Boost Leak at Fuel Injector

[ob1murry]

I have a pretty terrible boost leak where the #1 fuel injector meets the head.

I have already replaced all of the o-rings at the injector to rail, all of the injector spacers at the rail, and all of the insulators at the head twice, the first time I pulled them off a set of injectors that I had installed and never ran, and the second time was with a complete new set.

At one point I thought maybe the bolts were just not tight enough and gave them each just little bit extra and they just kept spinning, even when torqued to 8 ft/lbs.

I drilled and tapped some new heli-coils, and installed everything again, and still have the same issue.

The leak is definitely coming from the injector/head, since pushing down on the injector seals the leak. I find it hard to believe that after replacing the seals the second time, that they would be bad.

Can anyone help me out by providing any more potential problems?

I'm running them without pintle caps, but it was my understanding that they were not necessary, and 3 of the 4 injectors seem to be sealing just fine. Is it possible that the injector tip just is need thick enough and needs the pintle caps to seal correctly?

 

[MJBean420]

I had a similar problem once. I checked the area and cleaned it well. I ended up getting frustrated and using a dab of RTV on the seal. Gave it some time to dry and tested it again. Held up to ~20psi fine. Its been holding fine ever since.

 

[bryanwheat]

Not having the pintle cap could very well be causing your issue. There is going to be considerably more space between the seal and the injector without them.

 

[ob1murry]

Just for anyone who is interested, I was wrong, the injectors did have pintle caps, not sure why I did not think they did.

Just in case though, I went at replaced them with new one from injector-rehab.com, and although I had to place two orders, because I broke 2 of the first 4 I tried to install, I got them installed and tested again, and no longer have the boost leak.

 

[92AWDHX40]

Glad to hear you fixed that problem thanks for the link.