Putting motor back togethor..one problem and one question(pics)
 

first the problem...
http://i342.photobucket.com/albums/o...rookedstud.jpg
the bottom right stud is a little off, making it impossible to get the gasket on...let alone the exhaust manifold. What are my options.. rubber mallet and bang back into place? or.. replace the stud, which i dont know how to do.

the question is this..
http://i342.photobucket.com/albums/o...ed8609/omp.jpg

this is my attempt to put the s5 electric omp back on..when i line up all the holes with the bolts ..that picture is the result, theres a space on top that i know shouldnt be there. Im probably doing something insanely dumb..but i dont know what that is.

lastly this is my first time doing this so its gona be a very slow and steady process so i can assure myself im not doing anything wrong.. i was wondering if theres anything i should be aware of that someone like me might over look while assembling the motor.

First off, before you install it, make sure it rotates freely for at least 3 revolutions of the crank. If something fell out you will find it this way. And don't force it. I destroyed a rotor that way. Other than that, just take it slowly and don't force anything.

As for the exhaust stud, you need to replace it. You can get a new one from the dealership for a few bucks. To remove the old one, take 2 nuts; put the first one on backwards, the second one on forwards and tighten them together as hard as you can. Next, "unscrew" them by using a wrench on the innermost nut (the first one you put on) They will not come off, but will instead pull the stud out. Installation is reverse of removal :) Seriously, just do the same with the new stud but use a socket or wrench to "tighten" the outer nut. Just crank it on pretty much as hard as you can, but be careful not to break the stud.

i have studs on my old housings i can use.

What about the omp situation?

tried the technique for removing the stud on a crap housing i had lying around. I tightened the nuts onto each other and couldnt physically unscrew the stud, so i put a wrench on there and hit it with a hammer and it slowwwllyyy started to unscrew. after about 15 min of banging it just snapped..and i destroyed the nuts. im very hesitant to do this to the stud on my motor. whats wrong with banging it back?

Because theres still a chance you could snap it by doing that. Soak it in penetrant, heat it up, you should be able to get it.

good point

Silly me, but have you tried to leave the gasket off, and then tried to see if the exhaust manifold will go on? I saw no mention of the stud being bent, so I'm wondering what the deal is.

If the manifold fits, then take a ??? rat tail file to the exhaust gasket mounting holes and enlarge the one that is acting peculiar.

But........the bottom right one IS bent, isn't it. If so disregard what I wrote.

yea the exhaust mani wont go on. what about the omp..am i missing a gasket or something

I've never seen a series five electrical OMP. No help from here. Betcha someone out there has messed with 'em and will help out.