4-108 injector coppers

[escott]

just installed rebuilt injectors and am having leaks at the copper seals. they are new, are torqued to 12 ft-lbs but still spit exhaust. I have remounted them several time but still they don"t seal properly. Any help available?

[capttman]

Make sure the flat of the washer is against the injector and the rolled edge is against the intake

[Acushla]

The copper needs to be in a fully annealed state. This may not be the case if they have been on the shelf for a long period of time. To anneal copper it has to be heated until colour change and quenched in cold water. The annealed copper seals and all other mating surfaces must be spotlessly clean before fit up.

Regards
Acushla

[Barnhard_Marine]

Did you check to see if you got all the old coppers out? You may have carbon build up in the injector ports. Home Depot and buy a copper fitting cleaning brush close to the same size as the injector and clean the ports

[Jim Cate]

Originally Posted by Acushla

The copper needs to be in a fully annealed state. This may not be the case if they have been on the shelf for a long period of time. To anneal copper it has to be heated until colour change and quenched in cold water. The annealed copper seals and all other mating surfaces must be spotlessly clean before fit up.

Regards
Acushla

This goes contrary to what I was taught (and have successfully used for years).

To anneal copper, "smoke" the surface with carbon black from a candle flame or acetylene torch flame. Then heat slowly until the carbon just burns off. Then place the copper bit on a non heat conductive surface and let cool SLOWLY.

Quenching is the opposite of what annealing does.

Cheers,

Jim

[Acushla]

Sorry Jim you have this wrong,smoking the material only adds carbon to the surface and can be used to provide a higher carbon skin as in case hardening. In this case we are not trying to do that, the copper needs to be red hot then queched to anneal. The quench need not be water but a large heat sink is required but water is easy.

Google it if you are unsure

Regards
Acushla