Ok, I really need some help here. My fuel return rail is driving me insane. The bolts seem to tighten up pretty good but it is still leaking diesel out of one of the injectors pretty good and the other has a slight drip. I pulled the return rail and it doesn't "look" cracked anywhere but that's to the naked eye. I'm going to take some emery cloth to everything tomorrow and clean it and see if that does anything. Any other suggestions? This leak is making me sick watching all that $4 a gallon diesel hit the ground!!!

 

Missing any brass washers?

 

I've found sometimes you have to start with new copper washers after you remove them. After re-installing them, used ones will sometimes leak.

 

Have all brand new washers. even replaced some of the banjo bolts. I put some hy-tack on the washers. tightened the bolts down and tapped the bolts with a punch and hammer and tightened them some more. No more leaking so far...