[drkanavg]

I am a senior citizen, and a long-time car enthusiast, residing in the historic city of Panipat, NCR. I have been a driver since 1980, with a history of owning and driving various cars, including Fiat, Maruti, Ford, Honda, Innova Crysta and currently Toyota Fortuner, and MG Hector.

I am writing to seek your assistance and guidance regarding an ongoing issue with my MG Hector, which has been in the workshop for over 15 days due to a serious engine defect. Despite the vehicle being under warranty, the company has yet to begin the necessary repairs, and I have encountered multiple instances of delay, avoidance, and inadequate responses. Below are the details of my situation:

I purchased my MG Hector on February 24, 2021, with a 5-year warranty and have driven only 58,850 kilometers. On December 28, 2024, I noticed unusual vibrations in the engine and promptly drove to the local service center. After several days of testing and disassembling the engine, they diagnosed a broken piston (Piston No. 3) as a result of a manufacturing defect.

On January 1, 2025, Service Manager at Rahul Garage, Panipat, informed me that the cost to replace the damaged parts would be between INR 2 to 2.5 lakh, and this would be covered under warranty since it was a manufacturing defect.

That same day, I sent a WhatsApp message to the company stating:

"As discussed with service manager , the piston has broken at 58,850 km within the warranty period, with regular service history. We request a full engine replacement at company cost. A repaired engine is not acceptable. Kindly convey this to the concerned team. Awaiting your response."

However, the following events have been increasingly frustrating:

1. January 6, 2025: I visited the workshop again for a conference call with the Area Service Manager (ASM), who only offered to replace the child parts. Despite waiting for almost two hours for a written estimate, none was provided. Additionally, the service manager refused to share the ASM’s contact details, citing company policy.

2. January 7, 2025: Senior Service Manager, quoted a cost of INR 2.84 lakh for replacing the damaged parts and INR 4 lakh for the entire engine assembly. I again requested a written estimate.

3. January 8, 2025: At 11:30 am, I finally received a WhatsApp estimate for INR 1,34,538, which was significantly altered from the initial quote. It was clear that the company was trying to save costs by replacing only some of the damaged parts, and crucial components like the crankshaft, camshaft, timing belt, tensioner bearing, and valve guides were excluded. Furthermore, the dismantled engine has been stored in a dusty environment, putting the safety of the components at risk.

4. January 9, 2025: I reiterated my request for a full engine replacement, but on January 10, 2025, I received an email from JSW MG Motor India stating, “The entire engine assembly cannot be changed.”
It is crucial to understand that the piston is a key component of the engine, and such a defect, if left unaddressed, could lead to severe consequences, including engine seizure or even fire, jeopardizing the safety of all occupants.

The company’s refusal to replace the engine entirely, coupled with the deliberate delays and withholding of estimates, raises concerns about the intention to cut costs, even at the expense of customer safety.

Additional Issues:

1. A fictitious repair order for accidental work was generated on January 3, 2025, without my knowledge, indicating possible fraudulent practices to offset the warranty repair costs. The details of this repair order are as follows:
"Thank you for rejecting the LAMP ASM-RR FOG, FASCIA-RR BPR UPR, FASCIA-RR BPR LWR, MOLDING-RR BPR FASCIA LWR, MOLDING ASM-PUBX E/GATE O order NW07309228 of your MG HECTOR HR06X0332 on 03.01.2025."

2. The company had promised delivery of the repaired vehicle on January 6, 2025, but no work has been started to date. I have been forced to hire a taxi for my daily commute.
I also discovered on Team BHP that a similar engine failure occurred in another 2021 MG Hector after just 10,000 kilometers, which supports my claim of a manufacturing defect in the 2021 model. You can view the relevant post here: Team BHP Discussion. ; https://search.app/UyhyhhArdv3f2mk47

Given these circumstances, I respectfully request your intervention in this matter. I am seeking your support to ensure that MG Motor honors its warranty, acknowledges the manufacturing defect, and provides a complete engine replacement, as this is the only acceptable resolution to ensure both safety and customer satisfaction.

[SS-Traveller]

Originally Posted by drkanavg

It was clear that the company was trying to save costs by replacing only some of the damaged parts, and crucial components like the crankshaft, camshaft, timing belt, tensioner bearing, and valve guides were excluded.

