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Old 12-26-2003, 03:10 PM
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Location: Festus MO
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Removing Cyl Head (80 300SD) - timing chain

I've searched the archives, but not found what I'm looking for. I have also ordered the FSM, but haven't received it yet. I'm trying to remove the cylinder head from my '80 300SD (617 engine). The engine has pitifully low compression, and is leaking past the rings. I need to get inside to take a look. I have the intake and exhaust manifolds off, the power steering pump and bracket off, and have managed to remove the rockers, cam & towers. I am now left with the cam sprocket still trapped in the timing chain. I have also removed the tensioner "plug" with the spring that applies tension to the curved tensioner.

What is next? There is not enough slack to remove the sprocket from the chain. I can't figure out how to completely remove the "plunger" that the tensioner spring works against. Does this plunger come out the block side, or will it remain in place until I get the chain loose?

I can also tell that the black plastic "guide" will have to be removed. I think that I have read about using a small bolt and stack of washers to pull the pin that holds this plastic piece in place. Is this correct? Anybody know what size the bolt is?

I know I should probably wait for the FSM, but the weather is nice, and I have a little time to work on it now.

Should I grind the head off a chain pin, then drive it out?

Any help would be appreciated.

SteveM
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Old 12-26-2003, 03:25 PM
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The cam sprocket has got to be gotten out of the way. You will want to remove the tensioner if you haven't already. There is a pin that needs to come out of the upper slide raid - drivers side. Also, two allen head fasteners down in the head where the chain comes up of of.
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Old 12-26-2003, 03:38 PM
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How to remove tensioner?

Thanks for the quick reply. How does one remove the tensioner? I think I can get the pin pulled on the driver's side (using a metric bolt and stack of washers), but how does the tensioner come out?

Steve
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Old 12-26-2003, 04:19 PM
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Look real close at the pic and you should see the tensioner. There are a couple fasteners holding it onto the block. The big hex head that you can see screws down into a flanged part that bolts onto the block.
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Old 12-26-2003, 04:24 PM
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Here is a pic of a homemade "tool". I don't remember the size of the all thread I used to screw down into the pin but it is the same size as the fasteners that hold the thermostat housing "top" on on a 617 engine.
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