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Humm.... have you been able to get a good close-up look down in the hole to see if you can see any pitting, crap or a crack? A crack is unlikely, I'd be betting more on something preventing the washer from sitting flat. Either a ridge, gouge or a piece of crap stuck down in there.

Yes, had that same issue a few times. Assuming you had everything clean and did not have an extra washer stuck down in the hole... My advise is to take it apart again, make sure the hole, the washer and the injector are all clean. Reassemble and tighten the bolt. Take a hammer and something...