A piston 'broke', you say. It's not clear what the extent of damage was, but going by one of your pictures, the cylinder wall appears damaged too. If the components you've mentioned above have not been damaged, why would they need to be replaced? Or, are you insisting on a complete engine replacement instead of (I expect) a 'half-engine' replacement (i.e. they'll replace the block & pistons, while the cylinder head, crankshaft etc. are reused)?

[Jeroen]

It is rare but not totally unheard of pistons braking.

Of course the various engine components need carefully inspecting. But in most cases the damage tends to be limited to the piston, obviously and the cylinder. Not sure if this engine has separate cylinder liners? If it does, it is a relative and easy job to replace the liner as well. Obviously the cylinder head needs to be inspected. But if there is no obvious visual signs of the piston or parts of the piston hitting the head and or valve there is really nothing to worry about. Everything else will be fine too.

I appreciate you would like to have the complete engine replaced. But as long as the damage is contained to just the piston and maybe the cylinder (liner) there is no technical reason to do so. That might not be the answer you are looking for, but technically speaking that is just how it is.

With close to 60k on the clock I would also replace the piston rod bearing as a matter of caution. With the piston removed there is no extra labour involved, only a new bearing and they are cheap.

With a new piston, piston rings, possibly liner and bearing installed you need to run the engine in a bit. The dealer should give some guidance.

There is one other thing though. Production defects rarely, if ever, affect single items. Usually a whole series or batch would have the same issue. So I would like to understand what the production defect was exactly and why it would be limited to this one particular piston. To me that sounds odd.

I think it would be fair for the dealer to give you a couple of years extra warrantee on the engine to give you piece of mind. And to make sure the other three pistons don't suffer the same fate at a later date outside the regular warranty.

Good luck

Jeroen

[technicalytuned]

Go ahead with the engine overhaul since I don't think they will budge and give you an engine replacement. Ask them to give maximum engine warranty and get an invoice of all the parts replaced in warranty. Take care that they don't use your insurance for parts replacement since they might show your car as accidental and you will have a hard time selling it.
I don't think the entire engine needs a replacement with just one piston breakage. But tell them to get it done from their best mechanic since experience matters a lot with engine overhaul. Take care to do a proper run in and check for oil consumption for at least 2k kms. Ask them to compensate for the daily travel expenses and get a loaner car if available. As Jeroen has mentioned ask them to replace the piston rod bearing as well.

[Nonstop-driver]

Originally Posted by drkanavg

1. A fictitious repair order for accidental work was generated on January 3, 2025, without my knowledge, indicating possible fraudulent practices to offset the warranty repair costs. The details of this repair order are as follows:
"Thank you for rejecting the LAMP ASM-RR FOG, FASCIA-RR BPR UPR, FASCIA-RR BPR LWR, MOLDING-RR BPR FASCIA LWR, MOLDING ASM-PUBX E/GATE O order NW07309228 of your MG HECTOR HR06X0332 on 03.01.2025."

I got a similar message when I gave my Hector for regular service a few weeks ago. I asked the service manager and he said it is standard practice for parts being removed from the vehicle for repair/ replacement.

[pranavt]

Since there isn't any damage visible in the two uploaded photos, I get the feeling that the damage might be limited to broken ringlands on one of the pistons. In that case, it would be wise to check the remaining pistons since they'd all have been manufactured at roughly the same time. With damaged ringlands (going by my assumption), bore/liner damage is likely and the block would need a rebore to the next oversize or liner replacement with standard size pistons.

Apart from that, if the top half of the engine is in good condition, and as long as there is no damage to the crankshaft and connecting rods, it makes no sense to replace the entire engine; and one that has done almost 60,000 kms.

[Sheogarath]

Doesn't look like a case for a total engine replacement. Get the damaged part replaced and invoice all the items for full warranty.

P.S. Being a senior citizen will get you no benefits from a private company. Makes no sense tbh.

[professor.march]

Is this the petrol or the diesel engine? Diesel engine in my harrier had broken camshaft at around 60k km. It was replaced under extended warranty. I had to pay for consumables including timing belt.