AVO - 8psi Acurator:

- AVO - 3 BAR Map sensor - not mounted!

- Ecumaster - Digital ECU Tuner 3

~330HP/345NM

Stage 3

- AVO - 3" Stainless Steel - Full Exhaust System - Cat manually deleted

- AVO - Turbo upgrade to Stage 3 Billet

- FERREA - Valve springs, Reteiners, Seat relocation

- HKS - 2.1 Stroker kit:

- HKS - Metal Head gasket 1mm x2

- Xtreme - Dual Plate Clutch

After put my engine on my car I went to the dyno for tune. I was looking for over 400HP! But on 6900RPM (380NM and 1 BAR FI pressure) right heads explode! The valve tappet and Rocker arm pivot make hole in head cover and went outside! I changed valve springs to stiffer ones. It isn't enough? Knocking sensor did't recognize anything. It is possible that the reason is UEL AVO headers? What I'm doing wrong?

Tokay444 · 05-09-2016, 06:28 AM

There are far too many unknown variables to even begin to speculate, but I can all but guarantee you it wasn't that unequal length header.
One question, did the 3 bar map sensor ever make it into that motor?

EdiVip · 05-09-2016, 06:33 AM

Quote:

Originally Posted by Tokay444

There are far too many unknown variables to even begin to speculate, but I can all but guarantee you it wasn't that unequal length header.
One question, did the 3 bar map sensor ever make it into that motor?

No! I bought it but never installed

GsxrMe · 05-09-2016, 07:11 AM

Sorry for you luck. What rods and pistons was used?

Matt@Cosworth · 05-09-2016, 07:46 AM

I'd say broken valve follower, the FA20 has a history of this

FRS Justin · 05-09-2016, 08:13 AM

What year is the motor did you order the right valves for the year of the motor? Rocker arm pivot break? Need to know more along with pics if you have any

EdiVip · 05-09-2016, 09:40 AM

Quote:

Originally Posted by GsxrMe

Sorry for you luck. What rods and pistons was used?

HKS Stroker Kit 2.1l with 2x1mm gaskets on each side

Quote:

Originally Posted by FRS Justin

What year is the motor did you order the right valves for the year of the motor? Rocker arm pivot break? Need to know more along with pics if you have any

Valves are OEM. Rocker arm pivot break and went outside also. Similar situation to this but on ~7k NOT 9k rpm!?

http://www.ft86club.com/forums/showthread.php?t=73858

I'll post pics asap!

BRZoomTX · 05-09-2016, 09:48 AM

This is rocker arm failure. The valve rocker arms are not secured from the factory. You can pull 'em right off. If a valve ever sticks, the rocker arm is flying out the valve cover like you described. Happened to me, too, as well as a lot of others.

Element tuning has a small write-up regarding this failure on their site here:

http://elementtuning.com/competition...r-wrx-fa20dit/

Look for the Are there any weaknesses we address? section. The fix: find a way to secure them.

BTW, get that 3bar MAP sensor on. Assuming you're running the stock MAP sensor currently by your post, the stock MAP does not handle positive pressure well. Get that new MAP sensor on before you tune further.

BRZoomTX · 05-09-2016, 11:48 AM

Oh, video of the rockers for reference.

https://www.instagram.com/p/BEaO3riR...en-by=brzoomtx

GsxrMe · 05-09-2016, 12:34 PM

Does anyone offer a direct replacement to the factory rocker arms other than inspection?

SkAsphalt · 05-09-2016, 01:14 PM

Why would you be running such a high PSI tune without a map sensor installed that can actually read pressure that high?

EdiVip · 05-09-2016, 01:22 PM

Quote:

Originally Posted by BRZoomTX

This is rocker arm failure. The valve rocker arms are not secured from the factory. You can pull 'em right off. If a valve ever sticks, the rocker arm is flying out the valve cover like you described. Happened to me, too, as well as a lot of others.

Element tuning has a small write-up regarding this failure on their site here:

http://elementtuning.com/competition...r-wrx-fa20dit/

Look for the Are there any weaknesses we address? section. The fix: find a way to secure them.

