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Old 13-07-2017, 13:25   #1
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4.108 leaking injector

I have had a continual problem with the #1 injector leaking fuel. I finally bit the bullet, pulled it, replaced the copper crush washer and torqued it down. Still leaks-anyone have any ideas? Bob
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Old 13-07-2017, 13:56   #2
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Re: 4.108 leaking injector

It is probably not that gasket. That crush gasket usually seeps black goo, not fuel. The body has a gasket also, about the middle of the injector. Try to tighten that one.
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Old 14-07-2017, 08:22   #3
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Re: 4.108 leaking injector

One of my injectors on my 4-108 was leaking, but it was leaking from two locations.

The first leak was where the injector meets the head. There was a small compression leak. The evidence was tiny bubbles that would appear while the engine was running. Also, over time, there was a buildup of carbon on the head next to the injects.

The second leak was on the return line banjo fitting at the top of the injector. That seeped a tiny amount of fuel with the engine running.

Both leaks were stopped with new copper crush washers, one at the bottom of the injector and two more, one on each side of the banjo fitting.

As an aside, in a pinch I bought the 80 piece copper washer set for $3.99 at Harbor Freight and those washers worked. They're still being used today.
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Old 14-07-2017, 08:22   #4
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Re: 4.108 leaking injector

Duplicate post. Deleted.
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Old 14-07-2017, 18:20   #5
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Re: 4.108 leaking injector

Check that it is not a cracked high pressure pipe - we had a bad leak at the injector that we finally traced to a hairline crack in the pipe just in the connection to the injector. We were in the Gulf Islands of BC, headed north, and we were able to pull off the pipe and jam a hose on it to run the diesel back to the tank, and then ran on three cylinders until we could get to Silva Bay.

The helpful people at Silva Bay Shipyard were able to get us a set of new pipes from the UK in just a couple of days - and the shipping was amazingly cheap. What a crazy world.

Good luck!
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Old 14-07-2017, 20:12   #6
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Re: 4.108 leaking injector

Above posts contain relevant tips, however rather than just replacing the copper seals you may have to lap the faces of the seating area's with fine paste say 1000 or 1500 lapping paste, it wont take much lapping at all to get a good sealing surface, just be sure to clean all the paste away prior to installation with new seals,

If in the field and no new seals are available heat them up on the gas range to anneal them and then also give these a lap on a piece of glass or similar that is perfectly flat then re-install
https://www.vwdieselparts.com/forum/...pic.php?t=6431
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Old 16-07-2017, 04:09   #7
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Re: 4.108 leaking injector

Guy...you were right on the money. I never knew there was a copper ring there. Replaced it and no drips. Thanks...Bob
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