So I can pull my upper intake manifold and fuel rail in less than 20 minutes because I have now done it so many times. I've had a fuel leak at the injectors since January. I changed an injector out, it stopped leaking for a bit. I changed another injector and all the rubber, it worked for a bit, then started leaking again. I changed all the O rings, happened again. I changed all the O rings a second time, happened again. I changed all the O rings a couple days ago, it's starting to leak again.
I've pulled the fuel rail before and not had any trouble. But apparently I can't seem to get it together right.
I've tried putting things together in different order, tried all sorts of things. Nothing. So, someone have any idea what I'm doing wrong or where there could be a problem?
(the leak starts at different injectors (seen it at #1, #3, #4), fuel leaks between injector & fuel rail.
Any help would be great, I'm really getting tired of this.

 

where are you getting your o rings from? that could be the deal breaker right there. Are you lubing the rings before installing them? is the rail sitting flush with the mounts? or is there some dirt or something caught there?

 

Fel Pro is the brand, it's what my local Kragen carries for the injectors, they seem to fit right, but they make the injectors pretty tough to get seated in the rail.

I didn't lube them every time, then I read that you should lube them with gasoline first, as I did the last time. Everything was sitting flush as far as I could tell.

I'll pull it apart here soon and see where it's leaking this time.

 

Any chance you're leaking from the banjo bolts and not the injectors?

If it's the injectors, it can only be the rail isn't lined up, or the injectors aren't seated to the rail properly. Can always try actual Toyota o-rings, but I've never had issues with the oems...

 

Ya, when it it gets bad it's pretty obvious where the leak is, fuel sprays, I get a river of gas running down my engine. I'm going to go and get another set of injector o-rings tomorrow and I'll pull it apart then. I'm so tired of this... :/

 

The injector orings rip VERY easily. My 3zve was doing this after a head gasket change. The fix was going to napa and gething a lube called syliglide (it was a napa brand) and lubed up the injectors and orings before putting them in. No problems so far.

 

your fuel rail may be warped being aluminum i had problems after i cooked a head in the winter

 

I was extra careful installing it this time, I didn't bother to check where the leak was, but I feel pretty good this time. I installed all the injectors carefully and on any one that gave me resistance I used some white lithium grease and that did the trick.
I am missing a copper washer from the income line connection, any idea where I can get a replacement?

 

That's what I was wondering... :p They're cheap from toyota, never found em at any parts stores.