FormerPorscheGuy

I have been fighting with a fuel leak for about the last month now. I went in and ripped out all of my solenoids and found that my FPD and my primary injector o-rings were bad. Ok, time for new injectors. After ordering new injectors, o-rings, FPD, and a complete hose kit I was still having a fuel leak from the upper o-rings on my primary injectors. My primary fuel rail did not appear to be scared, and I didn't want to hunt down a new one only to find that it didn't fix the problem. After ripping the thing out several times and going through several sets of o-rings purchased from Ray Crowe, I decided to think out of the box to fix the problem.

I found that I was not getting a good seal on the top o-ring of my primary injector where it came in contact with the housing. So I started looking around to see what I could do to get a better seal on the top o-rings. I tried to find bigger o-rings with no luck. What I ended up with was some aluminum tape from home depot that I thought would fix the problem. This tape is nothing more then sheet aluminum with an adhesive side that is used for high temperature ducting on home heating systems.

I cut two eight inch long strips of the tape that were just wide enough to fit inside of the grove were the upper o-ring sits around the injector. The aluminum acts as a shim to add compression to the o-ring giving it a better seal in the primary injector housing.

After installing the shimmed injectors in the injector housing in the normal lube up and twist in manor, the extra pressure that the shim added to the o-ring held fuel pressure. So far I haven’t had any more leaks from my primary injector housing. This appears to have fixed my fuel leak.

I though I would share in the hopes of helping anyone else who is having problems getting their primary injector o-rings to seal and hold fuel pressure.

Jason C. Williams

911GT2

So basically the housing was out of spec, with the holes a bit too large. And you filled the gap by adding aluminum tape to the inside of the holes.

Good solution, but I'd probably think of it as a temporary fix while you either save for, or look for a new injector housing that is within spec.

RX7UP

Dude: I think the Mazda dealer would have performed this for free as a recall.......

FormerPorscheGuy

I was told the recall was for the fuel lines, not the injector o-rings. My car had the original recall done many, many miles ago and the lines needed to be replaced along with everything else that was rubber. Besides, I trust your average dealership mechanic down hear about as far as I can throw him.

So far the car is holding fuel pressure and not leaking. My primary housing wasn't scared or pitted as I have been told that they become over time, and I figure that since the shim is on the injector and not contacting the housing, it will not cause future abrasions.

paw140

That is very strange. You shouldn't have had to put any kind of shim in, and the injector housing shouldn't wear out or anything.

FormerPorscheGuy

When I was working through the problem I compared the old o-rings to the ones that I got from Ray, the old ones appeared to be slightly wider. Either Mazda changed the spec or I have the oddball fuel system. I have stock 550cc injectors by the way.

The lower o-rings that he sent me worked fine and sealed great. I just had a problem with fuel spewing out the top after I pressurized the system.

I followed the twist in method of installation and lubricated both the injector o-rings and housing with some 30 weight every time I installed them.

RX7UP

Ok, I guess... That make sense for you not to trust any mechanic. for that matter... On another note, over here there is a highly decorated Mazdaspeed shop that performed the recalls on my car,,, Mazdaspeed of Great neck NY. They have the most awards in the East...

paw140

As FormerPorscheGuy said, the recall only applies to the fuel lines, not the o-rings.

FormerPorscheGuy: It sounds like you did everything right... it's just very wierd. I've never heard of anyone having this problem before. I wonder if your injector housings are out of spec somehow, like 911GT2 suggested.

RX7UP

Like I said before "Ok, I guess."

FormerPorscheGuy

I just talked to Benjamin, he has also received a set of primary o-rings from Ray that were smaller then the o-rings he removed. Unlike myself, he was able to get them to seal though.

This would not be the first time Mazda has changed a spec on this car, it’s just a shame that they did it to such a vital component.

By the way, I am watching my fuel system like a hawk and have a fire extinguisher with me at all times until I become confident of my success in this endevor.

paw140

Wow... Yeah, I would be pretty worried too and make sure a fire extinguisher is always handy! I didn't even look at my o-ring sizes when I replaced them. Maybe they just happened to seal.

FormerPorscheGuy

No problems so far after driving it around all day. I will keep ya'll informed.

FormerPorscheGuy

I have been driving the car with shimmed injectors now almost daily for two months. I have had no fuel leaks, no fuel smells, and no fuel problems what so ever.

I have talked to several people about this mod and although everyone is cautious, the responses have been positive over all.

If you are having fuel leaks and can't seam to get everything to seal up, this repair works.

Jason C. Williams