300te Installing new head assembly to existing block
 

Got a rebuilt head to replace existing head

Does the new head timing pulley have to be timed up to the existing sprocket? how?

Yes you need to get it aligned up.
Read here:
http://www.w124-zone.com/downloads/MB%20CD/W124/w124CD1/Program/Engine/103/01-4150.pdf

alignment
 

Camshaft has on hole which is not tapped, must be the pin hole.

This pin hole must line up with CamSprocket unique hole, only 1 like it? aka idiot proof hopefully

turning the camshaft must be difficult, is it possible once head is back on? or will the sprocket be in the way.

instead of the slide hammer did you use im guessing a m5 x (L?) + 11mm socket + washer to pull out the cam guide pin

Since the original head might not go back on <pending:condition> need to find an answer ___

this head i pulled was a rebuilt but there have been many noticeable problems with the previous work, mainly;
-used excess amounts of silicone on all the gaskets, i mean all of em in the whole set. this = time cleaning white gunk
-head bolts varied in torque seemingly and there were several new style bolts with washers mixed with old style with washers
-Valves seem to be in good shape -minus 1 loose 13mm hex on #4 & a way loose #8 (the 2 on each end)

gasket is on its way via fastlane so looks like job will take place nxt weekend

This is what I used for guide pin removal...I have pics here in the article:
http://www.w124-zone.com/articles.php?article_id=36

What gasket are you using? Victor-Reinz?
If so...just my input...I did HG job in 2009...after 10k miles it started leaking rear side of the head for no reason -- I was meticulous the first time including getting the head skimmed + rebuilt. Replaced gasket 2nd time around in december, but this time I used 70nm torque + 2x90deg that the HG manual states rather than 55nm MB says. Not sure if it makes a difference, but wanted to give you food for thought.

read it & printed it
 

Thanks for the documentation, it is great to know what were getting into before hand.

As for the cam, the tool you made. Do you remember the metric size of the bolt?

Yes I am getting a victor reinz, it came via mail yesterday from fastlane.

It is up to you if you decide to go with MB 55nm torque or 70nm torque that VR specifies in the manual...

Just keep in mind I used VR 55nm my first time, then it started leaking 10k miles later. This time I did 70nm. I may have just had a bad gasket, but who knows...Just want to let you know.

I don't remember the size of the bolt, I just went through my random bolt draws and got lucky.

Head Warped > .013
 

Machinist turned down the head, said its warped .013.

May try and bake 400 deg. for a hour or so, clamped down to a flat surface to see how much it brings that measurement down. mmmm toasty!!

The valves are in pretty good shape and even a new cam shaft...

Looks like 3.535 is the overall height on the block. Not much to work with.

Trying a M6 x 20mm hex bolt w/ socket washer deal to remove alignment pin?