1.4 tsi CAVE melted piston

PoloGTI

Active Member
Jun 1, 2017
30
0
Hi guys,
I am sorry my first post has to be about a catastrophic engine failure, but here is the story.
Any idea what could have caused this piston to melt like that. This is my Polo GTI 1.4 TSI-completely stock. I was driving hard and the check engine started flashing together with the EPC warning light. Car was running on 3 cylinders. Drove for another 7-8 miles home, car was smoking badly and had no power whatsoever. Pulled the plugs to find out the electrode in cylinder #2 was missing completely.

Fault codes were misfire cyl 2, multiple cylinder misfire, previously stored codes for catalytic converter efficiency below threshold, evaporative emissions control system incorrect flow (also stored previous to the incident).
Car was heavy oil user and I had the piston rings and valve seals replaced 1200 km before this incident happened, head was completely dismantled and cleaned, injectors were ultrasonic cleaned.
I did not change the plugs because I could not find the correct plug for the car at the time and was going to order them.
Now, I will have the cylinder sleeved and change the piston, but I am a bit worried that it might happen again. can a bad spark plug/no spark/broken elctrode cause the piston to melt?
I realize that the cause for the melted piston and plug may be high combustion temperature caused by lean condition, but what caused it is a mistery. failed injector? Car ran perfectly fine except lumpy idle at start up sometimes, which will smooth out after just a minute or 2. car is produced late 2011, October I think. I will post the scan of the codes shortly.
 

PoloGTI

Active Member
Jun 1, 2017
30
0
Here is the log:

Address 01: Engine Labels: 03C-907-309-V1.clb
Control Module Part Number: 03C 906 027 AR HW: 03C 906 027 AR
Component and/or Version: 1.4l R4/4V TS H15 7924
Software Coding: 00250012000400000000
Work Shop Code: WSC 00788 648 00255
ASAM Dataset: EV_ECM14TSI01103C906027AR 001009 (VW25)
ROD: EV_ECM14TSI01103C906027AR.rod
VCID: 710688DCCBDF9CE7DE-8024
5 Faults Found:

2886 - Catalyst System; Bank 1
P0420 00 [237] - Efficiency Below Threshold
MIL ON - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 84430 km
Date: 2065.14.29
Time: 13:04:21

Engine speed: 1705.50 /min
Normed load value: 31.8 %
Vehicle speed: 73 km/h
Coolant temperature: 91 °C
Intake air temperature: 35 °C
Ambient air pressure: 930 mbar
Voltage terminal 30: 13.523 V
Unlearning counter according OBD: 40
Test of catalytic converter: measured value: 0.8281
Relative load value: 50.25 %
Exhaust temp on O2 sensor behind cat conv from model: filtered: 546.79 °C
Heated oxygen sensor bank 1: sensor 1: activation: 40.198 %

4057 - Cylinder 2
P0302 00 [237] - Misfire Detected
MIL ON - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 84849 km
Date: 2066.14.04
Time: 13:16:58

Engine speed: 5704.50 /min
Normed load value: 87.8 %
Vehicle speed: 164 km/h
Coolant temperature: 92 °C
Intake air temperature: 36 °C
Ambient air pressure: 930 mbar
Voltage terminal 30: 13.476 V
Unlearning counter according OBD: 40
Misfire sum counter: 4
Drive time with activated exhaust malfunction indicator lamp: 0 s
Leakage air: 2.5 kg/h
Long term adaptation of throttle valve for mass air flow sensor: 1.11469
Long-term fuel trim bank 1 at idle: 1.08 %
Crankshaft signal evaluation: status: GAPFOUND
Crankshaft signal evaluation: status-Test_Program_Epm H Cr S st Sig Mode State t UBYTE: 7

7960 - Cylinder Disabling
P130A 00 [032] - -
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 2
Mileage: 84851 km
Date: 2066.14.04
Time: 13:23:39

Engine speed: 2242.00 /min
Normed load value: 28.2 %
Vehicle speed: 15 km/h
Coolant temperature: 90 °C
Intake air temperature: 33 °C
Ambient air pressure: 930 mbar
Voltage terminal 30: 13.358 V
Unlearning counter according OBD: 40
Misfire sum counter: 3
Drive time with activated exhaust malfunction indicator lamp: 1 s
Leakage air: 2.5 kg/h
Long term adaptation of throttle valve for mass air flow sensor: 1.11469
Long-term fuel trim bank 1 at idle: 1.08 %
Crankshaft signal evaluation: status: GAPFOUND
Crankshaft signal evaluation: status-Test_Program_Epm H Cr S st Sig Mode State t UBYTE: 7

