(Engine experts needed) Chirp, Vibe, Pop (What is Wrong?)

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If it come through with force, I'd think it'd throw the bit into the tub. I don't see any markings in the tub.

It looks like the 7th injector has been busy:

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As close tolerance as those have to be to positively displace air, I wonder if that bent one of the rotors or both. When you turn the nose pulley, do you feel any drag?

I can't feel any difference when that area meshes. They might deflect under load?
 
I'm convinced that it came this way because I cleaned all of my intake tubes before installing, pressure tested the intake for leaks, and I've only ran the engine with a filter on. And this has been a problem since day 1. But if say this did happen while on my engine, don't you think my engine would also be having issues if a chuck that big went through?
 
I'm convinced that it came this way because I cleaned all of my intake tubes before installing, pressure tested the intake for leaks, and I've only ran the engine with a filter on. And this has been a problem since day 1. But if say this did happen while on my engine, don't you think my engine would also be having issues if a chuck that big went through?

One would think. But I have seen bit of turbo veins go through and engine without killing it.

But I trust you are correct and they sent you a badly rebuilt SC.
 
I hope they do too!

I'm looking forward to it being reliable and trouble free. Then I can work on figuring out and obtaining parts for more HP in a relaxed manor.

Yeah I’d rather not swap my 4.0 in the future and hope this pans out. Fingers crossed for you!!
 
But I trust you are correct and they sent you a badly rebuilt SC.

If I could think of a way that I damaged it, I'd feel stupid for sticking a #8 flat head down the intake, but I'd own up to it and offer to pay. And I have made plenty of those mistakes on my build and paid the cost.
 
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The rotors and tub seem really sooty for just over 1k miles. Since the fuel appears to be pooling from the 7th injector I wonder if the pop could even be the rotors rubbing enough to spark causing ignition in the intake.
 
Ouch. Well get the rotors fixed and proper tune. I don’t have enough knowledge to speculate whether the fuel could cause that but I guess anything is possible. We know it was running super rich, so you could point in that direction. To be honest with that much pooling I’m surprised there wasn’t a rich fuel smell
 
I'm convinced that it came this way because I cleaned all of my intake tubes before installing, pressure tested the intake for leaks, and I've only ran the engine with a filter on. And this has been a problem since day 1. But if say this did happen while on my engine, don't you think my engine would also be having issues if a chuck that big went through?
Remove all of the sparkplugs, and if there isn't plug damage, remove the head and have a look. The squish area over the piston would not have space for a piece of metal. It's likely a valve would have taken a hit also. Forced induction forgives many sins in the intake path. A damaged intake valve won't always manifest itself externally. You (and the SC manufacturer) won't be certain the lobe scoring was pre existing until you inspect downstream conditions.
 
Remove all of the sparkplugs, and if there isn't plug damage, remove the head and have a look. The squish area over the piston would not have space for a piece of metal. It's likely a valve would have taken a hit also. Forced induction forgives many sins in the intake path. A damaged intake valve won't always manifest itself externally. You (and the SC manufacturer) won't be certain the lobe scoring was pre existing until you inspect downstream conditions.

Would it manifest while not using the SC?
 
I looked back through my emails, phone calls, and forum posts. I've been dealing with this issue since November 15th and made BoostedTech aware of the issue on that day, that's the day after my first test drive (my drive was at night, so wasn't able to deal with it right away). Hopefully this is the end of it!