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Discussion Starter #1
I just finished reassembling the head, I spun it over it. its clearly not happy. The head is torqued up as follows:

10 6 2 4 8 7 3 1 5 9

1 phase 65 Nm
2nd phase 90°
3rd phase 90°
4th phase 90°

I'm not convinced the head gasket isn't leaking and certainly the injectors are, is there a check torque setting or do it loosen them all and retighten them?

Anyone know the best way of sealing the injectors I don't want to over tighten them.
 

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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.
 

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Discussion Starter #3
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.
The last 90 deg is seriously tight, a 2ft power bar did the trick.

The old head went off to be rebuilt but was history (idler disintegrated and cam belt came off) the valve guide had split. The head was new I lifted it from a complete engine. It went off to be skimmed but was clean and straight so they returned it. The head gasket wasn't notched (thicker) and came from shop4parts.
 
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