Engine/Transmission (1994 - 1998) 215 injectors leaking from down in head?

[Fordiesel69]

I double and triple checked that the injector lines and return fittings are not leaking. I even tightened the hold down nut more and fuel still seems to come out of where the nut holds the injector in. There are no combustion bubbles at all, what should I do to correct this? And yes I did use all brand new copper sealing washers.



Injectors were shimmed to 4000 psi.

 

[zstroken]

I would remove the injector and inspect the bore.

 

[Fordiesel69]

Bores were spotless, I had to clean each one. No combustion is leaking, fuel is leaking from the injector seam where the nozzle meets the body.

 

[BigPapa]

I have been told that over tightening the line nut will cause the line to leak.



Did the 3/4" nipple work for you?



Scott

 

[Fordiesel69]

I have been told that over tightening the line nut will cause the line to leak.



Did the 3/4" nipple work for you?



Scott

Yes the 3/4 solved the problem and so did an oem lugnut. I have aftermarket wheels and lugs, so therefor the lugnut did not work.



As stated in original post, it is without question the injector, not any type of line leak.

 

[Vaughn MacKenzie]

I am wondering if something wasn't put together right when the pop pressures were set and it's leaking around the injector body?

 

[Fordiesel69]

I am wondering if something wasn't put together right when the pop pressures were set and it's leaking around the injector body?

Could be, but the person seemed to be very knowledgable and credible. Although stuff happens I guess, any way I can take apart and check? A local shop said something about 9-10 times they need lapped, is this true?

 

[Fordiesel69]

I just took apart one of my 160hp injectors and there is nothing really sealing it. I have no idea how it stays sealed. What are my options?

 

[SRath]

This sounds kind of dumb, but I once thought my injectors were doing the same thing and they were always wet down in the pocket.



All I really had was a valve cover gasket seeping engine oil, not diesel fuel... It was running down in there and not leaving a trail to indicate where it was coming from. New vc gaskets and good powerwashing ended the problem.

 

[Fordiesel69]

Thanks but I verified it was fuel. It only did this since i installed these injectors.

 

[Forrest Nearing]

there's only two ways for fuel to come up from around the injector.



1. (the most common) is residual fuel trapped down in the injector bore left over from bleeding the injection lines and/or snugging up the return banjos



2. the injector body assembly not being tight and leaking

 

[CumminsPower98]

I was an idiot and bought a set of new knockoff 215s on ebay not long ago. I had several of those leaking from the bodies. I pulled them and tightened but this didn't really do much. I then bit the bullet and installed a spendy set of new PDR 215s and problem solved.

 

[Fordiesel69]

Download these 2 pics and enlarge them. They are good quality so you will be able to see the surface imprefections. This is why the injectors did not seal inside. It was leaking at the body seam. I ended up laying a piece of flannel on a special flat surface I had made for lapping lawn mower heads, then I applied automotive rubbing compound to it and began to rub the surfaced until they shined like a mirror. Then cleaned each part in fresh diesel to remove the rubbing compound. I did not get a reply fast enough so I read that volkswagen injectors of some kind get torqued to 30 ft lbs so I upped it to 35. Oh well, not far off from 22. At least they don't leak now. Fingers crossed.



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[Forrest Nearing]

I was an idiot and bought a set of new knockoff 215s on ebay not long ago. I had several of those leaking from the bodies. I pulled them and tightened but this didn't really do much. I then bit the bullet and installed a spendy set of new PDR 215s and problem solved.

why not some 370's?

 

[CumminsPower98]

Because I already have too much fuel for my stock turbo and I wanted a cleaner injector then the 370s. I wasn't going for more power, just replacements. My originals had 387k on them and the new ones made a significant difference in power and less smoke so I'm happy for now.