I had the gasket between the upper and lower housing for the intercooler go so I have to separate the intercooler this past weekend. When I pulled the fuel rail and injectors I noticed on one of the injectors, the hard plastic/rubber tapered section just below the lower o-ring on the nose had a gouge in it. The o-rings all looked looked fine though. Should I be concerned about this (is that a sealing surface or is the oring what seals the injector) or can I try to work it over and put it back in. I didn’t start pulling to see if I could pull that tapered section off. I’m thinking of putting it back in one of the front holes so If I have to replace it I can.

 

Can you show a picture of the damage?

 

Here's a couple pics of the injector

 

If the body of the injector is not cracked through to the center then I'd say it's good to go. As long as fuel won't leak sideways through that crack there should be no issue.