I posted this in the 12v forum, but thought someone might see it here also.



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well I was putting some 215hp injectors (from my 97') into a friends 95' & when we put it back together we had a couple of leaks, the last injector was leaking around the rubber washer between the body & the hold down nut, & the 2nd to last one was leaking where the return line bolt went in, after removing them I found that the return line bolt had been started crooked, & messed up the threads, so I took the body from one of the 180hp injectors & put the 215hp tip on, ( I know it probably needs to be pop tested, but figured people install their own nozzles & run them un-tested all the time , so any way) got everything back together, made sure the rubber washers were all seated good, started it up & now the third injector from the back is leaking around the rubber washer & the last one is leaking around the return line??? seems like I get one thing fixed & another screws up, I also should add that I used the thin washers from the kit, was told to use them w/my 300's & thought I'd read to do the same w/ 215's, could the washers be causing my problems, or is there anything else you guys can think of????? thanks in advance, Dusty

 

I had a heck of a time getting my return line to quit leaking when I changed mine. I finally had to remove it and clean the sealing surfaces with emory paper and install new copper washers. Are you sure the injectors are leaking around the rubber washers or is fuel dripping down from the return line. The rubber washers are just there to keep dirt out. Are you using a torque wrench to tighten up the return bolts?

 

Double check your torque values, the primary injection line should only be down about 22 foot lb., and the returns at 18 foot lb. As berner stated, the O-rings are not even needed, they are just there to keep dirt from creeping up the threads and act as a vibration damper, and do nothing for the seal. Make sure they were pushed all the way down before the threading was started, or you could have a chunk of O-ring stuck between the large nut and the threads on the injector, and that will allow the injection line to back off a fraction at each pump cycle and leak.

 

I think you're only supposed to use the thin washers for the 370's because the spray pattern is different and it gets the injector that much farther into the cylinder. I had trouble getting the thin ones to seal when I did mine, I've had luck just tightening the hold-down nut on the ones that's leaking while it's running. Don't get carried away with it though. As far as the return line, check to make sure the injector didn't twist a little bit in it's keyway. This would prevent the return line and injector from mating up properly. You may need to trade return line washers from another injector to get the last one to seal up. Good Luck

 

Quote:

Double check your torque values, the primary injection line should only be down about 22 foot lb., and the returns at 18 foot lb.

Don't you mean 18 inch/lbs?
I've never used a torque wrench on them but figure 18 ft/lbs would break the head right of those little bolts.

 

The return line bango bolts should only be torqued to 72 in-lbs.