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I followed the Green Book procedure!
When I did mine, I found that taking the manifold heat stove bottom section off gives the necessary view of the bottom nut for the stud at the bottom of the outer intake manifold. If you are using the crankshaft lock and cam alignment fixture, taking the starter out of the way is almost impossible unless the outer manifold come off first. (Can't get to the bolt holding the brace on the back of the starter.)
I checked the top of the block with a straight edge for flatness. A machine shop pressure checked the head for coolant leakage and vacuum tested the valves for seal. Then they took a skim cut at the gasket surface to assure that was flat. I used new head bolts!
Heating the cover and head to get the stripper for the old glue to do its job was a necessity.
Replace the gaskets and clean the oil trap while you are there.
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'96 965, 16' wheels, rear 18mm bar & Koni + 204HP cams at 125K. Had '85 745 Turbo Diesel for 200K.
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