how should I prep and clean the block for re-assembly? some of the old gasket is stubborn and stuck.
also I read in the repair manual that after removal of the head, there is a oil return tube that something has to be done to. I dont quite understand what the manual is trying to say. other than that, all is well. the head is at the machine shop getting a valve job at the cost of $450. parts are on their way and I am prepping away.

I replaced my head gasket on my 97 E320 a few months ago. Like you, I had trouble getting the old gasket off. I ended up carefully scraping it off with a paint scraper, and then with a razor blade (with a handle - like the one used to scrape off your inspection sticker). I also sanded the top of the block with fine sandpaper. I was worried about small metal and sand particles in the cylinders, so I stuffed them with rags before I started, and blew them out with an air hose after I finished.

You could also try some gasket remover. I tried it, but didn't have much luck.

So far, no oil leaks.

How many miles on your 97 e320 when you changed the head gasket?

After you've used gasket remover and a razor blade, go at it with a bench stone and stone oil or kerosene.

__________________
'82 300SD - 361K mi - "Blue"

"Good judgement comes from experience. Experience comes from bad judgement."

listen, look, .........and duck.

I would personally not use ANY abrasives of ANY kind. I have a large, flat mill file ground on the end to a 45 degree angle making a paint scraper of sorts. I use that and a razor blade on a scraper handle.

The WORST thing to use is the air powered tool that uses an abrasive wheel. I have heard of engines lasting as little as a thousand miles after this grit is distributed everywhere. They have now seemed to lost popularity, thank goodness.

It is time consuming, but a worthwhile step. Make sure you don't slip and score a cylinder wall with your scrapers.

Good luck,

just finished 300e and of course the head comes back perfect
and you have to worry about the bottom of the engine... most importantly are the bolt holes... i used q tips to get the water out and then i
used a tap i bought in a set from autozone for 18 bucks....

the tap really cleaned the holes... and it was important the get the absolute right size......i bought a nut for the bolts....



i used a razor scraper from big lots. 3 bucks... long handle it worked great.. and we used fine wet sand paper.... then i washed it 3 times with alchol...

the next time i do this i would like to use a copper head gasket... and i
would like some other way of cleaning the top...

i used a vac in the cylinders.