After fixing a small leak by replacing the injector seals, I find that I have made a much larger leak. Just by removing & re-installing the fuel rail, I have made the swaged end cap leak.

I've read that this leakage is not an uncommon problem to develop after some time, but seeing this leakage caused by such a minor action does make one wonder about the "engineering" of this.

Has anyone ever ventured to repair this thing? I'm wondering about taking the cap out and putting some female threads in the bore of the rail then machining a threaded plug with a flange at the top so that something like a fiber washer could be used to provide a reliable seal against the end of the rail.

Any thoughts or experience out there on this?


P.S. I did go ahead and order the new fuel rail and the o-ring seals for the fuel feed & return lines at a cost of ~$170!