Try starting all of the bolts but leave them VERY loose so you can move the intake loose to help position the end ones. The holes in the gasket should be at least as big as the bolt holes in the intake to prevent restricting movement. Can all of the bolts be started using only the gasket?

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"Rudeness is a weak man's imitation of strength" - Eric Hoffer

I did have the 6 bolts very loose. Issue is that center bolt from the head. There is no play there at all. Here's another one - I inserted the bolts in the manifold (which is off the car} and the head in the 2 end places. Measured distance on both units. They match! So, nothing is making sense to me yet. I can't figure why everything fits except the 2 ends and all the measurements add up. I have to clear my head & think about it some more too. Sugar Bear, appreciate your continued input. All comments and input can help.

If the gasket proves not to be the problem then elongate the center hole on the intake a touch. Just a couple of thousandths of an inch can make life difficult. Will all of the bolts start with just the gasket? Use the process of elimination to see if it is the gasket or the manifold causing the interference. Stay patient and don't force anything.

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"Rudeness is a weak man's imitation of strength" - Eric Hoffer

Why don't you post some pictures? I just did a head gasket job on an m103 a few months ago for the first time and had zero issues. In fact, I thought that job was more straight forward than doing the water pump.

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1990 190E 3.0L

I took 2 pix. How do I attach? I don't see how.

Here are the pictures. You can see that the manifold is up against the water pump and will not move any more. I cannot line up the center bolt from the head. You can see how far that is off too - about 1/8th inch. What am I doing wrong? I rather not take off the water pump because if I do who knows if it that will fit back??

The other picture is failing to load. I will keep trying.

Your pic isn't attached well enough for me to see. Look at my pic I am attaching. Go to advanced, then click the paper clip next to the smiley face, choose your file (pic), upload, then close that window

Attached Thumbnails

 

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1990 190E 3.0L

The pictures "fail to upload" every time. I don't get it! I will keep trying. Maybe the file is too big?? The usual frustrating stuff.

Just send it in a dm

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1990 190E 3.0L

Unfortunately I cannot get the pictures to download. I have done this before, but Pelican system will not accept.

What is a dm?

direct message, but if I can't see the image of what your issue is, then the only thing I can suggest is to start over now with what you have or end up causing irreversible damage and still have to start over plus spend money on buying whatever was damaged if its available.

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1990 190E 3.0L

I added one to my "album". THe other is too large. I need to retake and make file smaller.

Oh!! I got it. Go under the car and disconnect the exhaust pipe from the exhaust manifold (its only 2 bolts) attach to the head, then reconnect the exhaust pipe.

Disregard, that is the intake, not the exhaust side. Let me go check, I have a few m103s that are on stands or in cars.

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1990 190E 3.0L