Resolved 1G Fuel leak at rail?

[streiche]

So, it's June and the snow's finally gone (thanks, Michigan.) Over the winter I've been doing some small mods and cleaning up my 91 TSi FWD. I replaced the transmission and clutch. I pulled the rail, and painted it. I also switched to a modified PCV setup, and deleted the EGR valve.

Now when I start it, I have a large fuel leak from the injectors/rail (can't really tell exactly where). It also, obviously, runs extremely lean. I took the rail back off, and noticed I was missing one of the three "spacers" that the bolts slide through. I purchased a new one from the dealership, and JB welded them in, since everyone seems to lose them. I had assumed this would be the cause, but apparently not. I'm using Evo 8/9 560's, and they didn't leak last fall. So, the obvious answer is to buy another set of o-rings and seals for the injectors, but I was just wondering if anyone had seen something like this due to the fuel pressure regulator, or had any other ideas as to what it could be.

Also, assuming the problem is the o-rings, do I need stock 440 o-rings or Evo 560 ones? Stock rail, Evo injectors.

 

[1Gina2G]

So, it's June and the snow's finally gone (thanks, Michigan.) Over the winter I've been doing some small mods and cleaning up my 91 TSi FWD. I replaced the transmission and clutch. I pulled the rail, and painted it. I also switched to a modified PCV setup, and deleted the EGR valve.

Now when I start it, I have a large fuel leak from the injectors/rail (can't really tell exactly where). It also, obviously, runs extremely lean. I took the rail back off, and noticed I was missing one of the three "spacers" that the bolts slide through. I purchased a new one from the dealership, and JB welded them in, since everyone seems to lose them. I had assumed this would be the cause, but apparently not. I'm using Evo 8/9 560's, and they didn't leak last fall. So, the obvious answer is to buy another set of o-rings and seals for the injectors, but I was just wondering if anyone had seen something like this due to the fuel pressure regulator, or had any other ideas as to what it could be.

Also, assuming the problem is the o-rings, do I need stock 440 o-rings or Evo 560 ones? Stock rail, Evo injectors.

There's 2 basic o-rings you should replace every so often through use of taking off / putting on. The o-rings on the injectors themselves along with the seals that insert into the intake manifold are special and should be OEM & matched to the injector type.

Also highly recommend silicone spray on all o-rings prior to install, best lubricant for rubber. Otherwise, you could have a possible cracked fuel injector(s), fuel rail and/or bad fuel pressure regulator. I know if the FPRs go bad sometimes they can leak gas into the vacuum line connected to the intake manifold.

If you still can't find it they make a UV dye that is okay to use in gasoline / oil but I suggest taking everything off, replace the seals and take a real close look at everything. A cracked injector will usually have more gas drippage compared to a good injector.

 

[2gmitsueclipse]

I will also suggest changing the upper injector seals. The lower ones as well since you are there. The upper would cause a fuel leak, while the lowers would cause a boost leak.

One or more injectors may have become unseated during install and/or damaged/twisted the upper o-ring. ExtremePSI offers an OE replacement set that will work for the OE 2g and Evo injectors.

If you have removed either fitting from the ends of the fuel rail, the o-rings on those fittings may have also been deformed/damaged.

On another note, for the fuel rail spacers, I typically put a dab of bearing grease on the spacer to head mating surface to keep them in place.

 

[jimsgsx]

Just replace all the bottom and upper seals. I had fuel shooting out of a bad top o-ring once.

 

[streiche]

I just want to be clear, on the seals, using this link and OEM mitsu option will be the correct seals? And assuming that's the issue and it's not a crack or the FPR do I need anything else?

https://www.extremepsi.com/store/product.php?productid=17787