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.

http://home.comcast.net/~crmont/IMG_4410.JPG

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__________________
85 300sd 400k
99 e300td 101k (hers)
34' californian twin 5.9 cummins
1999 F350 Powerjoke 75k
2001 F150 Supercrew 51k
19681/2 GT/CS

Good to know it can be done without R&R of the intake...so, you didn't replace the crush washers, just the o-rings?

Clever use of the wire nuts to keep the valves clean!

I have heard the torque procedure is tighten to 30nm, then loosen, then tighten to 30nm then loosen then tighten to 35nm...but maybe that's only if you use new crush washers?

__________________
Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

That is correct. I did NOT replace the crush washers.

__________________
85 300sd 400k
99 e300td 101k (hers)
34' californian twin 5.9 cummins
1999 F350 Powerjoke 75k
2001 F150 Supercrew 51k
19681/2 GT/CS

Bump

__________________
85 300sd 400k
99 e300td 101k (hers)
34' californian twin 5.9 cummins
1999 F350 Powerjoke 75k
2001 F150 Supercrew 51k
19681/2 GT/CS