hosrom_951

Anyone had a crack in their intake manifold? better yet, the crack is where the injectors meet the intake itself. Could be extremely minor not to allow the injector(s) to fully seal (vacuum leak).

special tool

No way, you'd need a jackhammer - are you sure that the seal from the old injector wasn't left in the hole??

hosrom_951

Jim: The bores (injectpor holes) on the intake are free from debris, i would also note that the intake gaskets are properly installed.

pikey7

Wow. never heard of them splitting in that area. you got pics?

Chris White

If you try to pry the manifold off with one or more intake bolts left on you can crack it right where we are talking about. I have seen it done (customer car's previous mechanic).

Chris White

special tool

Oh God, really? Some guys who work on these things should just take up knitting, ****. You have to be pretty ****ing stupid to do that.

hosrom_951

I don't see any cracks at all, but the injector #4 just doesn't want to seal up properly, there is always a leak........

Chris: No, i never even thought of trying to remove the intake with any of the bolts still installed.

pikey7

tried a new seal?

MR951

So you have a vacuum leak right at the #4 injector but you can't see any defect in the manifold. Do you have good o-rings/seals on the injector? Also have you tried swapping injectors around? Maybe there something wrong w/ the #4 injector.

hosrom_951

Guys, i tried 3 new injector seal kits. One was universal and two were the Bosch OEM seals (purchased from the local dealer).

The bores on the intake are clean, no scratches (that i could see) and the intake manifold gaskets are properly installed. I tries swapping injector 4 with the other three, it still had a leak. But we are talking about a very minor leak, but it leaks.

The last thing that came to my mind, and after talking to 2 trusted vendors, was that the intake could be cracked.

Chris White

Leaks what? Air or fuel?

MR951

Got any machine shops in your area? They should be able to do a dye penetrant test on it to find the defect. A low viscosity dye is applied to the part and it "wicks" into the crack. A developer is then applied to the surface and if there's a crack there, it will become visible.

hosrom_951

Chris: There is an air leak, where the injector meets the intake manifold.

Yes, we have very good machine shops here (and i do mean good, i seen their work). But i don't really "believe" there is a crack.

This is just driving me crazy, since i took off and re-installed the fuel rail/injectors a number of times (seals are very good and nicely oiled, they were NOT damaged at any point).

I also followed both Clarks Garage instructions (installing the injectors on the fuel rail first, then installing on the intake) and the manual proceedure (driving in the injectors onto intake manifold, then pushing down the fuel rail).

Crazy Eddie

Intakes are pretty cheap ... I woud try to source one and try it.
If worst comes to worst you can sell it ....
With the time and money you will spend.... that's the route I would go ...
But then again, WTF do I know
Regards
Ed

pikey7

why don't you "believe" there's a crack there? It's either there, somewhere close, you haven't got it bolted up right,or you haven't got one. RU sure it's not on the banjo's above it? What points to the air leak being exactly on the injector? Why if you can prove in your own head its there, aren't you already on the way to get it fixed up?

I don't get the 20 questions and then the ostrich attitude!?