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Discussion Starter #1
I need to know what is wrong. IF ANYONE has ANY answers, they would be most appreciated.

Scenario: On a dark and cold morning, I turned the car on and let it warm up for a few minutes. I come back outside and get in and pull away, my headlights reveal a giant puddle of gasoline on the concrete. My brother tells me that I busted an O ring. So I think to myself, "Simple fix, right?"

We get in there, find the torn O ring attached to the fuel line going into the fuel rail, and replace it. We put everything back together, and lo and behold, a new leak springs up on another side. This happens at least two times each on every connection to both fuel rails. We even replaced the fuel injector O rings while we were at it. Now, it seems the new O rings from three injectors are now leaking. Could it be that I bought crap Rings to begin with, or is there a more sinister problem lurking?
 

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Discussion Starter #2
OH yeah, I have a 1996 3.5 Intrepid that hasn't run in over five weeks. I'm considering sending it to a dealer and let them deal with this frustration I am feeling. I'm a bit concerned about cost, but only my pocketbook would be feeling the pinch, not me noggin.
 

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It might be the FUEL RAIL ITSELF... i have a 96 3.5 liter myself.. but i didnt have a puddle.. i had it leak gas a little.. from the passenger side rail.. so i bought it myself and did the work.. but dealer might cover it under a (the) recall... DONT QUOTE ME ON THIS..
but let others respond to this first.. they probably know and have more info than i do....
I AM JUST MAKING A GUESS ON WHAT IT COUL BE BASED ON MY PAST EXPERIENCE
 

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To lose that many O rings in succession I suspect the pressure regulator is stuck closed and you're getting 60 - 80 psi from the fuel pump to all the fuel connections. You can verify this by undoing the return line, point into a container to see if any fuel is coming out at idle.
Normal supply should be 40 - 45 psi.
 

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Discussion Starter #6
The fuel pressure regulator shot out when we turned the key to restore fuel pressure. I bet that might be it. I'll go check it out.
 

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I remember the fuel rail recall many years ago when I had a '93 ES. I'd had no problems until they did the "upgrade". Then I had a fuel leak. They got it right the 2nd time though.
 

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Your fuel system should easily handle the pressure with the fuel regulator wide open. When you are under power it all sees full pressure anyways.

I suggest take the manifold off. Replace all the orings, the 2 on each injector and the 4 in the ends of the fuel rail.
Lube them with oil for a successful install. Lay them in place on the cylinder head. Connect the battery and energize the fuel pump by closing the fuel pump relay connections.
Now with everything exposed and the system under full pressure, look for the leak.
 

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Discussion Starter #9
Good News everyone! I Finally fixed that there leak thingy. I replaced all sixteen o-rings at once, and now there are no more leaks. I've driven it for a few hours and still no leak. Thanks to everyone for all the advice and support. Without this forum, I don't think I would have been able to fix my car. Kudos to DI.net.
 
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