Fuel Leak Problem
 

We finished re-installing the reman engine last night, and when we fired it up, significant amount of fuel was leaking around the injectors area. We could not see exactly where it was leaking because most of the fuel injection parts were blocked by the upper intake manifold. Both the lower intake manifold and the rotor housing next to the injectors were "flood" with fuel.

We took out the whole fuel injection assembly with the injectors zip tided to the fuel rails, connected the fuel lines, turned on the ignition without starting the engine. We saw the fuel lines were pressurized and there was NO leak found! Not from the quick connectors of the fuel lines, not from the upper grommets of the injectors, not from the pulsation damper. We don't know where it was leaking from.

I will try to replace the o-ring and the upper injector grommets today (that's all dealers have in stock) and see if it stop the leak. I was planning to replace the secondary fuel rail, fuel lines (the two hoses with red and blue qick release connectors) and lower injector grommets too but none of the dealers has those parts in stock. I hope it is not leaking from the injector itself.

Any idea/input is highly appreciated.

Thanks,

Sammy