4051 - Random/Multiple Cylinder Misfire Detected
P0300 00 [109] - -
Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 84849 km
Date: 2066.14.04
Time: 13:16:58

Engine speed: 5704.50 /min
Normed load value: 87.8 %
Vehicle speed: 164 km/h
Coolant temperature: 92 °C
Intake air temperature: 36 °C
Ambient air pressure: 930 mbar
Voltage terminal 30: 13.476 V
Unlearning counter according OBD: 40
Misfire sum counter: 4
Drive time with activated exhaust malfunction indicator lamp: 0 s
Leakage air: 2.5 kg/h
Long term adaptation of throttle valve for mass air flow sensor: 1.11469
Long-term fuel trim bank 1 at idle: 1.08 %
Crankshaft signal evaluation: status: GAPFOUND
Crankshaft signal evaluation: status-Test_Program_Epm H Cr S st Sig Mode State t UBYTE: 7

14751 - EVAP Emission Control Sys
P0441 00 [096] - Incorrect Flow
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 84660 km
Date: 2065.14.30
Time: 15:08:26

Engine speed: 1760.50 /min
Normed load value: 26.3 %
Vehicle speed: 75 km/h
Coolant temperature: 90 °C
Intake air temperature: 24 °C
Ambient air pressure: 940 mbar
Voltage terminal 30: 13.735 V
Unlearning counter according OBD: 40
Tank venting adaptation factor: 1.834
Fuel temperature: 62.3 °C
Accelerator pedal: switch positions-Bit 0: 0


Readiness: 0000 0000
 

PoloGTI

Active Member
Jun 1, 2017
30
0
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Big-Pete

Always on the Limit
Aug 8, 2010
3,032
2
gutted. got warranty?

mate of mines selling a whole long block u could use, its all running.

and as to spark- that looks like some savage blow by where a ring has failed, but thats an amatuer diagnostic.

these engines love- plugs/packs/oil/decent fuel if u stay ontop of 4 ull be fine
 

PoloGTI

Active Member
Jun 1, 2017
30
0
Hi Pete,
thanks for your reply and the offer for the long block, but my engine can be repaired. The head is off and already sent to a machine shop. Visually, there is no damage, but they will check it thoroughly anyways. I have ordered a new piston and once the whole engine is out, the block will be sent for repair. I will fit new plugs apparently (and coils if needed). I am also planning to have the injectors tested. Will check the catalytic converter as it may have melted...A hefty bill is coming My mechanic was puzzled as he had never seen a piston melt like that on a gasoline engine (diesel, yes) the car had a 3 year warranty only, so no warranty. i am really frustrated as i rarely push the car. How can it be so fragile? always put 100 RON, gas, had never had misfires before while driving. Really questioning wheather to sell it after I repair it. It is my wife's car. I drive an APR Stage 2 Audi 2.0 FSI quattro with 290 hp and that car has never missed a beat in the past 3 years, and I drive it very hard...

P.S. You have one mean Bocanegra:)
 
Last edited:

Big-Pete

Always on the Limit
Aug 8, 2010
3,032
2
Hi Pete,
thanks for your reply and the offer for the long block, but my engine can be repaired. The head is off and already sent to a machine shop. Visually, there is no damage, but they will check it thoroughly anyways. I have ordered a new piston and once the whole engine is out, the block will be sent for repair. I will fit new plugs apparently (and coils if needed). I am also planning to have the injectors tested. Will check the catalytic converter as it may have melted...A hefty bill is coming My mechanic was puzzled as he had never seen a piston melt like that on a gasoline engine (diesel, yes) the car had a 3 year warranty only, so no warranty. i am really frustrated as i rarely push the car. How can it be so fragile? always put 100 RON, gas, had never had misfires before while driving. Really questioning wheather to sell it after I repair it. It is my wife's car. I drive an APR Stage 2 Audi 2.0 FSI quattro with 290 hp and that car has never missed a beat in the past 3 years, and I drive it very hard...

P.S. You have one mean Bocanegra:)

cheers bud.

and yeah 1.4tsi are pure lottery lad. if ur going todo it wossner pistons are worth throwing in, along with some zrp rods ;)
 
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