can't fix leaking injector at fuel line

[neimis]

Injector is leaking between hard fuel line and injector. I can see it streaming out below the nut, so am quite sure it is not the return line.
First I tried reseating the hard line about 20 times, every which way, loosening the lines and clamps, reseating, aligning the line on the injector, tightening, loosening, etc. Nothing. Same leak every time.

OK, so I thought it was time to replace the injector line with a brand new one, did that. Same leak as before. Now I'm getting frustrated.

Is it possible/probable that the seating surface of the injector itself is damaged? I had no leaks for many years, nothing was touched.
Can the seating surface of the injector be touched up or smoothed with, say emery paper? I don't know how to avoid getting the injector contaminated with dirt and abrasive.

Any help or suggestions much appreciated, Thanks, Neil '92 Passat TD

[8v-of-fury]

You are entirely sure it is seated and torqued properly?

[neimis]

You are entirely sure it is seated and torqued properly?

I've replaced and installed lines and injectors a few times over the last 20 years. This time I've given it at least 20 attempts, and I'm pretty sure it's seated and tightened properly. I don't have any trouble with any of the other injector lines (replaced those with new lines cause I bought a complete new set).

[8v-of-fury]

I've replaced and installed lines and injectors a few times over the last 20 years.

I wouldn't know.

Interesting issue. Never seen one leak so incessantly.

[ORCoaster]

Threads Ok?  Cross stripping on the nut or the top of the injector?

[burn_your_money]

Yes you can reseat the injector. You can use carbide rasp/burr to do it but odds are you are going to need to take the injector apart in order to get all the metal shavings out.

[ORCoaster]

Steel ball and emery paper plus oil and option?

[neimis]

Threads Ok?  Cross stripping on the nut or the top of the injector?

Threads are all good, they hand tighten without any resistance.

[neimis]

Interesting issue. Never seen one leak so incessantly.

Puzzling that it suddenly happened out of the blue, after 4 or 5 years of no trouble... It's really gushing a stream.

(By the way, I did replace the return lines just to rule that out, but it's pretty obvious it's coming from under the nut)

I guess I'll try looking at the injector seat tomorrow with a magnifying glass to see if I can see any nicks or scratches, etc.

Burn, I'm not too keen on disassembling the injector myself. Do you think ORCoaster's suggestion might work? How would I keep the injector clean?

[ORCoaster]

Put the Injector on top of the ball so all the metal goes to the oil and paper.  Rinse with WD 40 by dipping injector into a small container of it.  Air dry with low pressure.  We are talking filings here not shavings from a grinder or saw operation. 

Inspect the top of the lines and the inside of the nuts.  Might find a hairline fracture on the inside that gets larger as you tighten it down. 

[burn_your_money]

It's a gamble. I'd make sure you have a spare that you can swap in incase everything goes wrong. I think you would want to cut the injector straight rather than rounded though.

[TylerDurden]

I have a hard time imagining a failure or void there.  Those bodies seem to be tool grade steel or perhaps hardened.

I'd put the injector on a pop tester and see if it really is leaking there or a maybe flaw where the return barbs meet the body.

[neimis]

I have a hard time imagining a failure or void there.  Those bodies seem to be tool grade steel or perhaps hardened.
I'd put the injector on a pop tester and see if it really is leaking there or a maybe flaw where the return barbs meet the body.

Well, there is a stream coming out between the nut and injector. It's so big it is very easy to see.

It's a gamble. I'd make sure you have a spare that you can swap in incase everything goes wrong.

That sounds like good advice. Car is undriveable right now anyway, though.
I guess I should start looking for a spare injector. It's a two stage. Giles installed and balanced the new nozzles for me years ago.

[srgtlord]

I wonder if its a leaky return line

[neimis]

I wonder if its a leaky return line

Just to be sure, I've replaced the return lines with new.
It is very easy to see the big stream of fuel coming out between nut and injector, there is no mistaking it.