After I bolted the fuel rail down, I pressurized the system and found a huge leak from the back of the last injector that's closest to the firewall on the passenger side; its also closest to the fuel pressure regulator.

I took it out and found that the o-ring had a chunk missing. So I replaced the o-ring with one of the o-rings from the injectors that I had just removed (those injectors were new and had no miles on them, they were just the wrong flow rate so the o-rings were good). After I reinstalled the injector with the new o-ring it began to leak again, but this time it was a dribbling leak. So I took out the injector, swapped it with another injector from the front and it still leaked (the injector closest to the firewall on the passenger side).

I don't have the retaining clips on the injectors, but none of them are leaking except for this one. Could it be that I need the retaining clip for that one only? Is there some sort of a known problem with that particular injector location that I don't know about?

The injectors are the Accel 30lb-ers. I greased up the o-ring when I wiggled it into place and everything. It seems to be seated fine - it doesn't move up or down, it has no room.

SOMEONE TELL ME WHAT TO DO IF THEY'VE HAD THIS PROBLEM!! I don't want to pull the entire fuel rail out, it seems like a HUGE pain to do so.

Could the fuel rail itself be leaking? Should I get the retaining clips? The local dealer wanted $8 per clip and they said that they were special order. Another dealer couldn't even find the part number. I rather avoid getting the clips if I can.

HELP!!

 

Inspect the pocket in the fuel rail for damage and burrs. Use clean engine oil on the 'O' rings instead of grease. Make sure the 'O' rings are the larger cross section GM style instead of the smaller Ford/Mazda style. Clips might help if only to assure that the injectors stay im place while assembling the rails to the intake, but they aren;t absolutely necessary. Of course, you'll want to be sure that the fuel rails are fully seated onto the intake base.

 

It all seems O.K. Have you heard of fuel rail leaks at the joint where they meets with the rail that the fuel pressure regulator sits on? I'm not sure if that's the problem. Importantly, none of the other injectors are leaking; this includes the one that was originally in the spot that's been leaking. I just don't get it.