Replacing Headgaskets and Intake manifold gaskets

[GEP]

Hi JC users, (sorry for the long write up)

Ive used this forum many times for tips and solutions to problems and have found the threads on here very helpful, especially with the how-to guides. I have 'bookmarked' all the guides I will need for this operation on my car but still have a few questions.

Ive brought all the parts I need for this redo including a full Matsumo intake (alloy) and header gasket set, new water pump, new tensioner, new pcv valve, new thermostat, new idler pulleys, all new radiator coolant hoses (x6), new heater tap (genuine GM, new oil filter (genuine GM, new header bolts and new rocker cover gaskets and grommets.

I have also purchsed castrol 10w-30 ultraclean, CRC cleaner, LiquoMoly for rubber seals and an assortment of other misc stuff like gloves.

I do have a few questions that I hope some experienced users might be anle to guide me on. Im deciding which silicone Permatex sealant to use for the valley of the intake, there copper, red, blue, black, grey..its all very confusing. I see many people use black but when I spoke to the supercheap auto guy he said the 250C max temp isnt enough for the intake manifold. My concern with the black is also oil degredation, however reading on the Permatex website it says that ultra black is just fine for intake ends. So im confused.

Also I notice that when I do an oil change my lifters and that whole assembaly inside is a brownish color to everything. I dont notice any dark sludge but it just has a ting to it, what would be a good way to clean that without taking it all apart as I dont have the tools or expertise messing with those lifters and springs or should I just leave well enough alone.

My knowledge of working on cars is probably abit above average, I recently changed the trans fluid and oil (not a flush), flushed powersteering fluid, changed differential fluid and ofcourse the regular oil changes. To the car side of things I changed the brakes and rotors last year. I have the workshop instructions on this headgasket and inlet gasket change over, so any tips woild be great. Just abit nervous and its cost me close to $400 for parts so far, so I dont want to have to repeat this.

Im pretty sure my cars got a blown intake gasket as many years ago I noticed oil in the coolant and the engine area is covered in oil, which Ill be cleaning off too.

Thanks guys for you tips and encourgment.

CAR DETAILS:
SEDAN
2003 VY BERLINA ECOTEC V6
260,000KMS

Owned the car since 80,000 and have not done anything to it except oil changes and the mentioned items above.

 

[GEP]

Also I will be overhauling the fuel rail system, cleaning the injectors and replacing the o-rings and filters on them. I will also be putting in a new fuel pressure regulator. Trying to get it all done while everythings apart. Ive set aside 2 days for the jobs but more if needed. Naturally I will be cleaning the plenum, intake manifold..all those parts. I have read that CRC carb clea er is good, or perhaps brake cleaner?

So any tips on cleaning the head surfaces and intake surfaces would be great too.

 

[Lex]

Rocker cover gaskets?
New radiator cap?

 

[GEP]

Rocker cover gaskets?
New radiator cap?

Got rocker cover gaskets but yeah forgot about new radiator cap, thanks man.

 

[BowTie]

I like to strip and rewrap the loom while i'm there. New conduit, tape and contact cleaner. Repair any burnt/brittle wire while there.

Adds time but stops a few electrical gremlins later.

 

[GEP]

I like to strip and rewrap the loom while i'm there. New conduit, tape and contact cleaner. Repair any burnt/brittle wire while there.

Adds time but stops a few electrical gremlins later.

Thats a good idea too. I cleaning the engine bay and detailed everything, this sounds like a good idea. What tape and conduit did you use, anything special? As for wires I havent seen any broken parts and there was Id leave it too the specialist as electricals are not my strong points.

 

[BowTie]

Standard conduit in three sizes with the best electrical tape I could find. I like to use silver solder for any patch work for durability. Any badly degraded elec connectors can all be purchased individually and patched in easily at that time too. The whole top loom will lay out over the front bar for ease.

 

[BowTie]

And heatshrink as needed.

 

[losh1971]

You shouldn't need any sealant on the valley gaskets. What you should do though is use aluminium ones since you have an Eco. Also with the LIM use a thin film of oil or RP7 on the gaskets. This helps the LIM slide around enough to get it into position and stops the thin rubber seal on the gaskets from becoming damaged.

 

[losh1971]

The place you want to use some sealant is on the four corners of the of the LIM where it sits on the front and rear of the engine. I'd be inclined to use the blue sealant or grey too and not black or orange. I wouldn't worry about the heat as I have used blue of the flanges of my Y pipe and it hasn't burnt away yet and it's been over six months.