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Joe:
I just did a head gasket on my 92 960 a couple weeks ago so it is still fresh in my mind.
It was not that bad of a job but will take some patients, a good set of tools(small and large torque wrench) and a little less than $200 worth of parts (use NEW head bolts). I did make the tools to pull the cam cover back together and would not recommend doing the job without them; in fact I will send them to you for postage if you decide to do it yourself. The job took me about 20 hours all together and a lot of that time was spent cleaning off the gasket surfaces and some more making the "squeeze tools". I found the head gasket failed on the exhaust side between the 3 &4 cyl. I would do a compression test to asses the overall condition and a pressure test on cooling system, and make sure it is not trans fluid in the coolant An interesting side note I did find 4 of the pistons had nicks in them from the valves so this motor suffered from the dreaded broken T belt at one time but is still going with the original pistons. If I can help let me know.
Rob.
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