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    • Audi 2.5 TFSI engine internal limit found? Iroz shop RS3 piston gives

      When pushing the limits this is part of the game. Additionally, regarding the 8S Audi RS3 and 8V TT-RS it is still early in the 2.5 TFSI tuning game so nobody really knows what the limit of the internals is. Iroz Motorsport may have inadvertently found it.


      Now keep in mind this failure could also be a fluke but it was interesting to learn the factory 2.5 TFSI pistons are cast, not forged. They still managed to take a hell of a beating.

      This happened on the RS3 sedan with their Xona Rotor upgrade and roughly 18k miles but those miles were hard, hard miles. This looks to be a wrist pin failure where the casting failed of the retaining clip which gave way.

      Fluke or not a fluke? You decide:




      This article was originally published in forum thread: Audi 2.5 TFSI engine internal limit found? Iroz shop RS3 piston gives started by Sticky View original post
      Comments 8 Comments
      1. Stevenh's Avatar
        Stevenh -
        Iroz's story has always been he wanted to find the limit so his customers didn't. I'm very curious where it was.
      1. spool twice's Avatar
        spool twice -
        That wrist pin apparently somehow un-pinned itself and scored the cyl wall on that one cyl. Strange that it only happened on one cyl, which makes you wonder if its a production fluke. This occured in the 700awhp range fwiw, stock internals, that's still pretty cool for a 2.5L stock block/internals. The rods/pistons/bearings/cyl walls otherwise looked clean without signs of wear.
      1. Bowser330's Avatar
        Bowser330 -
        very impressive however i see it more as a sign that the "safe" limit has been found, the Panama guy may have run 742whp but its only a matter of time until something comes undone...and as the article mentions the IROZ car has been beat on through demonstration runs for numerous customers, 1/4 track runs for record hunting and Hank just beating on it when he DD's it in the 100+ degree Las Vegas heat.

        it seems to me like good insurance to build a bulletproof block if you are wanting to put down more than 500wtq/650whp, that is where i would stop with stock internals.

        pistons, rods, head studs, all readily available for this engine and you have a shop like IROZ that specializes in building the 2.5L engine from back in the day Quattro iron block versions to the more recent aluminium version.

        Plus by opening up the engine you get the opportunity to install updated cams and valve springs to enable the engine to rev out to 8500rpm, that will make the damn thing sing a sweet sweet song named......

        .... Lamborghini
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by Bowser330 Click here to enlarge
        very impressive however i see it more as a sign that the "safe" limit has been found, the Panama guy may have run 742whp but its only a matter of time until something comes undone...and as the article mentions the IROZ car has been beat on through demonstration runs for numerous customers, 1/4 track runs for record hunting and Hank just beating on it when he DD's it in the 100+ degree Las Vegas heat.

        it seems to me like good insurance to build a bulletproof block if you are wanting to put down more than 500wtq/650whp, that is where i would stop with stock internals.

        pistons, rods, head studs, all readily available for this engine and you have a shop like IROZ that specializes in building the 2.5L engine from back in the day Quattro iron block versions to the more recent aluminium version.

        Plus by opening up the engine you get the opportunity to install updated cams and valve springs to enable the engine to rev out to 8500rpm, that will make the damn thing sing a sweet sweet song named......

        .... Lamborghini
        That's why the platform is awesome. Plenty of ways to upgrade.
      1. LessIsMore's Avatar
        LessIsMore -
        Good to know. I mean, everyone knows a lot of engines can take 800 whp once or twice before they fail.

        This one took probably 600whp+ for 18K miles of the hardest severe-duty. The takeaway here is how long the engine made huge power under hard running, not the exact hp it made when it failed. Most of us never want ot have to open up the engine on a DD car, and having an idea how far you can push it and have it last several thousands miles without blowing, is great info.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by LessIsMore Click here to enlarge
        Good to know. I mean, everyone knows a lot of engines can take 800 whp once or twice before they fail.

        This one took probably 600whp+ for 18K miles of the hardest severe-duty. The takeaway here is how long the engine made huge power under hard running, not the exact hp it made when it failed. Most of us never want ot have to open up the engine on a DD car, and having an idea how far you can push it and have it last several thousands miles without blowing, is great info.
        I mean we could ask @HankIroz what he thinks but last I saw he recommended building the motor when going into the 7XX range.
      1. HankIroz's Avatar
        HankIroz -
        Torque breaks things. I think 500wtq is oem forever torque, 530-550 good if responsible, 575 is playing with fire. The rod on the EVO engine is literally a Mk7R rod, so take a look at what we are doing along with others at how much fire is being played with. Hope that helps.

        And yes, we have a solid engine building program for this engine already. This will help some people that lived in the fire too long.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by HankIroz Click here to enlarge
        And yes, we have a solid engine building program for this engine already. This will help some people that lived in the fire too long.
        Please check your e-mail when you get a chance.