Just repalced my head gasket a few months back It started to weep at of the area near the thermastat. Was told its a common area. After the shop rates peoepl were giving me i thought id attempt it myself.
Aside from keeping the injection system clean the hardest parts for me were unplugging the temp sender from the back driver side of the head removing the fuel filter housing and removing the turbo.
dont hold me to the step by step since im going off memory. First thing i did was remove the things that were in my way. Airbox pulls out then remove wiper arms and tape the cowling up and out of the way. (makes access to the plugs in the cowl since u will be pulling up 4 pushrods through the cowl in 2 different push out plugs.) Then start disconnecting wires such as grounds and grid heater making a note where to put them. Disconnect hoses remove the metal heater lines they are thin and easily bent. Disconnect and remove air horn. I then removed the turbo then injection lines (this can be done as one piece if you carefully loosen the mounts first then all connections at the pump and injectors) I found doubled up thick aluminum foil worked great at keeping crap out of the injection pump and lines. Then i removed valve covers rockers and pushrods (dont forget to lable the order you removed them in. I used tin foil with tape worked great as a makeshift bag for the rockers and a piece of wood with holes drilled into it for the numbering of pushrods)After i had removed the over flow line (keep the copper seals from the bypass line they are expensive but reusable, tin foil again worked great to keep it clean) Removed the nuts holding the injectors in place (inspect seals of these they are cheap to replace and keep dirt and moisture from making an injector hard to remove) I took a lug nut from my front wheel cleaned it throughly and made sure the threads were good then screwed it onto my injector and used a pry bar to remove the injectors. (the lug is similar thread size and gives a good surface to pry from if an injector is stuck spray some penetrating oil on it let it set then try to rock it out.) Also its worth getting your injectors checked now. I did so and had 2 bad the rest popping 500 psi to early but still good spray pattern. Remove head bolts attack the engien hoist to the eyelets at front passanger and driver side rear of head and apply light pressure and try to pop it from its seal. Its sort of a slow process to remove it i had to tilt the head toward the back of the motor to clear my hood then level it out to clear the front.
I may have missed some details on the removal... When i got busy i forgot to take photos.
Once the head is out and msot of the gasket is clean check for any corrosion an indents on the block that are signs of blowing the gasket between the cylinders or coolant eatting its way to something. Once most of the gasket is clear and the block deck checks out sand block with 220 grit to remove any residue and it also gives the new gasket a surface to have some bite to. Clean with brake cleaner when done though.
With the head off its a great time to replace the rubber lines behind the injection pump if they are looking a bit aged.
Have the head inspected and cleaned at a reputable shop (mine needed .010 removed to remove the black ring left by the headgasket) Replace the valve stem seals if you want(cummins seemed better quality then the other store varieties.
Also why not do a quick port and polish job. Around the ports on mine nearly every cylinder had casting closing up the port by 1/8"
When putting the head back into the engine compartment do so with out the head gasket placed since its nearly impossible to position the head with out dinging up the gasket. Once the head has been lined up probably with only a 1" gap place the new headgasket into place. I then used the long head bolts as guides only threading a few into the areas where the shorter bolts are used.
They recommend new head bolts or u can just get some metric 12.9 grade cap screws from fastenal(grade 8 is SAE, 12.9 is metric) as a slightly stronger and substantially cheaper replacement I went this route and found 7/16" grade 8 washers fit tightly with all the cap screws but you cant use the washers with the rocker pedistal capscrews or the rocker covers will touch.
These are the capscrew sizes i used make sure you get the 12.9 grade and its a socket head cap screw (they are suppossed to be stronger then a regular hex head bolt)
6 12x70
14 12x120
6 12x180 thread pitch is 1.75 allen head capscrew
Not my photos but they are photos of the stock bolt and the alternative stronger bolt.
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Read some threads around here and else where. Definently grab a manual tons of good torque sequence info contained in one. Also you will need a few seals and gaskets in this job i spent most of my time running back and and forth to cummins for seals i forgot to order in.
Good luck the shop price in my area vs me doing it myself payed for my new injectors the port and polish kit and pulse exhaust manifold.
Update 4/2/13:
So far things are good I retorqued the bolts to 125 ftlbs lubricated with CMD Extreme Pressure Lube #3(good stuff no chatter when torqued) I thought I really messed the truck up awhile back cause I had kept the pedal nearly to the floor for a whole 15 miles was hitting speeds of 90-100 constantly at 3k rpm chasing a rabbit. Looked back and seen brown puking out the exhaust an clouding out the road. I could see the cloud still hovering over the road from 1 mile away before loosing sight in the hills. What ever it was hasn't happened again and it stopped as soon as I let off the throttle. My guess is high egts and me not using an egt gauge and just getting lucky. Havent modified the pump so didn't think egts would be an issue till that day.