From a previous thread (in the diesel discussion) inquiring about glow plug replacement, & after comparing Lightman's instructions it would appear the non turbo 96 has a different setup than the 99 w/ turbo. Without any intercooler & what appears to be a different intake manifold cover compared to the 99 (the 96 has a 2 piece as opposed to the 1 piece on the 99 turbo)
It looks like just removing the plastic valve cover,13 or so manifold bolts,& 4-5 10mm bolts on a bracket holding the egr assembly,would allow easy access to the plugs. Any advice specific to this model would be appreciated.

I'm in the process right now of removing the head on my 96 E. It is really straight forward. The crossover pipe has to come off which is not a problem. I ended up taking off the whole bracket that the crossover goes into. Also, depending on how many miles, you may want to think about replacing the seals in the crossover/connector. Once that's off, the IM comes off with all the bolts easily exposed and minimal vacuum and electrical connections.
Matt

sounds like we have the same age & mileage(130,000.) I also re built the interior mirror & would like to see the picture. Mine's holding up with only slight wobble.I adjust it high to compensate. Can you believe $500 to replace it from MB ?
Anyway,regarding the glow plug replacement. When you say the "bracket"you're referring to the passenger side where it goes into the block,correct ? Initially looking at everything, I see there's not much wiggle room otherwise to get the crossove pipe off.
I need to wait for the gasket to come in,so I can relax. Is the use of a torque wrench recommended for all plugs & torx bolts ? & if so how much lbs ? Seems like hand tight plus a snug wil do it (you can tell I don't own a torque wrench,eh ? -although not against buying one.)
Did you notice much gunk in the manifold to clean out ? My wires,hoses & harness all look good.Thanks for any insights.

Regarding the "bracket", yes, I think a total of 4 bolts and when I retightend things down, i used snug plus a little. Although on the IM I would get the torque specs, but even then there wasn't a lot of pressure to get it off. Inside the manifold wasn't a lot of gook so I didn't bother to really get after it. I may take a little more time on it this time considering everything else will be like brand new.
I don't think I took any pictures of the mirror when I dissasembled it (I think there are a couple of post that do have pics), but the first time using the silicon did not work for me. After using the construction adhesive, it's rock solid. If you can't get the torque specs for the IM let me know and I'll look it up later on.
Matt

hey Matt, The following is from a thread response (from lightman) in the diesel discussion where it was a 99 turbo having plugs replaced. These are probably a good indicator.
Go figure as I'm driving today neither the glow plug light or CEL is on. I suppose I'll be ready when they re appear.

" "9. Install the new glowplugs.You may also want to dab a little anti-seize on the threads. Thread them in and torque to 27NM. Install the glowplug caps, they will push on with an audible CLICK.

10. Remove old intake manifold gasket and clean head's surface. Remove all rags from the head.

11. Align and lay out new intake manifold gasket. Don't worry about it staying totally in place at this point.

12. Reinstall intake manifold onto intercooler tube, and be sure the egr assembly is 'plugged in' to the corrugated pipe. Install the clamp to hold them together, however just tighten enough to get the bolt threaded at this point. Be sure the egr is firmly seated on the intercooler pipe, and the manifold is seated flat on the head. Might take a little push to get it down flat.

13. Using a flashlight, look down the holes on the top of the intake manifold. If the gasket is lined up, install the bolts. If not, lift up very slightly on the manifold, and using a thin/long screwdriver, scoot the gasket until the holes line up. I suggest doing this at one and and then the other. Once you've done that, it's pretty well lined up. Be sure it's totally lined up with one more center bolt, and then reinstall all the manifold bolts. Thread them until they are all snug, not too tight. Then working from the center out, in a top bottom top bottom order, torque these bolts to 20NM, or 14 ft lbs. " "

Thanks again.Looks like I'll be doing this later than I expected. Now that I've bought the glow plugs & relay switch, anti seize,deep sockets,& a gasket on order I'm an accident waiting to happen !