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Originally Posted by DieselAddict
I don't use a torque wrench either, but the recommended torque on installing injectors is about 50-60 lb-ft, basically pretty much all the torque you can generate with one hand with a 1-ft ratchet. Be sure to use new heat shields! The torque on the injector halves is about the same.
For a OM617 Turbo the pop pressure should be around 135 bar. If yours say 115 bar, those are not the original injector bodies and the injectors have likely been rebuilt. The nozzles you want are 240/ and you want to bring the pop pressures within 5 bar of each other.
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The above is right on the money.
One that I might add is, I've had body halves leak even at the 60ftlb torque if I don't lap the parts before the ultrasonic cleaning. If you find your bodies leaking, you can go up to 100ftlbs with no ill effect, but take them apart and make sure the parts are SPOTLESS CLEAN and re-torque and try. 60ftlbs into the head (as DA stated above.)