BTW, get that 3bar MAP sensor on. Assuming you're running the stock MAP sensor currently by your post, the stock MAP does not handle positive pressure well. Get that new MAP sensor on before you tune further.

I think this is it! Below missing part!

Quote:

Originally Posted by SkAsphalt

Why would you be running such a high PSI tune without a map sensor installed that can actually read pressure that high?

My tuner told me that is not necessary because they can read FI pressure from different place. I don't know exactly from where but If U want I can ask him!

BRZoomTX · 05-09-2016, 01:35 PM

Quote:

Originally Posted by EdiVip

I think this is it! Below missing part!

Yep, just like mine. No pin failure but the rocker itself shot out as one entire piece. You're looking at possible camshaft damage as well. On mine, both right side cams received damage on the actual contact point for the rockers, so I've been advised to replace both.

SPCorBUST · 05-10-2016, 03:35 AM

whats the fix so that these types of failures don't occur?

05-09-2016, 05:22 AM	#1
EdiVip Member Join Date: Feb 2015 Drives: Mario Location: TM Posts: 31 Thanks: 6 Thanked 47 Times in 15 Posts Mentioned: 1 Post(s) Tagged: 1 Thread(s)	Right heads explode after high FI - Need help!!! Hello everyone! I have big problem with my new engine setup and I need advice/solution... First what i've done in my car: Stage 1 - AVO Turbo kit Stage 1: - AVO BOV: - Death Werks - 700cc - Walbro - 485 - Perrin - Oil Cooler Kit ~300HP/300NM Stage 2 - AVO - 8psi Acurator: - AVO - 3 BAR Map sensor - not mounted! - Ecumaster - Digital ECU Tuner 3 ~330HP/345NM Stage 3 - AVO - 3" Stainless Steel - Full Exhaust System - Cat manually deleted - AVO - Turbo upgrade to Stage 3 Billet - FERREA - Valve springs, Reteiners, Seat relocation - HKS - 2.1 Stroker kit: - HKS - Metal Head gasket 1mm x2 - Xtreme - Dual Plate Clutch After put my engine on my car I went to the dyno for tune. I was looking for over 400HP! But on 6900RPM (380NM and 1 BAR FI pressure) right heads explode! The valve tappet and Rocker arm pivot make hole in head cover and went outside! I changed valve springs to stiffer ones. It isn't enough? Knocking sensor did't recognize anything. It is possible that the reason is UEL AVO headers? What I'm doing wrong? Last edited by EdiVip; 05-09-2016 at 02:22 PM.

05-09-2016, 07:11 AM	#4
GsxrMe Senior Member Join Date: Jul 2015 Drives: Late 2014 Subaru BRZ Location: Cape Coral, FL Posts: 557 Thanks: 20 Thanked 184 Times in 139 Posts Mentioned: 5 Post(s) Tagged: 2 Thread(s)	Sorry for you luck. What rods and pistons was used? __________________ 2014 Subaru BRZ FBM Turbokit: GTX3076R - ECUTEK HRI FlexFuel tune - FBM 3" Turboback Exhaust - 550cc Injectors - Walbro 485 Fuel Pump - 4bar Map Sensor - FBM Oil Pan - ACT SB7-XTSS - AMSOIL all fluids - Forester XT Oil Cooler - Cusco engine, trans mounts - Whiteline rear differential bushings - Perrin shifter bushing - Firehawk 235/45/17 - AEM Failsafe

05-09-2016, 08:13 AM	#6
FRS Justin Senior Member Join Date: May 2014 Drives: 2013 Asphalt FRS Location: San Antonio Posts: 994 Thanks: 693 Thanked 695 Times in 417 Posts Mentioned: 22 Post(s) Tagged: 1 Thread(s)	What year is the motor did you order the right valves for the year of the motor? Rocker arm pivot break? Need to know more along with pics if you have any __________________ Instagram FT86PROJECT9S Facebook FT86PROJECT9S 710whp

