Intake Manifold/head alignment
 

I blew the head gasket in my 1989 300SE. Rebuilt the head and installed. Re-installing the intake manifold and all bolts align except for the two on the ends. Doesn't make sense to me since all others line up properly. I probed in the bolt space by #6 and it seems like the head is slightly in the way. How is this possible? Any ideas as to overcome? My first rodeo here, so any suggestions would be very helpful since I am beyond frustrated.

Make all of the other bolts very loose and then carefully use a small pry bar to push the intake in the direction it needs to move.
Patience will pay on this to avoid stripping the head.

Thank you for the advice. I will try, the only thing that I can see that might not cooperate is the fixed position bolt coming out of the head. Do you think this will be an obstacle?

The center stud will probably help the situation by keeping everything thing in the "ballpark".

This isn't in the book but from the busted knuckle bachelors program... although you shouldn't have to, don't hesitate to oblong the hole in the manifold with a rattail file OR put a stud and nut like the center bolt to facilitate the install. The stud and nut could remain forever.

This is critical, do you understand the one way ratcheting chain tensioner?

Ah. OK. I will pursue on the manifold.
On the chain tensioner, I know this is a majoy key issue. I did not get to that reinstall yet, but I have read and will read more, but if you can share I would appreciate and am all ears.

Let me know after you read up on it, it only tightens and will quickly tear up the gears and chain if not done properly. It must be disassembled to be installed, no way around it. Once it was removed it went to full tight automatically.

Any issues removing the manifold? Is the center stud bent?

Something isn't right here....

MILS this does sound off, I don't remember is there a centering sleeve/collar on the head for the intake similar to the head gasket?

to Sugar Bear - thank you. I will read up more. Not there yet. Have to get the manifold situation under control

To MILS - Thank you too, but stud is straight. Nothing visibly wrong. I had the six inner bolts all in the head. Only the two outside would not line up and go in.

I am going to try some of the suggestions today & will report back. Any other ideas though as to why they don't match? Very odd since they are the same components that were married already. I'm very confused as to why they don't go together again.

The hole at each end won't line up. Does it look like the manifold is somehow too long overall or does it look like it is too far back or too far forward?

It could also be the gasket holes are slightly different, compare the gaskets old to new or try dry fitting the intake.

Could get two longer bolts, cut the heads off, thread only those two into the end holes and try to install the manifold. This may allow you to see the problem.

The manifold appears to line up perfectly. Why I am confused is that it is in fact the same manifold and head. And, that I had all of the middle bolts - six of them - screwed in place. I don't think it's the gasket because I inserted an awl, very carefully, in the #6 bolt area to see how strong the obstruction was and it felt like the head, not a gasket. I do have a very small camera that I am going to peek down that bolt hole and see if I can determine more. I know you said that I could file the hole on the manifold, but would that be a cause for potential air leak?

No it wouldn't cause an air leak, but filing the hole would be my last choice/ option as I think something else is the issue. The seal is created between the intake runner and the port in the head with clamping force on the gasket, the bolt only supplies the clamping force not a seal. If filing is necessary we are talking about a few mils e.g., 0.010" not an 1/8". If a few mils doesn't get it home something else is wrong.

This is a long shot but are the manifold and the head being kept at roughly the same temp? e.g., the manifold was in a warm house and the head was in a cold garage? The intake is aluminum and would expand faster and more in the heat than steel.

You are working properly by not forcing the bolt and trying to figure it out.

Thanks again Sugar Bear for your advice.
Both car and manifold are in the engine compartment in the garage - same temp. I was thinking the same thing as far as the filing goes. Last resort because you can't reverse that. And given that these two pieces were connected at one point ... I will be going back in shortly to do some more investigation. I will keep you posted. Many thanks again.

I removed the manifold from the car again. I examined both the head and the intake manifold and the gasket mating. All match up. Prior to removal, I did use my camera and the head was definitely in the way of the #6 area bolt. Now that the manifold is out I pondered the situation again. The manifold has to go to the left, so I was thinking that maybe the water pump somehow is in the way slightly? Is that possible? Again, the other 6 bolt holes all lined up OK, so I am thinking that if I move the manifold to the left to accomodate the end bolts, will that not put those 6 out of position? But, will that even be possible given the fixed position of the center bolt??

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?

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.

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.

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

Pictures - intake manifold/water pump
 

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??Attachment 167834

pix 2
 

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

Pix
 

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

pix
 

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.

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.

pix 2
 

Here's the other.

I attached the other picture to my album. And, yes it is the intake manifold that is the issue.

Move the two black spring tension hose clamps off the rubber coolant hose each to their extreme ends and retry.

There is your problem. That hose has to be put on after the intake is on. Take it off and then you're good. There is not much wiggle room if the hose is there.

The hose goes between the water pump thermostat area and the head. It is very difficult to install without pulling the water pump. Since it is already installed I'd do my best to leave it. Reposition the clamps first and gently try prying the intake forward an increment if needed. You can completely remove the clamp if needed and install a common type worm gear drive clamp without removing the hose.

I've never seen those type clamps in that spot.

When he tries to remove the clamp, its going to bow outward and make it even more difficult to move. The hose should definitely be removed. I guess you can tried sliding both clamps towards the head to create room, then reposition, but if you end up with a leak in that area, then you will need to remove it anyways. Another option is to cut the clamp and replace it with a worm gear clamp as Sugar Bear suggested.

Gentlemen. thank you both for your help. It has been great because this is my first time in 30 years doing this. It seems like moving the clamps totally towards the head did the trick. I got the bolt by #1 on and a center bolt. I am going to take a break now and resume tomorrow. I am tired and don't want to make any errors. I am very careful, and can't believe that those clamps caused the problem. The issue, small as it is, will be getting the clamps on that hose. I will have to get the spring clamps off and use the standard worm gear clamps in that area. Certainly doesn't look like that there is any room to get them on, but I will do. I was trying to use the spring clamps because I thought they would be better than the worms. Again, I will post again tomorrow to let you know how my next step works out.

Use german clamps with the radiused edges they dont cut the hose over time. You are patient and persistent!

Gentlemen, intake manifold is on and secure. All bolts went in/on smooth as silk. Even no issues on the bottom brackets. I can't believe that the minute amount of thickness caused by the clamp was enough to throw off the whole thing. Everyday learning something new! Thanks again.

Welcome, glad you got it!