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Hi JMH,
I have done this on a newer diesel (1987 300D) which is different than yours, but the basic idea is the same. Anyway:
1- The usual shop labor quote is between 12-20 hours for experienced mechanics to do the job, start to finish. I would plan on 20-30 hours, if you have no major problems, and have the factory service manual (not just the Haynes) by your side as you do the work. It took me roughly 40 hours or so but I spent a LOT of time cleaning up the engine compartment and being *really* careful about everything. I could probably do it again in 20-25. Your engine is a bit simpler, and may be quicker, I'm not sure.
2- A valve job would he a good idea. At least have it checked by a machine shop while it's off the car. The valves shouldn't need replacement but may take minor lapping or something.
3- I believe you need to remove the belts & stuff but I'm not positive. On my car I removed the serpentine belt just to have more room to work.
4- Yes, replace the timing chain. You will want to replace the guides & tensioner while the head is off, but the chain itself can be done separately, and is best replaced with the head installed.
5- While it's apart you could have the injectors tested. Also set the injection pump timing (wait until AFTER you replace the chain, or you'll need to do it twice.) If you get the pump lock tool (about $25 from the dealer) you don't need to mess with the "drip" method.
6- You will need the special 27mm injector tool, which also is handy for the crankshaft center bolt (to turn the engine). (Some regular 27mm deep sockets work, other don't.) You will also need the tools to R&R the prechambers, unless you don't mess with the head, then you might just leave them in there. I can't think of any other special tools needed off hand... read the manual and see what it says.
BTW - what makes you think the gasket is failing? Oil in coolant or vice-versa? High pressure in the cooling system when cold? Overheating? It's not very common for head gaskets to fail on the iron-head diesels...
Good luck,
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