I am battling a leaking banjo fitting on the fuel distribution block where the return line takes off. I had to re-position the banjo fitting to route the return line. Since then, I cannot get it to stop leaking. I replaced the crush washers and it still seeps. I Put an extra pound on the torque value and still it continues to seep. I even tried annealing the copper washers to make them softer and still no luck. I am about at witts end. Anyone else have this happen? Any remedies? I just ordered 2 more washers from leading edge.

I read about the ends of the banjo bolts contacting each other before the washers squeeze enough, hence the reason for replacement. The ones I used are 1.5mm thick. The high dollar rotax ones are 1.4 mm so I cannot see that as a problem.