Upgrading Injectors + nozzles

[Dj_Ghost]

Some of you know that I was thinking of doing a crazy thing by converting my TDI (90 BHP) engine to GT TDI (150 BHP) what was a crazy thing to do.
After thinking and reading I just decided to keep my old engine, but had to buy a new Diesel Pump which cost me 750 pounds . After installing a new pump found out that all my injectors are blocked and I will have to buy 4 injectors which cost 90 pounds each. I heard that by putting bigger injectors I will gain more power by 15-25 BHP. Is it true and which ones should I put on? Thanks

[Stevef.]

Fitting bigger nozzles into the injectors will give you more power, the 90hp cars have .184 nozzles one size up for you would be .205s these are standard size in the 110hp cars next size up is .216 these will give about 5-10hp more than the .205s on an otherwise standard car unless you are going to go bigger with the turbo any bigger than .216s and you will probably smoke a lot. As for your new pump was it fitted properly as this needs to be timed up properly and is driven by the timing belt, as far as your injectors go does your car run? any debris getting into the injectors could quite easily block them the holes in the nozzles are the sizes above these are in mm. I have a spare set of injectors if you get really stuck which I would sell I also have a spare pump which you could of had for £100 I also have an assortment of nozzles, when you reasemble the injectors it is important everything is clinicaly clean to save any contamination problems. If you get stuck let me know I may be able to help.

[Dj_Ghost]

Thanks for the reply. Where have you been before? I been looking for a pump for more than 3 weeks and after failing of founding one I had to buy a new pump from Euro Car Parts. All 4 injectors have been blocked, tried to clean them but could do it, put them on 2.5 TDI to clean them up with a pressure. Look like it cleaned them. Timing belt has been set correctly and the a new pump is pumping diesel to the injectors, but thats where it stops. So after trying to unblock them on 2.5 TDi car, put them back on my car and started, but we use diesel from a clean bottle, not from my tank. After connecting pipe from my tank to the pump couldn't start the car. Tomorrow going to change diesel filter, take my old diesel from the tank, fill it up with a clean diesel and try it one more time. If injectors will not work, will have to buy a new one.
Is it possible that I can only buy nozzles because full injector cost 90 pounds, just a nozzle should be cheaper.
Stevef if you have 205s will you sell it to me for a reasonable price? IF im going to install 205s instead of 184s will it make enough pressure from the pump to pop the nozzles? Sorry for a silly questions.....

[Stevef.]

I only have .184s and .216s i have a set of .205s which i took out of my car a while ago, but i left them sitting in light oil and it dried out in them, I think they are blocked. PM me if you are still interested. With .216s and a decent remap you should be kicking around 150hp+. I also have a clean slightly ported intake and a gutted egr valve lying around too. I can send you some pictures later tonight if you like.

To answer your question about the nozzles , they will pop fine.

[Dj_Ghost]

So if I put 205s I'm not going to have a lot of smoke from the back?

[Stevef.]

Thats right one size up will give little or no smoke, 2 sizes will give a little more add a chip and its more again. You are better off getting your car running properly first, if it ran feeding directly from a container and not your fuel tank ,I`d say theres nothing wrong with your pump or injectors there must be a restriction or split in your fuel supply lines/filter etc that it cant pull fuel past or is just sucking air through. Get this sorted first then look at tuning, I have a set of bosio pp520 nozzles that will fuel about the same as .216s but smoke no more than a .205 they are used I took them out of my car yesterday they have done a touch more than 5k miles and are fine. PS a chip will give the best increase on its own, if you are going to do nozzles do these before you get chipped and get chipped somwhere good with rollers.

[ini]

If you are using bigger nozzles, i would also increase the boost pressure slightly to keep torque/fuel economy at the max.

[Dj_Ghost]

Just came back form the garage and all my four injectors are blocked and instead of spraying diesel into engine, two of them just licking, one of them spraying properly and the last one is not working at all (blocked). Phones up VW Dealers and they said 50 pounds for each injector and will take about 4 days for a delivery. They don't sell nozzles on their own, I will have to buy whole injectors.
Tomorrow going to a scrap yard, hoping to find something there



P.S. Stevef how much do you want for your nozzles?

[Stevef.]

£50 each sounds really cheap to me, did you get nozzles on those aswell? Its more than likely just the nozzles what are blocked on yours (this is where the smallest holes in the injecor are) , anyway i am asking £85 for the .216 nozzles and £100 for the bosios (pp520s) the bosios are a more expensive nozzle. I think if the injectors come with nozzles you should just buy those but from a 110 they will have .205 nozzles in, if they are the same price anyway.

[Dj_Ghost]

They nozzles are the one that blocked, that why I tried to buy them, but they don't sell them separately, only comes with a full injectors. I cant really go for more that 205 because my turbo has already done 100k and it smokey a bit, dont wanna leave a big black cloud behind me when I drive. If you got 205 and are working perfectly I will buy them of you. Thanks