I need to replace the camshaft on my 81 240D and while looking over the instructions in the Haynes manual, I become a little concerned about how to remove the camshaft sprocket. The manual says in classic Haynes vagueness: "Remove sprocket and washer and use a piece of wire to hold tension on the timing chain"; however the method used to hold back the chain in the accompanying photo appears like it would be very easy to allow the chain to slip off either the crank or the IP. I was just wondering if anyone had done this before and had some pointers on the best way to go about it.

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'95 Geo Metro 3-cyl 5-speed
'97 Geo Metro 3-cyl 5-speed x2
'81 Mercedes 240D 4-speed manual RIP

Set the engine on TDC.
Zip tie the chain to the sprocket.
Remove the tensioner.
Make a support to hold tension on the sprocket.
Remove the cam bolt/washer.
Attach the sprocket to the support.

Now you can remove the cam and towers.

I prefer carefully removing the sprocket while keeping tension on the chain, then support/tension the chain out of the way.
A bit more effort, but it makes it easier to just slide the cam out the front.



.

__________________
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Dynamometer.
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Technical Quality Auditor.
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1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

And remember to loosen the cam tower bolts in the correct order or you'll snap the cam.

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

I'm considering using a bungee cord tied to a hook in the ceiling of my garage to keep tension. Looking at the chain digram, it doesn't seem like the chain could possibly pop off, even with the upward force. Thoughts?

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'95 Geo Metro 3-cyl 5-speed
'97 Geo Metro 3-cyl 5-speed x2
'81 Mercedes 240D 4-speed manual RIP

Yes, it will work.

This is how we did it when we changed the head on the 300SDL.

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~Michael S.~
Past cars:

1986 300SDL
1987 300SDL
1982 240D
1982 300SD


Current:

1987 300SDL