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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old March 21st, 2017, 05:51   #1
Millennium Falcon
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Join Date: Nov 2016
Location: Central pa
Default Injector calibration?

Who/where is a good place to get sprint nozzles and calibration from. Kerma wants 160 for nozzles and 200 for calibration... I would also need a tune so that is a lot of $$$ to dish out. Is there a cheaper option? Ive done a lot of googling but I like to hear about real experiences from people that have tried it themselves. My car has a stock turbo, g60/vr6 clutch and 11mm pump. Thanks! I also live really close to German Diesel werks in Pennsylvania. I have emailed them with questions and for a quote but havent heard back yet...
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2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old March 21st, 2017, 06:12   #2
Dieselmonkey02
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I got my stuff from Cascade German. I think DFIS is who they use.
Sprint 520s and setup. I got a package with a new turbo, g60 smf, tune, and a few other odds and ends. Stage 4 Malone, injector balance looks good from vag com, iq needed a very slight hammer mod.
An old strut top nut will fit the injectors to pull them. I ground off the nylock stuff and welded a nut to fit my slide hammer to it. Worked great.
No discernible smoke, may need a little tweaking to get everything perfect. Runs great, drive ability is great.
Pm me if you have any questions.
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Old March 21st, 2017, 07:00   #3
Millennium Falcon
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Thank you for that info! Are there any members on here that build and balance injectors?
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old March 21st, 2017, 08:46   #4
john.jackson9213
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Don't want to start another battle, but Frank06 pop tests them. Cascade German does use DFIS, but does not sell Bosio nozzles (if you are stuck on that brand). Why don't you call your near local guy? Easy to get distracted from email. Also, very good to have a relationship with your local guru.
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Old March 21st, 2017, 10:12   #5
Rrusse11
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Falcon,
If you're close to German Diesel, go pay them a visit in person. Good people and VW enthusiasts. You definitely need to establish a good working relationship with your mechanic. The good ones are working on cars, not spending hours in front of a screen answering emails.
Cheers,
R*2
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Old March 21st, 2017, 16:40   #6
Millennium Falcon
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All good advice....thanks! KermaTdi just called me back.......and im pretty sure I will never be able to afford power mods for this car lol $500 for new nozzles for my injectors and $550 for a tune & loader.... dang! I guess I will just live with the stock configuration for now. I would love to give my car a little boost in hp/tq but there is no way I can justify spending that kinda money!
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2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old March 21st, 2017, 16:51   #7
Millennium Falcon
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Kerma seemed kinda pushy and gave me the impression that they really wanted all my money. I just want to get as much fun for as little money as possible.....like we all do. He wanted my to buy turbos/exhaust/clutches.....the whole 9 yards... and basically said....that anything less than 190hp/300ft-lbs is a waste of money! That really isnt what I was looking for or looking to spend.
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2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old March 21st, 2017, 17:04   #8
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MilleniumFalcon,

What about RocketChip/Jeff Robertson? He's in Red Lion, PA. Not sure how far he is from you. I have RC1+ on my 2005 Beetle (BEW). It really made it peppy BUT I also had to upgrade the clutch as it would slip if I really got on it.

Eric
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Old March 21st, 2017, 17:45   #9
Owain@malonetuning
 
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205 section nozzles with an 11mm pump will work just fine for your use. No sense swapping out a perfectly good turbo and clutch and spending thousands on parts you don't need. Those powergate V2s (q-loader, flashzilla etc) can be reset on ALHs by alientech distributors so a rental should have been offered if you're just looking at a single install.

Nozzle install price is pretty universal given that nearly everyone is working through DBW.
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Old March 21st, 2017, 18:21   #10
flee
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I also recommend a tune, it's the best bang for your buck. Talk to your local guru.
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Old March 21st, 2017, 18:41   #11
Millennium Falcon
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Red line is about 2.5 hours from me... I will have to check out rocketchip.

So, $500 is the going rate for nozzles and assembly???

My car has a brand new Sachs vr6/g60 clutch 21# SMF so i think it should be able hold a little more than stock. I am just looking for a little bump in performance without spending a fortune. I will talk to the guys within driving distance.....Malone also got back to me with some good info.

I really appreciate your input! thank you. I guess I have some decisions to make.
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old March 21st, 2017, 20:31   #12
Fix_Until_Broke
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Make sure everything is in good working order in stock form first, then get a tune only and be happy .

Since you have an upgraded clutch, you can get nozzles without any problem, but get the tune first (more advantages than just nozzles - and less expensive) and if that keeps you happy, you're done.

If you decide you want nozzles later on - most tuners will do an upgrade to the tune for a nominal charge.
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Old March 21st, 2017, 21:10   #13
Andyinchville1
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Fwiw- My engine is stock except for a Malone Stage 1 tune w/ dynamic EGR...It made a big difference in power and I actually got a slight MPG boost (from low 50 ish to about 52 on my 500 Mile run).

Malone can upgrade a tune for extra $$.... BUT I hear Kerma does upgrades for FREE!

I wish somebody here could do dyno runs and figure out who truly has the best tune...

I like my Malone Tune BUT for about the same $$ Kerma has FREE changes to their tune.

My next upgrade (very soon) will be DLC 1019s

I have 242K on I believe original injectors so Im thinking (or using it to justify) the upgrade in nozzles...

Hope this helps

Andrew
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Old March 22nd, 2017, 04:37   #14
Dieselmonkey02
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I think darkside has some nozzles they claim are better than bosio, idk anything about them, but it might be worth a look.
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Old March 22nd, 2017, 06:11   #15
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Call Jeff and make an appointment. It'll be worth it.
http://jsrmonster1.globat.com/contact_us.php
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