Audi Repair: Engine Oil Believed to Be Excessively Overfilled, exhaust manifold repair, flange bolt

Question
QUESTION: 60% or more Overfill...Too much oil - Excessive...Can it lead to engine failure

I recently had my car in for an exhaust manifold repair in a local chain of exhaust shops...when I picked up my car it was making a ticking noise and would not idle properly...the mechanic stated that it would not idle properly now and to put some carburetor cleaner in it and drive it for a few days and it should be fine.

The original repair was for a broken flange bolt on the catalytic converter, connecting to the exhaust manifold.

I was told the bolt broke for the second time in 2 years due to a failing/deteriorating set of engine mounts and I needed to replace the transmission mount, as well. When they were unable to successfully remove the bolt with 4 drill bits and a broken easy-out bit...they advised me they would need to remove the exhaust manifold and have it drilled out by a machine shop or replace the exhaust manifold. When they attempted to remove it, they took off the heat shield and discovered the exhaust manifold was cracked and would probably need replaced, which I agreed to such.

After a complete estimate, they also advised me the only other needed repairs that the car needed was brakes and a couple tires, I told them to replace all parts noted, except for the brakes (which, I said I would bring back in a month or so.) and I said I would replace the 2 tires at my local tire dealer, where I normally have my engine work and repairs done other than exhaust and struts.

The total bill was slightly over a thousand dollars, which I paid when I picked up...this is when the ticking noise was discovered and rough idle was noted by the mechanic.

My original repair was as follows, I lost low end power and was getting a little exhaust noise due to the bolt being broke, causing an exhaust leak.

They replaced all the parts, as requested and I took the car home and sprayed the carb cleaner in the air cleaner and carb as instructed by the mechanic...the idle did smooth out, although the ticking continued, primarily during acceleration and/or when going uphill, when I would take my foot off of the accelerator, it would stop.

I was slightly concerned, so I made an appointment with my regular repair shop/tire dealer, soon after my engine started making a slightly louder ticking noise and then it got louder and started smoking...I pulled over and had it towed immediately.

I have since been told a piston cracked at the bottom and there was now anti-freeze in the oil pan.

When I contacted the Manager of the shop which did the work, he had quit the prior business day and I had reached the regional supervisor over the entire chain of Exhaust/Repair shops. We discussed the occurrence and he offered to repair if they did something wrong...we agreed to discuss further once my shop fully diagnosed. After we hung up, he called back to let me know that prior to picking up my car, that the mechanic believed and/or thought that the oil level was 2 quarts low...so he added 2 quarts of oil...although he never noted this on the work-order...I was never told such and it was never noted in the work-order or final invoice, nor was I charged for the oil, why would a mechanic add 2 quarts of oil and not note it...

I want to note this is a 4 cylinder 1987 Nissan Pulsar, the engine only requires 3 3/8 quarts of oil, if it were 2 quarts short and it would be rattling like a caged animal...not a little tick...it would be hammering. The filter only holds a 1/2 quart...this is a very small engine, if the mechanic misread the dipstick, by not fully inserting the dipstick in the tube...then added 2 quarts...the total amount of oil would be about 5 3/8 quarts...2 quarts too much (about 67% too much oil)...

Would this/Could this cause major engine failure???

I am thinking it would cause excess pressure in the pan and on the seals in the block, causing the damage to the bottom side of the piston and also cause the anti-freeze to leak into the cylinders, thus causing poor lubrication.

This happened in less than 50-60 miles of the repair.

Please confirm my thoughts...

I would like to note, this is a one owner car with only about 125,000 miles...and I had the engine tuned up about 14 months prior, less than 10,000 miles prior...including a new timing chains, pulleys, belts, plugs, wires etc...the engine was very sound and smooth operating.

Please advise me of your feelings.

I am now facing a $3,500.00 engine replacement.

Respectfully yours,

Kevin J. Wallace       
mrbellevilleman@yahoo.com

618-530-7890 Cell
618-277-5042 Home


ANSWER: Kevin,

Thanks for your question.  A ticking noise after a job like this probably means an exhaust manifold gasket leak. Since the exhaust manifold was replaced this makes sense, and is further validated by the fact you noticed the noise was louder when you put more load on the engine.  With reference to your question, while an overfilled engine can indeed suffer damage, I do not think it can cause piston cracking like you describe.  Certainly it makes no sense that water somehow got into the oil; even if the piston cracks there should be no water in the oil, unless the block broke or the cylinder head failed.  So the statement from the second shop does not make sense.  I do think, however, that your engine is probably beyond repair.  I would look for a replacement engine, and would certainly look at the first shop for compensation.

Please note you had submitted your question to a forum for Audi vehicles, I am not so familiar with Nissans; I thought your situation warranted a reply anyhow.  Good luck with getting this resolved.  Let me know if there is anything else I can help you with.  Sincerely,  Jan

---------- FOLLOW-UP ----------

QUESTION: Jan,

Thanks for your quick answer...

I do believe there was a head gasket failure...

and my regular shop said they put a scope in the engine and the can see antifreeze in the cylinders...they suspect that the block is cracked resulting in the antifreeze presence in the pan and cylinders.

I want to add when the engine became noisy the car lost power and white smoke was coming out...

Only one piston cracked...

Is there anymore feedback to help me with my case.

By the way, I did note that you were an Audi expert...there were no Nissan experts available, so I searched for another import expert since the question was a general question about overfilling. Someone I know said overfilling an engine would not harm it, they stated it would just be real messy and I had heard years ago that overfilling an engine was as bad as unfilling an engine, due to the engine having more internal pressure due to too much oil...please confirm...

Thanks again for your promptness and any additional advice or info you may provide.

Respectfully yours,

Kevin J. Wallace

Answer
Hi Kevin,

It actually depends on the exact engine whether overfilling can cause actual harm to it.  In most cases it has to be extremely overfilled before it does damage.  Underfilling is never good, as that can cause oil starvation which always leads to serious damage.  

Based on your story I would search for a replacement engine and work out a deal with the shop who performed the first repairs to cover it.

Let me know,  Jan