[whyzee125]

I recently developed a fuel leak that has really turned into a pain in my butt.

My port injection has started leaking from the front plug.

At the front, it has an AN6 ORB plug that can be removed to install a fuel return if desired. At the bottom of the rail it has another identical AN6 ORB plug next to the feed line.

The front one began leaking fuel through the O ring. I replaced it and while I was at it, I put a new O ring in the bottom one too. I used viton AN6 replacement green O rings. The bottom one went in perfectly and sealed with no issues.

The front one, however, will not fully 'disapper' when tightening the plug. It crushes and spills out the sides, leading to a torn O ring and more leaks. I removed both and found that the lower plug hole in the rail has a chamfer to accept the O ring, but the front hole really doesn't despite having an O ring and using the same plug.

I think this is poor machining but I can't figure out how it ever sealed in the first place as it didn't develop its first leak for about 8 years.

[onebluemcm]

I don't know why they'd do it like this, but the only thing I can think of is the front one needs a crush washer/gasket rather than a o-ring. If there is no recess to capture an o-ring, it'll never work.

[whyzee125]

Originally Posted by onebluemcm

I don't know why they'd do it like this, but the only thing I can think of is the front one needs a crush washer/gasket rather than a o-ring. If there is no recess to capture an o-ring, it'll never work.

Thanks for the response! I initially tried that but that wouldn't seal either. I tried the banjo bolt type washer, then a copper washer, then another viton O ring like the other one has. It originally had an O ring.

I'm pretty sure it was incorrectly machined from new, but how it lasted this long, I have no idea lol.

I ended up removing the PI kit and am just running E40 for now since I needed the car running while I sort it out.

I'll likely keep my injectors and fuel line and switch to the BMP / Precision Raceworks kit, but if anyone has any ideas for how to get this one working, I'm all ears.

[onebluemcm]

People say to have things machined all the time but I know it can be a lot easier said than actually finding a machine shop to take on small jobs like this. That said, if a chamfer or recess could be machined into the end hole - gravy.

[Tambohamilton]

Can you get a dowty washer the right size?

[whyzee125]

Originally Posted by Tambohamilton

Can you get a dowty washer the right size?

Probably! I had tried a copper washer with no luck and found a few dowtys from my diesel truck but no dice. I think I got it to seal. I have it removed from the car right now but can hook it up by my ethanol sensor and build pressure to see if it holds before reinstalling!