Engine Damage: Workshop Error?

I bought a new set of fuel injectors on eBay and, due to a lack of time and motivation, had them installed by a mechanic.

When I picked up the car, I noticed a faint squeaking or hissing sound that seemed to be related to the fuel injection of one of the cylinders. So, I went back and pointed this out. However, the mechanic couldn't hear anything and said that the engine was running smoothly and that everything was fine.

Today, I broke down on the A45 highway near Siegen! Thanks to the 0800-AUDIHELFE service, the Audi center in Siegen towed my car and started troubleshooting.

The injector nozzle on the first cylinder was loose, and that's where the compression was leaking out! So, remove the injector nozzle and locate the fault!

After the mechanic removed the fuel injector, he desperately searched for the copper gasket that should have been between the fuel injector and the cylinder head! He then found a melted metal ring that had taken the shape of the fuel injector!

http://www.edv-schreiber.at/audi4ever/fdb/pics/489_10c2e6bd4a9a4d29185e300b46147ed7.jpg

Startled, I removed the other injectors, but they all have the required copper seals in place!

The loose injector has damaged the seat in the cylinder head to such an extent that the entire cylinder head needs to be replaced! And I probably won't find out what the cylinder bores look like until the head is removed!

I have such a sore throat!

Of course, the workshop that's carrying out the work will be closed for the long weekend and won't be reachable again until Tuesday!

Now, thanks to the mobility guarantee, I have an Audi A3 for 7 days, but even with that, the ESP warning light has been on for the last 30 kilometers!

I'm curious to see if I'll end up stuck with the loss.

Regards,

Manuel.

Well, I think the first workshop that installed it should be responsible for the damage, and I would definitely insist on that.

It's quite obvious who installed something incorrectly, even though the 'ring' almost looks like a clamp? Or is it just oddly shaped?

It's quite obvious who installed something incorrectly, even though the 'ring' almost looks like a clamp? Or is it just oddly shaped?

The sealing ring, made of an unknown material, has deformed due to the pressure and now conforms to the shape of the nozzle in the area of the cylinder head!

Too bad that I will now never know how many kilometers the original engine would have lasted!

I'm also starting to suspect that the piston might have been damaged! Since the copper gasket is about 2.5-3mm thick, and this strange ring was maybe only 1.5mm thick, the nozzle head was protruding about 1mm further into the combustion chamber! Nothing would have fit properly then! When the nozzle was loose, the nozzle tip was even protruding about 2mm further into the chamber!

Let's see, if the head comes off!

Regards,

Manuel.

I assume that the relevant piston has not been damaged, as your engine is equipped with a concave piston, which provides ample space.
Could you also not detect any pressure build-up at the nozzle?
I think a replacement cylinder head will get your engine running again.
The workshop should handle the installation of the injectors.

I assume that the relevant piston has not been damaged, because your engine has a recessed-top piston installed, which provides plenty of space.


I didn't have this suspicion because of potential contact problems between the pistons and injectors, but rather because of completely different injection parameters!

Since I installed the injectors, I've driven about 600 km, and I've been exceeding 3,000 RPM. There might have been some problems caused by that!

But never mind. Hopefully, I'll know more by Tuesday!

Regards,

Manuel.