Leak at injector.. what can it be?

Greetings,

300tdi Defender

Three or so weeks ago I removed all four injectors, took them to local BOSCH garage and got them cleaned & pressure tested.
Upon re-installation I made sure that:
1: Brand new copper washers were used and installed with the ridge facing the injectors.
2. The injector housings were as clean as possible
3. The old copper washers were removed before installation of the new ones.
4. Injector brackets were installed correctly on studs and tightened well.

However, despite the above efforts I am getting a fairly significant leak coming from around the body of injector #2. It kind of looks like oil mixed with diesel that is blowing pass the injector and seeping out.

What would you suggest I should do to fix this? Replace washer again perhaps? It wasn't happening before I removed the injectors .

Are you sure it is the injector to head seal that is leaking?. Just wondering if it could be the leak-off banjo seals leaking (or even the main fuel feed) and it is running down the injector in to the pocket?

I had the same a few years ago on a 200 and it was the new tip body to injector joint that was leaking.

Kwakerman said:

Are you sure it is the injector to head seal that is leaking?. Just wondering if it could be the leak-off banjo seals leaking (or even the main fuel feed) and it is running down the injector in to the pocket?

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Thanks for replying. Not banjo seals or main fuel feed. Both are dry. Upon a closer look it seems the possiblity exists where it might be coming from the oil fill cap and a section of the rocker cover and running down and into the injector cut-out. This is just a theory so I guess it would make sense to replace the rocker cover gasket and the oil filler cap gasket at this point.
If my memory serves me correctly it is a cheap pattern gasket that is currently on the rocker cover. Is there a huge difference between the OEM supplied gasket and the cheaper options?

lynall said:

I had the same a few years ago on a 200 and it was the new tip body to injector joint that was leaking.

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Thanks for reply.
I am thinking it might not be this as the leak is quite dark like oil, and does not smell of diesel at all.

LeftFoot said:

Thanks for replying. Not banjo seals or main fuel feed. Both are dry. Upon a closer look it seems the possiblity exists where it might be coming from the oil fill cap and a section of the rocker cover and running down and into the injector cut-out. This is just a theory so I guess it would make sense to replace the rocker cover gasket and the oil filler cap gasket at this point.
If my memory serves me correctly it is a cheap pattern gasket that is currently on the rocker cover. Is there a huge difference between the OEM supplied gasket and the cheaper options?

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Cheap 200 rocker gaskets are just fine, its just the d-seals need some sealant applied when fitting
New oil filler caps are as cheap as chips