Fuel rail leak

[alredline04]

I had my car out yesterday for a open track day at a local road course, Waterford Hills Raceway. The car ran real strong and very fast. After the first 15 min. I did the usual walk around the car and noticed fuel dripping from the fuel rail. When I tried tightening it I only made it worse. Now when I turn the ignition to activate the fuel pump it sprays out real strong. I replaced the o-ring at the track and that did not help. Ended up calling a flat bed. I have it apart in the garage and everything looks good accept for the leak. The only other times time I have touched the fuel rail was on two occasions over the past few years. First to install 42lb'rs and later the 60lb injectors almost a year and half ago.

Anyways here is a picture of where it leaks from. Right where the line goes into the fitting.


I think I will just be ordering a new fuel rail as everything I have tried hasn't worked.

Any thoughts as to why this would happen?

[IMkenNY]

Is the O ring getting torn while tightening?
Crack in incoming line?

[golden chicken]

there's a recall for that on '04's i think.

[alredline04]

Originally Posted by IMkenNY

Is the O ring getting torn while tightening?
Crack in incoming line?

The new o- ring looks in good shape as does the old one. There is no crack I can see.

[alredline04]

Originally Posted by golden chicken

there's a recall for that on '04's i think.

Wouldn't I get notice in the mail if there was a recall?

[NoRemorse]

Originally Posted by alredline04

Wouldn't I get notice in the mail if there was a recall?

I might have an extra 1/2 rail, lol.

I have from that circle thingy (I never did get a straight answer on what that is) to the part that is leaking for you.

[golden chicken]

Originally Posted by alredline04

Wouldn't I get notice in the mail if there was a recall?

beats me. let me ssee if i can find it for you anyway.

[golden chicken]

Make : SATURN Model : ION Year : 2004
Manufacturer : GENERAL MOTORS CORP. Mfr's Report Date : JUN 08, 2004
NHTSA CAMPAIGN ID Number : 04V281000 N/A
NHTSA Action Number: N/A
Component: FUEL SYSTEM, OTHERELIVERY:FUEL PUMP
Potential Number Of Units Affected : 670
Summary:
CERTAIN VEHICLES EQUIPPED WITH SUPERCHARGED 2.0L 4-CYLINDER (LSJ) ENGINE WERE BUILT WITH A FUEL FEED PIPE THAT COULD CRACK AND LEAK FUEL NEAR THE FUEL RAIL. IF FUEL LEAKS FROM THE FUEL FEED PIPE, THERE WOULD BE A NOTICEABLE FUEL ODOR AROUND THE VEHICLE.
Consequence:
FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy:
DEALERS WILL REPLACE THE FUEL FEED PIPE ASSEMBLY. OWNER NOTIFICATION BEGAN ON JUNE 9, 2004. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Notes:
GM RECALL NO. 04053. ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION¿S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

[alredline04]

Turns out the line is cracked. I got a real close look at it today and there is a few small cracks right at the flare.

[04RedLine04]

wow same problem as me (exact same spot) Hint*I fixed mine by leaving the plastic seal and using the o-ring from our stock injectors(its a bit bigger but it fits).It worked perfect,I tried new o-rings and nothing as soon as I put the Injector o-ring I had no problem Its been about 3 month now and still no Leak.... Please let me know if this helps u, Pm me