Well that's a first...

[Jory]

Today I was putting the finishing touches on a 1.6 n/a that I recently built from the ground up.
As I was installing my newly rebuilt injectors, all was going well... until the last one.

Just as I was getting close to 51 lb. ft, I felt a "pop" and it started turning much too easily.
Turns out a ****ing chunk of the head just decided to separate. Basically, the outer half of the injector threads cracked away.

I've never seen this before, and honestly am quite perturbed. Has anyone else dealt with a similar situation?
Looks like the only way to salvage this head is to pull it back off (and trash the brand new, never run headbolts and mls gasket) and have it tig'd and re-tapped...

Sorry, no pics currently.

[rallydiesel]

You always want to apply torque towards the head. Never away.

[theman53]

YEp! first head I ever did myself I did the same thing.  Push toward the head and usually it doesn't happen. Since I have been doing that it hasn't happend since.
Take it off and to a really good tig guy with a junk injector and all should be well.

[Jory]

That's the crazy part of it, I was pushing towards the back of the car... 

I like the junk injector idea, might even try welding it with the head still in place.

[theman53]

If you don't have the IP on then it is possible.

[Quantum TD]

I hold the head of the torque wrench to give it a pivot point when using an extension. Never had a problem. This will alter the actual torque values, but once the heat shield gives, it really doesn't matter.

I also make a habit of chasing the threads on the injector bores, and cleaning the threads on the injectors themselves. Finally, some gray anti-seize when they go in.

[monomer]

I hold the head of the torque wrench to give it a pivot point when using an extension. Never had a problem. This will alter the actual torque values, but once the heat shield gives, it really doesn't matter.

I also make a habit of chasing the threads on the injector bores, and cleaning the threads on the injectors themselves. Finally, some gray anti-seize when they go in.

anti-seize will also mess with torque.

the heat shield does seal it, so as long as if crushes proper you should have no issue.


You're not the first that this has occurred. I've never had a problem with them, but last I took injectors out was on a fresh(er) rebuilt head. some PB blast (or ATF, if you don't have any) should make them come out easier. Do check both threads before installation!

On welding, I would be worried about warpage. A proper welding shop would be your best bet for a good fix, I wouldn't do it in the garage with the head still on the car (but thats just me)

[Mark(The Miser)UK]

Never use maximum torque initially.
Most times it's not needed, and gives you that bit of spare tightening  if there's an issue in the future.
Using one of those pivot joints eliminates the side leverage. I also use a 'T' bar.

I now do it by feel...
Feel the shield give way; and then add a bit.

[carrizog60]

i removed my engine from a damaged car and the head had an injector that on the crash,damaged the head.
just removed the pump and at the machine shop they welded it and its holding fine since.

[Smokey Eddy]

I saw as killed TIG welder fix one of those before but if that's not an option there is a site that sells chinese knock off parts for our VWs and sells very cheap 1.9L heads which will cross over to a... crap your NA is likely mechanical...
this post is irrelevant. Should i even click post?
Sorry mate, i hope you find a fix...

[wdkingery]

My injector kep falling out with the Bentley prescribed torque, so I torqued mine to 140 foot pounds and managed not to do this. But I know it's coming so I'm waiting on how you fix this

[Wayland]

I had the same thing happen with my first injector change back in 2004. I cracked it, but the piece didn't fall right off, so I drilled several small holes through the broken piece into the head. I cut some short pins out of bicycle spoke, slathered them with JB weld, and tapped them into place. I then covered the whole area wtih a gob of JB Weld. I drove it for a couple of years, then sold the car. To my surprise,I recently came across my old engine in another car (he had bought the engine from a wrecker) and the patch was still holding. I can't say I recommend this method, but it's held up for 7 years!

[vdubspeed]

bicycle spokes and jb weld. Ridiculous 

[Smokey Eddy]

bicycle spokes and jb weld. Ridiculous 

or genious

[Jory]

I had the same thing happen with my first injector change back in 2004. I cracked it, but the piece didn't fall right off, so I drilled several small holes through the broken piece into the head. I cut some short pins out of bicycle spoke, slathered them with JB weld, and tapped them into place. I then covered the whole area wtih a gob of JB Weld. I drove it for a couple of years, then sold the car. To my surprise,I recently came across my old engine in another car (he had bought the engine from a wrecker) and the patch was still holding. I can't say I recommend this method, but it's held up for 7 years!

hahaha awesome! 

I forgot to update with the results. I ended up TIG'ing the head while still on the block and with the motor still in the vehicle.
The injector torqued right down and the motor has been running like a dream.