As most of you know I am preparing for the switch to E85 and needed larger injectors. I looked at several different options and decided to mod some stock injectors. I bought a set from Liquidforce so that I could send them off while continuing to drive my car. I looked around and stumbled on a place called WitchHunter Performance. These guys are awesome. In less than a week I had the injectors back. For $110 they replaced every single o-ring, all the filter baskets, modded the injectors, cleaned the injectors and flowed them. Edit: Forget all the rest of the stuff...this is a little upsetting. Not sure if mine was an isolated instance, but I had 2 things that I was very upset about with these injectors on closer inspection. 1st. While taking a look at one of the injectors before installing it, I noticed a large shard of metal under one of the o-rings. It was on the side that goes down into the engine. It looks like when they modded the injector a piece of metal somehow did not get cleaned off...large shard of metal that could have potentially gone down into the engine....BAD NEWS. I cleaned it off and inspected the other 3 injector tips carefully. Seemed to be the only one. 2nd after installing all 4 injectors, I thought to do a pressure test just to make sure I had no leaks. One of the injectors was spewing fuel like no one's business. I had 2 that leaked and after re-seating them both, I was down to just the one. It was still just pouring fuel out of the top of the injector and it was going everywhere! So I took the whole thing back out and looked at the offending injector...one of the o-rings looked like it was a factory defect. I had just assumed that all the o-rings were new and in good shape. As it turns out this one was a factory defect. It was not even round. It was not damaged in any way, it was just not round from the factory. I am sure that Witchhunter did not purposely put on a bad o-ring, but they could have at least looked at the o-rings before putting them on the injectors. As it was, it cost us about an extra hours work. Thankfully one of the old injectors still had a good o-ring on it. I was able to re-use that one and make the whole deal work. Moral of the story, while witchunter is cheap, I am less than impressed with their attention to detail. If you get your injectors modded there, just take extra care to inspect them after you get them back. While they looked like they were in good shape at first glance, that just was not the case...that piece of metal in one of the cylinders could have been bad news!!
It is not uncommon to pinch the orings and not have them seal right. I really doubt they sent you a defective ring. You have to make sure that you intall the fuel rail evenly. Deatschwerks provides a nice lubricant to install the injectors. I normally use a little motor oil. Anything with less viscosity may cause issues. Even when the fuel rail is tight you should be able to spin the injectors a little. It is really important to have that top o-ring seated properly.
They were all spinning freely. We use gas to lubricate them per the instructions we found on NASIOC. I am telling you the o-ring was oblong, not round and did not hug the injector like it should. I don't think that pinching it would cause to to go out of round would it? And the metal shard I found right after taking it out of the bag they shipped it in. It was tucked right up under the o-ring on the TGV side of the injector.