Fuel Rail and Lower Intake Question

[Strype]

Hey ladies and gents I'm trying to trouble shoot a problem so that I can continue trouble shooting a problem- Make sense?

BBK SSI intake. I am changing the injectors on my car back to stock. I pulled the old ones off and they looked fine and always appeared to hold pressure. I put the stock ones back on and primed the fuel pump.

Gas started pouring out of the 2 middle injectors on the driver side at the lower intake. I pulled rail back off and inspected the injectors. The 2 middle ones were fine but the one closest to the fire wall had a cracked open cap. It wasn't leaking though!

Me -->

I happened to have a brand new cap and o ring set. I fixed the cracked cap and o ring. I made sure they were all seated. It was a 110% pain in the arse to get that fuel rail on but I finally did it. I went to check prime the injectors again and POOF!!!

The 2 middle injectors + the one with the new cap and o rings started leaking

I noticed that the bottoms of the injector caps had nashes in them and it looks like the molding on the lower is causing it, and this is a known problem for the BBK SSI (bought it in 2005 or 2006, just now installing).

My question is this-

Why didn't the old injectors I pulled off of it have a problem??? Am I doing something wrong? It is rediculous how hard you have to bear down on the poor injectors to tighten the fuel rail up, but the stock rail is a pain as well.

Is this a BBK issue or a Strype issue???

 

[BlownFiveLiter]

You're having a hell of a time with that thing!

I had my injectors leak like that, too. It looked like they were seated, but they weren't fully seated into the fuel rails. You may have to pull the upper intake back off, but once you get them seated, they should be good to go. I used a hammer handle against the rail and a rubber mallet to smack the hammer handle. It forced the rail onto the injectors and they haven't leaked since.

 

[stykthyn]

You're having a hell of a time with that thing!

I had my injectors leak like that, too. It looked like they were seated, but they weren't fully seated into the fuel rails. You may have to pull the upper intake back off, but once you get them seated, they should be good to go. I used a hammer handle against the rail and a rubber mallet to smack the hammer handle. It forced the rail onto the injectors and they haven't leaked since.

I dont think I would have the nards to do that

 

[Strype]

I did that the 2nd time... And the upper was off

 

[Strype]

Any other ideas? I don't want to file that part of the intake.

 

[67coupe]

I noticed that the bottoms of the injector caps had nashes in them and it looks like the molding on the lower is causing it, and this is a known problem for the BBK SSI (bought it in 2005 or 2006, just now installing).

My question is this-

Why didn't the old injectors I pulled off of it have a problem??? Am I doing something wrong? It is rediculous how hard you have to bear down on the poor injectors to tighten the fuel rail up, but the stock rail is a pain as well.

Is this a BBK issue or a Strype issue???

Is it possible to take any pics of the injector holes in the lower intake? Sounds like casting flash or a machining issue.

Did the old (used) injectors have caps? The other side not leaking?

 

[Chuckman]

Is it possible to take any pics of the injector holes in the lower intake? Sounds like casting flash or a machining issue.

if its taking that much pressure to seat the things, its sounding like the bosses either werent reamed or were reamed to small. i barely have to use any force on my tfs with stock rails. are the rails having this problem too?