Replacing Headgaskets and Intake manifold gaskets

[GEP]

So I got started this afternokn, around 3PM. Just finished now. Cleaned and degreased engine, trottle body, plenum and LIM. Its bedn a lot more work then I thought, and somewhat stressful.

Everything was going okay until I went to unbolt the plenum from the LIM. Wgen I went to undo the first bolt the socket fell off the wrench and straight down the hole into where the little valve things go. This happen twice, I was nearly beside myself with stress.

The first socket peice was somewhat easy to get our, the second however made its way behind the valve stem...it was wedged in there and I had nothing small and long enough to geab it. So I went to supeecheap and got a long nose pliers. After some considerable anxiety I manged to get the other socker peice out. I thought Id have to remove the heads to get this out, which I had not been prepared for.

Tomorrow I have to clean the throttle valve, some bolts and the intact manifold surface. Depending on how I feel I might start reassembly.

 

[GEP]

An interesting point the gaskets on the LIM seem fine to me, I cant see any noticeable cracks or warping. Also the waterpump aswell appears fine, apart from a shot bearing. Everything looks nice though, theres actually silver color under all that grease and grime.

The throttle valve is just entirely black on the inside and under the plenum lid, I was blown away at how dirty it was. Without a word of a lie the entrance of the air intake vale was a good 1-2mm thick of grime, It was almost like a hard rubber that was caked everywhere. I spent a good hour just cleaning this, using can of carby cleaner and kerosene...just scrubbing away with a wire brush. I cleaned the plenum lid the same way.

I also cleaned the LIM which was a lot of work as there was grease and grime everywhere. Gave everything a light once over with some antasol polish, not to get it shiny but just clean it up abit. The waterpump came of nicely, as did the idle wheels. Definitely a few shot bearings there too. Interesting to note is that the pump looked in fine condition, the blades werent worn away...but the bearing is gone. For a 260,000KM everything seems okay.