gistfile1.txt

Cylinder 1 failure fost 

Before tuning, customer was made aware the focus st engine is known for engine failure due to piston issues.  Engine failure on this 
platform is a common phenomenon. There are posts every day with focus st engine failures with melted pistons and cracked ringland.  
While some of these may be tuner error resulting in hot spots on the piston over time causing pre igntion events (knock) to grendade the ringland.
The focus st engine is a closed deck motor and certain cylinders get less fuel/coolant flow and run hotter.  This must be accounted for
in the tuners fuel curve, however these engines typically run a 12.5 AFR from the factory. 

Customer ran our 93 tune for around 1,000 miles at most. The customer then installed a turbosmart wga and was given a remap for no additional
charge which is a complete re work of boost control.  Boost was dialed in at 23-24 psi peak falling to 13 psi after 5000 to redline.

Customer was educated on OAR and ignition corrections in cylinder 1 and 3 and to report any negative corrections or changes to OAR going 
more positivie.  On our map the customer did not have negative corrections, only knock events where the engine attempted to advance timing
which is normal engine operation.  During the boost remap the customer was made aware of a boost spike towards the end of the pull and a lean 
condition was was occuring and told to not go wot.  After investigating it turns out the customer was going into their access port
every time when turning the car on and setting their fuel cut rev limiter to 6500 after being told to perform a data log from 2500 to 6500.
Bouncing off the fuel cut limiter is extremely punishing to the rotating assembly. After telling the customer that fuel was cutting out at 6501 rpm
exactly they informed me that they were doing this. 

After the 93 map was finished the customer was given an e30 map.  The customer was told that map slot 1 was 93 and map slot 2 was e30.
The customer did not understand this, but did not question this either and performed an e30 datalog on the 93 map.

Sumnmary:

When tuning with us, the customer had no negative corrections and OAR was consistent -1 on both 93 and e30 as reported by the customer
and backed by the datalogs. 

Customer was made aware that focus st engine are well known for premature piston failure in cylinder 1.  Kyle Mcintosh (tuned by another tuner)
lost his motor at 7k with a failed cylinder 1 that was repaired under warranty.  These engines fail stock for cylinder 1 failure.

It's very possible the engine failure was exascerbated but boucing the car off a fuel cut limiter at high rpm when wot with boost.

During the entire time tuning, there was no knock events that triggered a negative correction on the vehicle at wide open throttle.