Osirus9

iTrader: (10)

Whenever I fire up my car its ok for about a minute, then fuel starts gushing from the fuel rail all over the LIM, and down the transmission. I thought it was a leaky PD, but I replaced the PD with a banjo bolt, and no change. I thought it was because I used old crush washers, so I went around town trying to find new ones, but nobody had them in the right size. So I bought ones that were too big and cut them down with a dremel. They aren't pretty, but they are damn close to stock sized. No change in the leaking after that either. The only things I can think of now are:
A. go on mazdatrix or something and replace the washers again
B. get an FPR because maybe the fuel pressure is too high with my 255 pump

note: the problem started after I removed my vac rack, and I have been running the 255 for months.

SureShot

Are you sure the leak is from the pulse damper?
If the FPR was stuck you'd be running way rich.
I'd look closely at the injector O-rings. They are not a real tight fit and the slightest scratch in the rubber will make them leak.
The best practice is to replace them if the're old. Then any time you seperate the injectors from the rail, clean the rail sockets & injector grooves very carefully, and lightly oil the O-rings just before reassembling..

alexdimen

iTrader: (13)

You can re-anneal your old copper washers by bringing them juuust to red hot with a mini torch and then letting them cool. Do a google search on re-annealing.

What about the injector o-rings where they insert into the fuel rail and make a seal with the inner bore?

Did you replace the lines and clamps when you were in there?

arghx

iTrader: (3)

The best solution here is to remove your UIM. Jumper the yellow fuel pump check connector on the passenger side shock tower area and feel around for leaks, obviously with the car off. Don't do this guesswork stuff. Whatever is causing this (since it's not PD) is likely a $10 part or less (piece of fuel hose, grommet, whatever). You just need to take the time to diagnose it properly.

Osirus9

iTrader: (10)

all 4 injectors are rebuilt with new rubber as of a few months ago.

I'll look up re-annealing though...

where is the pump jumper?

arghx

iTrader: (3)

it's on the main engine harness. It's a yellow two pin connector, near the passenger side shock tower.

pfsantos

iTrader: (1)

Yellow plug near the airflow meter - plug has a rubber boot around it...follow the Boost sensor/Variable resistor wiring. Once jumpered with ignition on, activates the fuel pump circuit.

If you don't find it, turn ignition on, and move airflow meter flap (after getting access to it).

The Wankler

iTrader: (14)

Sounds like maybe a pinched o-ring on the top of the injector. It is not hard to do when installing them, and will let let fuel flow out like a ****. Couple the yellow conector and see if you can see the leak then. Protective glasses are a must!

Osirus9

iTrader: (10)

I see the connector. that will save me a ton of time! now I dont have to put the whole car back together to see if it still leaks!