I'd recommend using some WD40 on the o-rings and not fuel. They will slide right in.
You can either replace the washers or just sand them down a little to make them flat again. They are cheap so I'd go with new ones.

I'd recommend using some WD40 on the o-rings and not fuel. They will slide right in.
You can either replace the washers or just sand them down a little to make them flat again. They are cheap so I'd go with new ones. I have also just reused crush washers in a pinch and not had problems too. Your pick.

I'd replace ALL of the little rubber hoses for vacuum and coolant that are easier to access while the intake is loose. I just did this on my 22re. <img src="/forums/images/graemlins/kewl.gif" alt="" />

I'd also recommend replacing the fuel pulse dampener, because I know they leak and they're very hard to see while the intake is on the engine. It's on the firewall end of the fuel rail, on the passenger side rail, below the intake mani.

The FSM says to use gas, so that is what I would use.

While sanding them flat does help, you need to make them "dead soft" for maximum sealing. To do this you need to anneal them. To do this, as stated above hang them on a piece of wire and heat them to cherry red, let cool. You can use a small propane torch to do this. Owing British MCÆs all my life I have annealed many a copper gasket including solid copper head gaskets.

The FSM says to use gas, so that is what I would use.

While sanding them flat does help, you need to make them "dead soft" for maximum sealing. To do this you need to anneal them. To do this, as stated above hang them on a piece of wire and heat them to cherry red, let cool. You can use a small propane torch to do this.