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Interesting write-up by the OP. However, I did not read that he removed the intake manifold, which my shop found necessary to make the job a far more pleasant task. BTW I; when the manifold is removed worn manifold gaskets can be replaced, which my shop discovered can change the CO% by as much as 1%! BTW II; it's also a good time to replace the aging cylinder head temp sensor.
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Keep the Shiny Side UP!
Pete Z.
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