05-09-2016, 09:48 AM	#8
BRZoomTX Senior Member Join Date: Mar 2015 Drives: '13 BRZ Location: Texas Posts: 362 Thanks: 179 Thanked 235 Times in 149 Posts Mentioned: 4 Post(s) Tagged: 0 Thread(s)	This is rocker arm failure. The valve rocker arms are not secured from the factory. You can pull 'em right off. If a valve ever sticks, the rocker arm is flying out the valve cover like you described. Happened to me, too, as well as a lot of others. Element tuning has a small write-up regarding this failure on their site here: http://elementtuning.com/competition...r-wrx-fa20dit/ Look for the Are there any weaknesses we address? section. The fix: find a way to secure them. BTW, get that 3bar MAP sensor on. Assuming you're running the stock MAP sensor currently by your post, the stock MAP does not handle positive pressure well. Get that new MAP sensor on before you tune further. __________________ '13 WRB BRZ ~470whp // Instagram // YouTube

05-09-2016, 11:48 AM	#9
BRZoomTX Senior Member Join Date: Mar 2015 Drives: '13 BRZ Location: Texas Posts: 362 Thanks: 179 Thanked 235 Times in 149 Posts Mentioned: 4 Post(s) Tagged: 0 Thread(s)	Oh, video of the rockers for reference. https://www.instagram.com/p/BEaO3riR...en-by=brzoomtx __________________ '13 WRB BRZ ~470whp // Instagram // YouTube

05-09-2016, 06:28 AM	#2
Tokay444 Banned Join Date: Feb 2016 Drives: 17 White 860. RCE Tarmac 2. RE-71RS Location: Not Canada Posts: 1,752 Thanks: 938 Thanked 1,025 Times in 581 Posts Mentioned: 10 Post(s) Tagged: 0 Thread(s)	There are far too many unknown variables to even begin to speculate, but I can all but guarantee you it wasn't that unequal length header. One question, did the 3 bar map sensor ever make it into that motor?

05-09-2016, 07:46 AM	#5
Matt@Cosworth Senior Member Join Date: Dec 2015 Drives: blue - Cosworth SC stage 3.0 Location: Northants - UK Posts: 333 Thanks: 3 Thanked 395 Times in 185 Posts Mentioned: 34 Post(s) Tagged: 1 Thread(s)	I'd say broken valve follower, the FA20 has a history of this

05-09-2016, 12:34 PM	#10
GsxrMe Senior Member Join Date: Jul 2015 Drives: Late 2014 Subaru BRZ Location: Cape Coral, FL Posts: 557 Thanks: 20 Thanked 184 Times in 139 Posts Mentioned: 5 Post(s) Tagged: 2 Thread(s)	Does anyone offer a direct replacement to the factory rocker arms other than inspection? __________________ 2014 Subaru BRZ FBM Turbokit: GTX3076R - ECUTEK HRI FlexFuel tune - FBM 3" Turboback Exhaust - 550cc Injectors - Walbro 485 Fuel Pump - 4bar Map Sensor - FBM Oil Pan - ACT SB7-XTSS - AMSOIL all fluids - Forester XT Oil Cooler - Cusco engine, trans mounts - Whiteline rear differential bushings - Perrin shifter bushing - Firehawk 235/45/17 - AEM Failsafe

05-10-2016, 03:35 AM	#14
SPCorBUST Senior Member Join Date: Dec 2011 Drives: 2013 Subaru BRZ Limited Location: Orange County, CA Posts: 935 Thanks: 525 Thanked 399 Times in 255 Posts Mentioned: 23 Post(s) Tagged: 2 Thread(s)	whats the fix so that these types of failures don't occur? __________________ Setup 1: KW C38, Grams 550, Grams 265, 4bar, FlexFuel, Delicious Setup 3: JR C30, DW 700, Grams 265, 3bar, FlexFuel, Moto-East Setup 4: JR C30 HBP, DW 700, Grams 265, 3bar, FlexFuel, Church Setup 5: JR C30 HBP, DW 700, DW 300, 3bar, FlexFuel, Delicious, Built Motor Setup 6: JR C30 HBP, DW 700, DW 300, 3bar, FlexFuel, Delicious, Closed Deck Built Motor

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