Ok I had a boost leak at the throttle body shaft seals( when I pressed on the throttle wheel leaked stopped) , so i decided to go ahead and order a ported throttle body and intake manifold. After everything was back together I had a massive boost leak at the #1 fuel injector. I swapped and reseated the stock injectors numerous times with no luck. I have a set of FIC 750 so i decided to stick them in, still leaked. I ended up getting it to seal(kind of) by using washers(maybe a mm or 2mm shorter) instead of the plastic spacer on the driver side fuel rail mount bolt. Like this it held close to 20lbs before it started to leak. Until today... going to lunch my idle went crazy bouncing around and comes to a stop at 2000 rpm. I get home and find that the o-ring for the #1 injector has a massive leak again. I reseated again and there is less of a leak but now constant leak but nowhere near as bad as before. Any idea's on how to fix this? I was going to replace the injector o-ring but all the other one seal just fine and I've swapped them around numerous times. Is there a sealent or something I can put on it? Thanks for any ideas you guys can come up with.

 

So just the injector#1 even you swap the o rings? Did you try to use the stock o rings from stock injectors?
or have you measure/looked at the manifold alone and compare the holes where the injectors seats? (maybe the#1 is slightly bigger or not round or flush?)
Did you torque the fuel rails to the manifold also?

 

stock injectors nozzles are different size so o rings will not swap. Yes they are torqued. and as far as I can tell the ports are the same size. I might try to to pick up a micrometer tomorrow on the way home to measure all the fuel injector ports, but that is what I think the problem is. I could not see any issues with the ports they all look the same but is kinda hard to see with the manifold attached to the car. I was just hoping someone had an idea that didn't involve me pulling the intake manifold back off.

 

Try to put the stock injectors and stock orings then try to boost leak test it with it just to compare from FIC.

 

already did this initially could not get it to seal at all. I may try again if I pull the injectors back out tomorrow to measure.