Quote:
Originally Posted by dannichols1474
Finally, I connected the fuel pump and switched the ignition on (key on, engine off) to check for fuel leaks. I heard the fuel pump start running but it sounded odd, then I looked at the pressure gauge on the fuel pressure regulator and it wasn't building pressure (it was set to 38 PSI). Then I realized why, fuel was gushing out of both fuel rails and down each injector. I turned the key off.
I loosened the 6mm screws on each rail to their mounting brackets and pushed down to make sure the injectors were seated in the rails. Then I re-tightened the 6mm screws and re-tested the fuel system - still leaking huge amounts of fuel.
By this time, I had a gasoline lake under my car.
Once the lake evaporated a bit, I removed one of the fuel rails so I could inspect the injectors. I found the upper o-ring on each injector to be very hard and shrunken - there was no sealing / snugness of fit to the pocket in the fuel rail. Meanwhile the lower o-ring was still flexible and supple, the bottom of the injector fit snugly into the pocket of the ITB, as well as, the fuel rail. Clearly, the upper o-ring that is normally always in contact with gasoline hadn't fared well after being dry for 6 months.
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In my case the issue was not the design of the fuel rail nor their mounting brackets. It was due to the upper o-ring on the injector becoming hard and shrunken after being in service and in constant contact with fuel then being dried out for six months while I rebuild the engine.
When I installed new injectors with fresh o-rings, the injectors fit snugly into the fuel rails and the ITB's and the fuel leak problem was solved.