Engine/Transmission (1994 - 1998) Injector still leaking, can't figure it out

[JGheen]

So I thought the source of my leak at the #1 injector was the fuel drain manifold horse-shoe sealing washer and it turns out it wasn't. After I replaced all the old original drain manifold washers, I started the truck and waited to see if the leak would come back. Sure enough after about 1-2 minutes of staring at the injector I noticed that the clean fuel was coming up through the inside of the hold down nut where the square-cut o-ring is supposed to go on top of the nut.

So I can't figure out where this leak would come from. It is not coming from the injector line nut, it is good, clean and snug. Could the body of my new EDM'd tipped injector be cracked or something causing the leak up through the hold down nut, hopefully not filling up the injector bore with fuel? The fuel is clean and not sooty, oily or black so it can't be coming from the injector washer sealing it in the clyinder, not to mention it is not missing nor seems like I have any compression loss with how well it runs. The leak is small but it fills up the area where the hold-down nut o-ring is supposed to go and then evaporates some as it drips down to the exhaust port and manifold. Anyone ever had a leak like this and what did you do to fix it?



Thanks, Joe

 

[Redram 1]

re

Sounds like a cracked tip to me.

 

[JGheen]

Shoot, I hope not! It's brand new, how could it have cracked?

 

[Will24]

Did you get the old copper washer out of the #1 hole before the new one went in? is the hold down nut TIGHT? (you have to really crank on them sometimes)



-Will

 

[JGheen]

Hold down nut is torqued to 44ft. lbs. and old washer came out with old injector. New injector, new washer.

 

[Will24]

Well, the next step I'd do, get the injector out of the hole, do a visual inspection etc. While it's out, clean the injector bore really well, get an injector cup brush and make sure all the crap is out, use electrical contact cleaner to wash the hole down, then dry everything out with air, get a new washer and try it again if the injector looks ok.



-Will

 

[JGK]

Swap it with the injector from the next cylinder and see if it follows (probably does). At least you'd know its the injector or not.



I would bet an worthwhile vendor would work it out with you. You haven't had them very long, right?



-Jay

 

[JGheen]

Ok, got the injector out this morning and it looked Ok. Tip was dry, no signs of cracks and washer seemed to show no signs of leaking or breaks in the surface that was squashed. The injector was real wet with fuel though when I pulled it out. I am thinking that the body has a leak somewhere from all the fuel around it when removed. Went ahead and cleaned bottom of injector bore and put it all back together. To me it looked like the copper washer had a good seal and the body of the injector is probably seeping fuel from the threads where the injector is screwed together. Still early here but will fire it up soon and see what happens. Stacks have been wakin' up the neighbors lately. :-laf



Joe

 

[JGheen]

Well, so far, the injector is not leaking anymore. If this continues, I am not sure what caused the leak. For some reason I think I haven't driven it enough yet and the injector bore is just filling up with fuel right now and maybe a few more miles it will start again. :{