Originally Posted by El Solis
Hello all, my 200tdi has developed a pretty significant fuel leak from the spill rail hoses. This started after the head and valves were completely redone. Engine runs better than ever but I see the fuel and the lines are wet. I have replaced them all with braided (what was on it to start) appropriately sized hose but still they leak. What's the next step?
If my theory is correct, you won't be able to stop the leak.
What I see all the time are injectors that are damaged right where the washer on the spill over banjo bolt goes.
This gouging happens when people remove the injectors from the head and put a wrench, pliers, or vice grips on the top of the injector right where the crush washer goes.
The gouge leaves a channel that the fuel takes a path through and no amount of tightening the banjo bolt will stop the leak.
The next thing that happens is the same knucklehead that gouged the injector will over tighten the banjo bolt trying to stop the leak and break the hollow banjo bolt off inside the injector.
People get angry, act shitty, and so on when they send me 200TDI injector cores that can't be used and loose the $125 core value.
In some cases, the area where the crush washer seats against the injector housing can be machined flat, but the setup and machine work for this runs between $50 & $100 to have done properly.
It's tough to provide exchange sustainability when people are careless when they remove the injector cores.
So my theory is that one or more of your injectors has a gouge providing a leak channel for the spill over fuel.
You should be able to see the gouges, if my theory is correct.
My only clue is that you stated "this started after the head and valves were completely redone" and this generally involves removing and replacing the injectors.
Drew at Sarek Autowerke in Richmond, VA came up with the best way to remove 200TDI injectors. He welded 2 nuts together to fit a slide hammer.
This allows Drew to connect the slide hammer to the injector where the fuel line connects and with one slide, jank it out of the head.
Check the crush washer seating area of your injectors and let us know if you find any gouges.
It doesn't take much to let the pressurized fuel leak by