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Sorry, not familiar with the Bloomington area, so I can't help you there with either question.
Worst case could be a stud or two breaking off, fixing that could potentially take almost none to a lot of work depending on how it breaks off. Other problems could be a warped or cracked manifold (which would not, BTW, be covered even under a hard quote), bolts being unexpectedly tight, plug threads needing to be cleaned or retapped (or worst case, helicoiled, again not covered even under a hard quote).
Having worked on and parted out quite a few of these, I wouldn't worry too much about it. If the mechanic is careful and knows what he's doing stuff breaking off is fairly unlikely on an 940. Maybe a stud or two will come out of the head with the nut rather than the nut coming off, in which case it's usually a good idea to replace the stud, that kind of thing.
Hey, even though I'm not a shop (yet) I do some maintenance for others, and if they ask for a hard quote (ie. I _will_ perform the work for no more than that price) I usually tend to add a generous margin for unexpected problems. Which by the way is exactly what a shop does. Hence the two numbers. Lets face it: If all the nuts are good that manifold will be off in minutes. If all the nuts (nominally needing a 13mm socket) are corroded and start rounding off the moment you touch them with a spanner or socket, it can be a much longer struggle to get everything off intact, plus new nuts and possibly studs added to the req'd parts list. Especially the front two nuts (subject not only to heat but also to every type of liquid thrown up from the road) can be corroded down to having to hammer a 1/2", 12mm or even 7/16" impact socket on to them to get some grip.
Bram
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