I have successfully replaced the O-ring seals on the delivery valves without removing the intake manifold. The job was alot easier than I thought it would be. The windshield washer bottle must be removed.
1. remove bottle.
2. Remove the two fuel lines that go to the fuel pump shut off valve. Remove the black rubber fuel return line from the filter canister and trap it somewhere out of the way. MAKE SURE YOU HAVE 1/2 TANK OR LESS OF FUEL OR PLUG THIS LINE IMMEDIATELY! Cap off fuel line ports at fuel shut off valve.
3. Remove injector lines from delivery valves only. Remove enough of the plastic clips to gain enough slack in the lines to move them out of the way. I used red wire nuts (without wings) to cap off the delivery valves.
4. Remove all of the delivery valve retainer rings. Take carb cleaner and clean out the crap under the rings. Use compressed air.
5. Remove the delivery valves and replace the O-ring ONE AT A TIME. Hand tighten. There is a little spring under each delivery valve that will likely fall out. Take note if the little copper washer is still in the pump or stayed in the delivery valve. If it came up with the valve make sure you don't loose it while you are replacing the O-ring. Lubricate O-ring. Replace valve as removed.
6. Torque The valves to 30nm wait then to 33nm. I used an 18" torque wrench that just fit under the manifold.
7. Install lock rings. Attach fuel lines. Replace plastic clips. Replace fuel lines. Fire her up. Check for leaks. Replace bottle.
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