Got the engine back together, now there's a fuel leak!

Looking for thoughts.

I replaced the heads on our 5vz-fe. Just got it all back together and started it up. After a couple of cranks it ran but I heard something leaking and shut it off. Fuel! Lots of it.

Ugh. Freaked out a little bit and tried to get as much info as I could before the fuel dried up. It looks like it's coming from the injectors or fuel rail. Top of the intake was soaked. Funny thing is, I never removed the fuel rails from the intake. I left it attached to the intake the whole time it was off, just removed the high pressure hose. The high pressure fitting looked dry (I did use new washers and tightened it down good).

Dang not sure what to do besides start removing the upper intake so I can get to the rails. I hate the fuel rail setup, torquing on that assembly.

My first thought is to examine the rails and be sure they are torqued down correctly. I wouldn't have thought this would be an issue.

Thoughts?

 

Yeah when you put that fuel rail back together.......learned the hard way..

After tighten rail, spin each injector back and forth a little to make sure feels right...
had one not seated right.......fuel fuel fuel everywhere........

 

I didn't tighten the rail this time. Maybe I should have intentionally loosened and tightened each of the bolts after attaching the high pressure hose. The injectors were serviced about 45k miles ago and had new o rings.

Question is, do I go ahead and order the oring kits before taking apart everything? Ugh. Lots of ugh with this truck.

 

If you didnt touch....it should not be leaking....
make sure its not something else.....like that banjo bolt.....

Shouldnt have to replace those o rings, should last life of injector....
however different injectors use different orings.....

the new updated injectors for my 2rz from denso have diff designed/ diff oring...
if i'd left or reused old ones .....may of been screwed.....

If it is o-rings, most likely its the little tiny ones on top.....

 

The good news is, at this point an injector o ring job is freaking cake.

 

I've replaced a few 5vz-fe's. First one I did pissed fuel like that. It was the injector o rings. Napa auto parts had some Japanese made ones. I replaced all of them and that fixed it.

 

Thats reason I love my little under power 4-banner.....much easier to redo my mistakes....

You might be able to take one of those injectors to parts store and match top oring....
bet most all the 4 and 6 engines used same rail size on top.....

 

If you didn't touch the rails Logic would dictate it came from the high pressure banjo bolt you took apart. I'd start with that take apart again and put in new crush washers.

 

You might try twisting just that leaking injector before u do anything....
might get lucky......

 

I can't remember what it looks like inside the fuel rail, but if I recall it's just aluminum right? I was just looking at the parts diagrams and I don't recognize the small grommet. I recognize the large grommet that seats into the intake, and the 2 orings of course. But where does the small grommet live?

 

I checked the banjo but it looks dry as can be. I used 2 new washers from yotashop (they are actually solid washers). It's gotta be injectors/rail. All I can think of is that when I was tightening the banjo maybe it tweaked the whole assembly? The rails mounted on top of those 4 standoffs has always seemed weird to me. The whole assembly moves when tightening up the banjo. It actually looks like injectors 5 and 6 are wet, which are closest to the banjo assembly.

 

One time all i did was touch an injector and fuel sprayed out from the o-ring in the rail, you should replace all the O-rings on all the injectors.

 

"The rails mounted on top of those 4 standoffs has always seemed weird to me. The whole assembly moves when tightening up the banjo" - Very good observation.

I removed my fuel rails several times and the last time I noticed a small V-shaped crack at the injector closest to the banjo. I realized that when torquing the banjo, the fuel rail will twist quite a bit and the injector body can contact the edge of the fuel rail hole. On mine the crack did not extend past the injector oring so I just put it back together and it was OK. I did order a new fuel rail though.

Its probably not that but thought I would mention it - take a good look at the fuel rail where the injector inserts. I think the crack was on the outboard side.

 

I'd just get some o rings and crush washers and swap everything out. I did my injectors and fubared one of the seals, and as soon as I started it got fuel everywhere. I also highly suggest to use a VERY small dab of super lube on the o ring rather than gas/fuel. The Motorwest Denso injectors come with small tube of super lube. It was my experience that the gas made the rubber o ring expand too much, and get pinched. A very small amount of super lube made everything go together without pinching anything.

 

Motorwest sells a complete o ring and washer kit, which is inexpensive. I would get that, take the rail off and do the whole injector re-install with careful attention to torque specs. It’s an easy job really, won’t even take the whole afternoon, especially if you’ve already built out an entire engine.