How to Change Your Fuel Injector - Got Fuel?

At this point it makes sense to continue with full disassembly of the fuel rail assembly in order to replace the various o-rings that keep the fuel where it belongs.

During the disassembly process it is helpful to rotate the arms of the fuel-rail assembly in order to provide improved access to the bolts that hold it together.

During disassembly, the o-rings may come out with the fuel transfer tubes, or they may stay hidden within their fitting.

Careful use of a dental pick or other similar tool will help remove o-rings from their recess, but be especially careful not to nick or damage any of the sealing surfaces.

This photo shows the location of the o-rings on the fuel regulator block.

Here, you can see the relative locations of all the various components that make up the fuel-rail assembly.

We had to buy an o-ring kit for the fuel-rail assembly from our local Chevrolet dealer (PN 17111696). Twenty-seven bucks for nine little o-rings-at that price they ought to last forever!

Note the orientation of the retaining bracket to the fuel feed line.

The new o-rings will be a snug fit as they go together, so use a little Vaseline or other compatible lubricant to facilitate reassembly.

Now we proceed to the installation of the adjustable fuel-pressure regulator cover. It does not come with a new diaphragm, which must be ordered separately. However, the regulator cover does come with a metal disc that must be placed between the adjusting bolt and the diaphragm spring.

The original fuel-pressure regulator cover is held in place with special anti-tamper TT10 Torx screws that have a raised nub in the center in order to prevent access with a standard T10 Torx socket. However, the new adjustable fuel-pressure regulator cover does come with the necessary special Torx socket to do the job.

Note that the original fuel-pressure regulator cover included a retainer ring to evenly distribute the tightening load to ensure even compression and sealing of the diaphragm. The new adjustable cover incorporates a thicker flange that makes the retainer ring unnecessary; in fact, the new cover has a longer nipple for the vacuum line, making it impossible to fit the retaining ring to the new cover. During the install, we found that this nipple, which threads into the regulator cover, was only hand tight; we had to snug it up during assembly.