Boost Leak from HELL!!!

[AWD_FIEND]

So my car has a massive boost leak that is audible at idle and the car wont hold more than 4psi under boost. When I connected the boost leak tester my injector isolators were all leaking. No problem, went to Satan bought new isolators and threw them in. It fixed all the leaks except one around the #3 injector. So I removed it and discovered the pintle cap was cracked, which I figured wasnt sealing against the insulator. So I threw in an extra injector with a good pintle cap and it still wont seal. Tried a little RTV and it still wont seal. No matter what I do the F-ing thing wont seal. The leak is so bad that my power brake booster sometimes doesnt work and when you shut the car off there's an insanely loud wooshing sound as vacuum escapes the manifold I have a feeling there might be other leaks but I cant locate them because I cant get the insulator/injector to seal Any ideas or suggestions, anyone else had an unsealable injector?

A bit of background I just replaced the head gasket and the coils and removed the fuel rail/injectors in the process of removing the coils. When I put everything back together that's when the insulators started to leak. The car ran great before and held 20psi all day long. I hate how everytime you take something apart on these cars it breaks something else...but I digress.

 

[LunarEclips]

im gonna guess its probably not the injector seal. Its probably the intake manifold gasket or something stupid. You used soapy water to verify its location? or are you just guessing?

 

[Tyeler18]

Insulators installed correctly? There's a lip on them that needs to be facing the correct way otherwise they don't seem to seal.

 

[AWD_FIEND]

im gonna guess its probably not the injector seal. Its probably the intake manifold gasket or something stupid. You used soapy water to verify its location? or are you just guessing?

Yeah I used soapy water and have been suspicious of the manifold gasket all along because it's very hard to see if the water isnt dripping down onto the manifold and being blown onto the injector. I can definitely see bubbles around the insulator though. The mani gasket is next maybe this weekend.

Insulators installed correctly? There's a lip on them that needs to be facing the correct way otherwise they don't seem to seal.

I noticed the lip on the old insulators, but the ones I got from Mitsu dont have such a lip they are the same shape top/bottom like a generic rubber doughnut. I assumed the lip was worn into the old insulators or something.

What's strange is I swapped all the insulators and they cured all the other leaks except on #3, I even swapped the other injectors and insulators that were sealing in the other ports to #3 and it still continued to leak just on #3. I'm also suspicious of the fuel rail possibly being warped and not pressing the injector into the insulator hard enough. Possibly warped fuel rail anyone?

 

[4G63conquest]

It cost literally literally 5 doll hairs to make a REAL boost leak tester. Go to HDR (Home Depot Racing) buy a 2.25 or 2.5in PVC end cap as well as a coupler. Drill it for a air tool fitting which is NPT (National Pipe Thread) a taper thread so it seals as you tighten it. Drill a hole in the end cap and tighten yout air tool fitting into it. Attach it to your turbo or throttle body whichever you decide to buy the PVC end cap to correlate to. Also dont over pressurize the system. 20-30psi will work. Your welcome

 

[AWD_FIEND]

It cost literally literally 5 doll hairs to make a REAL boost leak tester. Go to HDR (Home Depot Racing) buy a 2.25 or 2.5in PVC end cap as well as a coupler. Drill it for a air tool fitting which is NPT (National Pipe Thread) a taper thread so it seals as you tighten it. Drill a hole in the end cap and tighten yout air tool fitting into it. Attach it to your turbo or throttle body whichever you decide to buy the PVC end cap to correlate to. Also dont over pressurize the system. 20-30psi will work. Your welcome

WTF are you talking about?! Is this some copy paste response to get your posts up or something This has nothing to do with my issue.

 

[AWD_FIEND]

OK so I replaced the intake manifold gasket and it definitely helped as coincidentally the gasket was broken right below the #3 injector. Its holding about 8psi now of the 18 the boost controller is set for, but the injector isolator is still leaking badly on the #3 injector. Any more ideas cause at this point I'm fresh out. The only thing left I can think of is the fuel rail is warped and not seating the injector all the way. Help me out.

 

[13guest13]

hey question are u hitting fuel cut? because my injectors are leaking too and im getting fuel cut....

 

[LiquidX]

Did you lube of the insulator before putting the injector into it?

 

[AlaskanDsm]

OK so I replaced the intake manifold gasket and it definitely helped as coincidentally the gasket was broken right below the #3 injector. Its holding about 8psi now of the 18 the boost controller is set for, but the injector isolator is still leaking badly on the #3 injector. Any more ideas cause at this point I'm fresh out. The only thing left I can think of is the fuel rail is warped and not seating the injector all the way. Help me out.

Are you testing from the turbo or the TB? Reason I ask is because if you test right at the TB you will be able to bypass any other leaks in the system to increase pressure at the intake manifold. And I agree with LiQUiDx, did you lube the insulator? I know I had issues with this before. I wouldn't imagine the fuel rail being warped but it is possible and pretty simple to swap another one in to check.

 

[AWD_FIEND]

Sorry its been so long since I've responded, the internet has been out at my house the last two days!!! I've barely survived I've been testing from the turbo because my leak tester is too big to fit the throttle body elbow, it's working fine at the moment though. Yeah I lubed the insulators with grease to help seal them, but as it turned out when I finally finished replacing the intake mani gasket the injector leak went away. Dont ask me why but I'm grateful. But now it's leaking through the throttle shaft/return springs on the throttle body! Anyone else had the throttle body leak in that area? It's impossible to spray soapy water on the bushing the throttle plate spins on because there are plastic retainers for the return springs covering it. I'm so sick of my luck with this car

It just so happens there's another guy experiencing boost leak around his BISS and one of the responses was specifically about throttle shaft seal leaks. I guess they are pretty common eventually, its just ironic that I'm experiencing all these leaks AT THE SAME TIME anyway here's the link. I'll "rebuild" my throttle body in the next couple weeks and keep you updated. Here's a link to a FAQ page on seal replacement.

TB Shaft Seals VFAQ