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BLACK93TSIAWD

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Discussion starter · #1 ·
Hi all,
Please throw out any ideas you can think of, cause this is baffling me. I did a boost leak test only to find a loud hissing near the intake manifold. I ruled out the intake gasket since the 93s come with a metal one. The only other option that crosses my mind is the injector o-rings and insulators. I change both the rings and insulators and boost leak test again. The same hissing comes from the same place. After closer inspection, you can actually see the spray pattern of the fuel coming out of the head near the insluator. So, figuring it's a bad injector or something, the rail comes out once again and I swap in a spare injector with the new o-ring and insulator. One more boost leak test proves that nothing has changed. The spray is clearly visible when you duck your head in there. It's only around the one injector, second in from the driver's side. You can even get a smell of gas at a light sometimes. I know this can't be safe, but have no other ideas. I mean even if the fuel rail was warped or something, wouldn't it affect more than the one injector? Any suggestions would be greatly appreciated. Thanks.
 
Hey Ash, I assume you swapped out the injector that was leaking right? :( Is it possible that the o-ring / gaskets just aren't seated or sealing right? I can't think of any reason why that wouldn't fix it.

Besides that, you've proved that the leak isn't at the throttle body right?
 
Discussion starter · #3 ·
Hi Tom,
Yeah, Manny and I swapped the injector, although we didn't have it actually tested to say it was leaking. It LOOKED ok. We swapped it with a spare one and put the new o-ring and insulator on it. I think everything is seated right. I mean the fuel rail bolts are snug and I would think that an unseated insulator would just be pushed into place once the fuel rail is bolted back on, no? The only thing I can fathom is a hairline crack in the head, knock on carbon fibre:D But seriously, I think everything went back in properly. I'm thinking I'll swap the fuel rail next.

Again, I can't say we proved the throttle body isn't leaking, but we did use a length of rubber hose to try to listen to the leak and it was very apparent that it was coming from the one injector or intake gasket below.

Thanks for the reply and suggestions Tom.
 
No problem. I would talk to Shane (I'll get you his email if you don't have it) as he's pretty knowledgeable about the whole fuel rail thing. He's got some monster upgrade ready to go in for his ride - did you see that big blue fuel rail he bought? :eek: :)

BTW, welcome to DSMtalk eh! :D
 
Discussion starter · #5 ·
Thanks. I have his email, so I'll give him a shout. He actually took a look at it at the last meet, but didn't have any ideas. Yeah, I saw his Holley rail. Pretty sweet :D Thanks for the welcome too! It's kinda wierd to see you on a different board. Guess it shows that we're the hardcore surfers! Later.
 
whoo

I've got the exact same prolbem you had in the 3rd injector from the drivers side. I can also see the spray!!!!(VERY DANGEROUS) did you ever fix it, what did you do. I have replaced the o-rings, spacers and upper o-rings(fuel rail the injector)!!Still leaks horrably, fuel and boost!...........All the inectors leak boost and i cant stop it for anything. Im thinking of grinding down the spacers a little inorder to make a tighter connection between the injector o-ring and the head. HELP PLEASE!!!!
 
Discussion starter · #7 ·
Hey Cam,
Unfortunately, I never had the chance to completely figure out the problem with that injector. I basically did what your sig describes to my black Talon and ended up buying another 93 TSi AWD that's dark green. I'm sure I'll find some leaks in this one anyway, cause it's all stock and probably never had any of that stuff maintenanced. The only idea I had was what you suggested, file down the spacers. Other than that, I'm still stumped. Sorry, I couldn't help out there, but I hope you figure it out before something bad happens. Later.
 
fixed it real good

I ended up sanding down the spacer/mounts for the fuel rail about 3/4 of a cm, got new o-rings from the dealer soaked them in 10w30 oil put it all together and it worked just dandy!!! Does not leak at all!!! Boost or Fuel!!! My injectors use to be able to spin while assembled, now they are nice and firm in place.
 
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