[Engine] DV6B injector spill rail nightmare

[IHateMyDadsM59Berlingo]

Hi all. Been having a hell of a time with my dad's DV6B Berlingo and the fuel injector spill rail(fuel return rail). I seemed to have broken it when I was leaning over the engine when I changed his starter motor recently. No biggy got a good quality one (I believe) from autodoc and fitted it, since then I've had to replace the seal twice on the number 3 injector post and now the number 2 post. When I got the replacement the seals were a bit to big makinging impossible to get them in so I reused the old (probably a mistake) with the replacement seals they are from a spill rail that came of a DV6 8v from a mk4 mondeo. Seals are Identical but for some reason are still tearing after a while causing a leak. When I push the posts down they are definently seating correctly as I am able to get the hold down clip in no bother. Am I doing something wrong or is there a trick or something I am unaware of. 

Cheers people 

Baz

[saskak]

Hi all. Been having a hell of a time with my dad's DV6B Berlingo and the fuel injector spill rail(fuel return rail). I seemed to have broken it when I was leaning over the engine when I changed his starter motor recently. No biggy got a good quality one (I believe) from autodoc and fitted it, since then I've had to replace the seal twice on the number 3 injector post and now the number 2 post. When I got the replacement the seals were a bit to big makinging impossible to get them in so I reused the old (probably a mistake) with the replacement seals they are from a spill rail that came of a DV6 8v from a mk4 mondeo. Seals are Identical but for some reason are still tearing after a while causing a leak. When I push the posts down they are definently seating correctly as I am able to get the hold down clip in no bother. Am I doing something wrong or is there a trick or something I am unaware of. 

Cheers people 

Baz

Mine is DV6A, not B, but I have undone the return things more than several times. I have noticed that they click in place and the metal clip is just a safety precaution. Sometimes, some of the injector return pipes do not click in place, hard to explain in a post here, but you can feel them clicking rather than being pushed in if you know what I mean. Some of my seals are a bit flailing, but still not problem with sealing. When I notice that they do not click into place I take them out and do them until they click into place.

Not much of help, I know, but perhaps they are not seated well.

[brajomobil]

Order new seals nitrile green and check them in diesel. 
If they are not falling apart then fit them on. Fit them while wet from diesel.
Don't fit them dry. Also check if return pipe is vibrating too much. Possibly the vibration
is "eating" the seal. 

Best regads,
brajomobil