TDI: Bosio Injector Nozzles

[malone]

We now carry Bosio products; PP357, PP520, PP764, R520, etc.

Canadian residents: 2-3 business day Xpresspost shipping will be only $10 CAD.

If you have questions or if you'd like to place an order, then PM me, post here, or send an email to sales@dieselinside.com

[myke_w]

Malone, can you get nozzles for PD's yet? if so, what are options / prices?

[malone]

We currently don't resell PD injectors. www.kermatdi.com carries OEM PD150 injectors (new) as well as Bosio Race (aka R783) injector nozzles.

[lord_verminaard]

What about the new 7-hole race nozzles?  I know Kerma sells them but only if you have "Kerma tuning" which I think is really shady.   :evil:

Brendan

[malone]

Kerma's explanation is that whenever vendors like Rocketchip has to tune cars equipped with Kerma's unique hardware, they tend to blame their tuning problems on the hardware, which can tarnish the hardware's reputation.

It already happened over tdiclub.com (RC enjoys every opportunity to slander Kerma) so it makes sense for Kerma to restrict his hardware sales and warranty services to his tuning.

[myke_w]

hey malone, can you post current prices for TDI VE nozzles?

[malone]

Here's the current price list. All nozzles are in stock:

SPRINT 357, 520, and 764 $225.00 USD

POWERPLUS 357, 520, 764, and 502 $340.00 USD

RACE 520 $425.00 USD

[myke_w]

thanks!

Do you have a good source of info on characteristics or suggested applications?

Myke

[malone]

The nozzle application info is sprawled all over the Internet. AFAIK there's no one-stop nozzle guide yet. However if you tell me your application I will explain which nozzles are suitable and why.

Let's start with a common example: For MK4 VE TDIs (such as the 1999.5-2003 model year TDI in NA) PP764 and PP502s are often recommended.

PP502s are only slightly larger than PP764s; both are comparible.

If it's a NA-spec 1999.5-2003 VE TDI with manual transmission (which indicate a 10mm fuel injection pump) then the PP764s won't smoke much, if at all, and all healthy clutches should hold up. Power gain is 20-25hp. A minor 2-minute VAG-COM IQ adjument MAY be recommended for SOME TDIs to adjust smoke level or low-speed shudder.

If said TDI is an auto (which indicates a 11mm pump) then the PP764s will smoke under medium to heavy load due to the extra fuel flow. If you have no plans to remap the ECU (chip tuning) and if you don't want the exhaust smoke, then the smaller PP520 nozzles are a better choice. Otherwise a good ECU tuner will remove the smoke.

Note that PP764s and PP502s are the same price as the smaller versions and they leave more room for extra fuel flow for future power upgrades "just in case."

[malone]

We had someone with R520s (Race 520s) in an otherwise mostly stock MK4 1999.5 Jetta ALH TDI (11mm pump) with good results. He eventually upgraded to a larger turbo so the R520 nozzles, albeit more expensive at first, was well suited to his long-term plan. PP764s will typically flow enough fuel to average 170whp max., give or take 20whp depending on the rest of the engine setup.

A large number of TDI owners with basic turbo upgrades like the VNT-17 or SS18## series hybrids still run the cheaper PP520 and PP764 with satisfaction.

It's not all about max. whp though: Since R520s have larger holes they can flow more fuel in a shorter injection duration than PP764s given the same horsepower, which means a more complete air/fuel mixture (increased efficiency) and lower EGT. A 11mm pump size may be recommended to ensure decent atomization with the large nozzle holes. This should really only concern aggressively tuned TDIs.

[myke_w]

Thanks for the info- it's confusing knowing what to buy for what level of tune..

I can speak for the pp520's in my wifes AHU Jetta.. and man, they woke it right up and no real smoke to speak of.. just fantastic

I get the impression (and too late if I'm wrong) that the pp520's are for stock or mild tunes where everything else starts moving you up the scale into different stages...

I was more digging for a list like, might help newbie people decide what is right. I get a lot of question about it, I'd like to be able to stick a tabke in their hands and tell them to decide..

pp520 - stock to mild tune - clutch stock OK - egt, boost guage not required

ppXYZ - medium to full tune - stage 2 clutch, FMIC- egt, boost gauge required

etc..

[malone]

pp520 - stock to mild tune - clutch stock OK - egt, boost guage not required

ppXYZ - medium to full tune - stage 2 clutch, FMIC- egt, boost gauge required

That criteria is usually for canned chip tunes, especially for MK4s. A low power chip can be made with PP764s in mind. It can range from very mild (75HP by cutting back fuel in the tune) to wild (around 170whp for these nozzles). PP520s are limited on the "wild" side and they're not cheaper. IMO PP764s are a smarter investment with small help from a good tuner.

Chip resellers without remapping skills almost always control fueling by choosing nozzle sizes carefully. That is not desireable seeing as you'd have to swap nozzles more often as you do further engine upgrades and fueling may still not be perfect. He may also be incapable of fine-tuning boost curves, which has to be done in almost every TDI.

If chip tuning is not planned, then the PP764s may smoke too much in MK3 TDIs (1Z, AHU, etc.) and MK4 TDIs with 11mm fuel injection pumps (standard if vehicle is equipped with automatic transmission). Stock clutches can handle PP764s as long as they're not old & worn.

The 1999.5 and earlier cars (and some really early 2000s) have stronger factory clutches that can hold up to both tune+injectors quite well.

Small exception: I usually just start with PP520 for the MK3 TDIs or early Passats as the PP764s may be a bit overkill for the low-pressure pumps. The owners also rarely upgrade turbos.

A good tuner's list would look like this:

With chip tuning:
ALH (all): PP764 minimum
1Z, AHU: PP520, or PP764 if turbo upgrade is planned

Without chip tuning:
ALH (manual 10mm): PP764
ALH (auto 11mm): PP520
1Z, AHU: PP520

[myke_w]

exactly what I was looking for.. I'll let you know when I'm ready for another set of 520's my father in law's car is well overdue..

Myke