Clattery when cold
Join Date: Feb 2012
Location: United Kingdom
County: Greater London
Did you fit new injector seals? They work-harden in use and new ones are needed - or, provided the seals don't have surface damage, anneal the old ones to soften them (for copper: heat to red heat, immediately drop into cold water or dilute HCL, ensure the surface is smooth and clean using fine wet & dry or Scotchbrite).
If in doubt about the seal seats, re-cut (can be done in place, with grease to collect the swarf, the tool is pretty cheap on eBay).
Injector clamp nuts are 25-28Nm, from memory. That's probably right as it's what I remembered a few weeks ago and the injector hasn't leaked.
On my 1.9 16v JTDM the head bolt-down procedure and numbers were the same (though ISTR a first stage of 35Nm) - and ye gods, by the last stage that is tight.
Was the head skimmed? Block surface spotless? Correct gasket used? (On my engine at least there are several different thicknesses available. Recon heads where the valves seats have not been recut to suit the skim need a thicker type.