I removed my Intake plenum to clean it and I found all this gunk, is it normal to see that much? What should I do clean it? I thought while I was in there i should replace some gaskets, valve cover, valley pan and some new injector seals. Should i do anything else? Truck has 240k kilometers and runs good.
What do you think about this gunk
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Mine looked pretty much the same when I did my heads at 130K miles. I scubbed her down with a brush in a bath of diesel, concentrated mostly in the crevices and drains in the bottom of the trumpet pan. As long as the gunk is tightly adhered (varnished) I wouldn't worry too much about it. Remove the trumpet assy to clean and be very careful not to drop anything down your open intakes... 
I believe the gunk comes mainly from the valve cover breather. Valve seals, wear... all that good stuff. Someday you'll need to recon the heads.
I wouldn't mess with the valley gaskets till you're ready to do the heads. I would, however, look at replacing your fuel pressure regulator and injectors while your plenum is removed. (especially if original)
(reconditioned orange tops e-bay http://cgi.ebay.com/ebaymotors/89-90-91 ... 4ced02a4d7)
I believe the gunk comes mainly from the valve cover breather. Valve seals, wear... all that good stuff. Someday you'll need to recon the heads.
I wouldn't mess with the valley gaskets till you're ready to do the heads. I would, however, look at replacing your fuel pressure regulator and injectors while your plenum is removed. (especially if original)
(reconditioned orange tops e-bay http://cgi.ebay.com/ebaymotors/89-90-91 ... 4ced02a4d7)
I removed all the pcv junk from a plenum/manifold in parts cleaner and a wire brush. It really seemed to collect at the lowest points where the head meets the manifold. I was supprised at how much bigger the passage ways were after i cleaned it up. I got way better throttle response, gas millage, and acceleration. It was a dirty job but way worth it.
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