Hey guys. I started noticing my car having gasoline smell whenever I start the car and saw that there's some fuel leak on intake manifold. I traced it back to source and it's coming from the connection between fuel rail and fuel filter hose.

Here's the picture. I already tried replacing the washer between the fuel rail and the connector but it doesn't help. I even tried putting two and doesn't help either.





It's causing fuel to flow along this bolt that's holding the fuel rail on intake manifold and dripping onto the manifold. Here's the picture of it being soak in gasoline.



I would like to know how I can fix it. I may be missing something at the connection. I am not sure what kind of washer to use. I asked the people at Autozone and that's what they gave me. The copper washer. It's still leaking. If anyone has the assembly picture and information, please let me know. I can't find this anywhere. I may not be looking for the right words.

EDIT: My car info is 95 Civic DX with Y8 manifold and fuel rail.

 

Is there a crush washer on both sides of the fitting? I am pretty sure there is supposed to be, but looks like you have one.

 

It is a copper washer that you need, but you need one on both sides of that banjo fitting...

http://www.hondaautomotiveparts.com/...L+PIPE+%282%29

it is #36 in the picture

 

One will go on bolt side, one on the rail side.

 

Thank you guys. Yes. I only have washer in one side. I thought the other side wouldn't need it because it was a perfect fit. It's not a flat surface on the bolt side. I'll try to put on both side and see if it fixes. Autozone people told me it should only be on one side....

 

that is freakin' autozone for you!

Sorry to anyone who works there, but 99% of Autozone (or Orielly's) employees don't know what they are talking about.

 

Autozone in town has 3-4 that know what they are talking about but a few of them couldn't change a battery I am sure. My brother works there and I know how to operate their system lucky me. O'reilley never had luck with them or advanced

 

Ok. So, I just tried to put the washer on both sides. It's still leaking but got worse. Here are pictures. I think I got the wrong size.







If you look at the second picture, the bolt's bottom surface is not flat. It fits into the connector. I am not sure whether I got the wrong size washer or something else.

 

Bolt side washer got bend.

 

Here's part of your problem, PM me your VIN number and I'll see if I can pull up the the proper washers diagram. The tongs sticking out are meant to hold the line into position so that the bolt can be tightened properly. Right now they are just hanging off into space.

Look at this altered version of one of your photos:

http://www.flickr.com/photos/30955309@N06/8424182199/http://www.flickr.com/photos/30955309@N06/8424182199/ by http://www.flickr.com/people/30955309@N06/, on Flickr

 

I dont use a crush washer I just wrapped it in Teflon tape and no leaks

 

Teflon tape on a flammable joint is a serious no-no. If it starts to spray at the normal 35-45 PSI while you are driving and the mist finds its way to the alternator you'll have a full blown car fire that will probably total your car.

 

Here is what it should look like, it's identical on my model even though it's a D15 Engine:

http://www.flickr.com/photos/30955309@N06/8424291245/http://www.flickr.com/photos/30955309@N06/8424291245/ by http://www.flickr.com/people/30955309@N06/, on Flickr

http://www.flickr.com/photos/30955309@N06/8424291395/http://www.flickr.com/photos/30955309@N06/8424291395/ by http://www.flickr.com/people/30955309@N06/, on Flickr

Now I need your VIN to find out if you are also missing a Fuel Pulse Dampener, which is stock on my engine. I realize you have a franken engine, but it may still help.

 

lol didn't know that says high pressure but how high of pressure can thin tape be been driving around with it on the threads for 2 years now no problems


but totally gonna carry a fire extinguisher now

 

Do I see the old crush washer still stuck at the bottom of the bolt head in post #8? If so, that's one big problem.

Your replacement washers look too large, and the banjo bolt should be torqued to 16-ft-lbs.

 

It seems that my washer is indeed too large for the bolt. I didn't notice it until I checked. Autozone sold me 1/2" washer instead of 12 mm. I just got the 12 mm on my way back from school. I'm gonna try to put it in.

