oil leak from top of injectors, and oil rail

smc · October 29, 2009

i have a 2003 f350, 6.0, build date 4/22/2003. i am have serious trouble trying to get the oil rail to seal on top of injectors, it has 4 reman injectors, and new seals in the others, i even tried a new rail! any one have any suggestions? i am a my witts end with this thing.HELP!

BrunoWilimek · October 29, 2009

Maybe things have changed, but the o-rings at the top of the injectors were not supposed to be serviceable. Are they all leaking or just the ones with new seals in them?

LARRY BRUDZYNSKI · October 29, 2009

Holy crap I beat Bruce to it. If you have a Alliant Power source(if not I have them in stock) get AP0002 6.0 Injector Seal Kit. They come with upper rail seals. They run @$9.00 a kit.

Jeff_E · October 30, 2009

First things first fellas, What symptom is the vehicle exhibiting? Do you actually have a no start condition due to low ICP, or are you just air testing the HP system after the injector replacement just to make sure everything is ok?

The reason I ask is because if you are just air testing the system for the heck of it after a repair, it is common to get a false leak there due to the fact that the upper injector oil seals won't seal properly until oil is applied under pressure. It's possible that nothing is even wrong with those seals, and I even had my butt kicked this week chasing a similar perceived leak issue in the same area from an air test... The problem is that I convinced myself that there must be a leak and let the hissing noise at the injectors lead me into taking apart all kinds of stuff that had nothing wrong. Mine was a rare HP pump failure and I made more work for myself than I needed too. I'm not saying this is necessarily your situation, I'm just trying to save you from going through what I did.

mchan68 · October 30, 2009

First things first fellas, What symptom is the vehicle exhibiting? Do you actually have a no start condition due to low ICP, or are you just air testing the HP system after the injector replacement just to make sure everything is ok?

The reason I ask is because if you are just air testing the system for the heck of it after a repair, it is common to get a false leak there due to the fact that the upper injector oil seals won't seal properly until oil applied under pressure. It's possible that nothing is even wrong with those seals, and I even had my butt kicked this week chasing a similar perceived leak issue in the same area from an air test... The problem is that I convinced myself that there must be a leak and let the hissing noise at the injectors lead me into taking apart all kinds of stuff that had nothing wrong. Mine was a rare HP pump failure and I made more work for myself than I needed too. I'm not saying this is necessarily your situation, I'm just trying to save you from going through what I did.

VERY WELL SAID!!!

I was just thinking the same thing myself. This reminds me of a time that I air tested the high pressure oil system after reassembling everything on an E-Series a couple years back. I don't remember, but I think I posted a thread about it here. This was the one that had had the STC fitting SUPPOSEDLY replaced with the update (with the reinforcement bracket) according to OASIS. I had both valve covers removed, unable to find any deteriorated o-rings or any obvious signs of leaks. Yet when I applied air pressure, all I could hear was leaks all over the place. It wasn't until I learned that oil had to pass through the entire system before the test could provided any valid results. This particular truck ended up actually being the STC fitting that was leaking. It turned out that the dealer that the part was actually charged out and the tech paid for the repair, without the repair actually being done.