About the post #8 picture of the bolt head, I'm not sure whether it is stuck or not because it wouldn't budge when I tried to check. It seems to be a perfect fit into the connector. I didn't think about it because the leak is coming from between the fuel rail and the connector. I'll check that too after replace the washer.

One more thing is that I checked my fuel rail closely and I am missing that bar that holds the connector in place like in stateofjustin's picture. Is it possible to put a flat bar between the rail and the connector to make it straight and tight the bolt?

 

So, I just replaced the washer. While I was at it, when I was putting it all back together, I put a stack of feeler gauges in the space between rail flat surface and the holder of the connector. Made sure I kept it even with the surface and tightened it 16 ft-lb. Now, I don't see the leak. But I can't tell yet since it usually happens during cold start. I'll be able to find out in the morning.

@stateofjustin I can't provide you with VIN number because like you said, my car is a Frankenstein car. If you have my VIN number, it'll be rather useless because every autoshop gets confused by it. Even the mechanics. Why? Because here are my car's specs.

95 DX trim
Manual transmission
D16Y8 Engine (not stock)
D16Y8 automatic transmission intake manifold (not stock)
GSR throttle body (not stock)
AEM long arm intake (not stock)
AEM 4 to 1 exhaust manifold (not stock)
Aftermarket fuel pump/filter (not stock) *don't know the name because previous owner put it on*

This car has nothing stock left. 95 DX that is made to be 95 EX + 96 Del Sol SI VTEC. Now, tell me how will you be able to find this by VIN number? Thanks for the help tho. You gave me an idea of keeping the connector level to the flat surface. It seems to be working so far.

 

Del Sol Si Vtec came with a B16a3, the regular Del Sol Si had the y8, bu more of a like 96-00 ex clone=P. Anyways props on using feeler gauges.

 

Alright, so which engine's fuel injection system did you keep is I guess what I really need to know. That will tell us if you need different washers, which I'm pretty sure you do... and if you are missing a fuel pulse damper that normally (as you saw in my pictures) goes on that end of the rail.

 

Whoever said something about Teflon tape, no. Teflon tape is NOT made for fuel or oil lines. Petroleum-based products will eat through it slowly, turning it into the consistency (and flammability) of napalm.

Petroleum-safe Teflon tape is stupidly expensive, and stupidly hard to find. Your local hardware store probably doesn't carry it.

 

Oh ok. It is most likely 96-00 clone. It's using OBD II. But the thing is, I got used to saying Del Sol Si Vtec because that's how all the auto shops get my parts right. If I tell them 96 EX or something with 1.6L Vtec, they bring out z6 and parts always wrong.

@stateofjustin It is using Y8 fuel rail. They don't have those damper as far as I know. I'm not so sure.

 

Man. After I saw this, I started fixing it until there's no leak. Lol. I don't want to die by car blowing up. With that much pressures, it might actually explode. Haha. I was driving the whole day with with A/C fan forced on so that if there's ever fire, it'll blow it out with cold air outside. Haha.

 

Ryan, a fan isn't going to put out a fuel fire - it's going to make it worse.

 

Oh I know. I know when the fire starts, it's gonna spread everywhere fuel is. But when I have the fan on, fume of the gasoline is blown away from alternator to the outside of the hood from where the air vents are at. Lol.

 

You're right, there is no fuel pulse damper. See the images below for proper orientation of the fuel line. I'd suggest ordering the correct washers from Honda, although if you can tell me the trim level of a car that came with a D16Y8 engine I can tell you what the diameters are.

http://www.flickr.com/photos/30955309@N06/8426522823/http://www.flickr.com/photos/30955309@N06/8426522823/ by http://www.flickr.com/people/30955309@N06/, on Flickr

http://www.flickr.com/photos/30955309@N06/8427530736/http://www.flickr.com/photos/30955309@N06/8427530736/ by http://www.flickr.com/people/30955309@N06/, on Flickr