WANTED: Bosio race 683 nozzles to fit v6 tdi engines

Layerz

Veteran Member
Joined
Feb 23, 2007
Location
Leicester
TDI
Audi A4 2.5 TDI AKE
Can injector bodies not just be swapped?

I think Adams somewhere has a post where you'd need to repin the lift sensor connector.

I picked up a spare engine that came with injectors part of the reason being when I get them swapped/calibrated (or self calibrate if I can get the 2 stage kit) I can still use the car as it's my daily.
 

Layerz

Veteran Member
Joined
Feb 23, 2007
Location
Leicester
TDI
Audi A4 2.5 TDI AKE
diffas what pumps are you guys running on these?

And where would the 3 plunger AKE run out of flow?
 

diffas

Veteran Member
Joined
Jun 25, 2008
Location
Finland
TDI
B5q A4 Avant 2.5TDi+, B7q A4 Avant 3.0TDi
Stock Akn pump with ake pump head seems to be quite nice working combo. Ake pumps itself are duration limited on pump ecu and thats a shame since seems they are capable producing nice power. Therefore older akn pump with less restricted duration is able to push more. 400hp i think is not impossible to break. And ake is smallest of three plunger pumps, 3x6mm plunger and biggest i've seen from cummins are 7.5mm.
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
Hi Guys!
I was looking for Bosio Race 683 for my 2.5 TDI AKE
Does anyone have a set of 6 or knows a source where I can purchase them?
Thanks!
 

poope

New member
Joined
Nov 5, 2020
Location
Romania
TDI
AKE
hey. so i m kinda new to this and after some reading still not sure which way to go. Suggestions from you guys: I have a 2002 ake with tiptronic and rear wheel drive. I want to get some more power and suggestions: should I keep the stock housing and go as big as possible in the wheels inside it? What kind of nozzels do you recommend for the stock AKE injectors? Bosio or?
 

diffas

Veteran Member
Joined
Jun 25, 2008
Location
Finland
TDI
B5q A4 Avant 2.5TDi+, B7q A4 Avant 3.0TDi
If deal doesn't get trough, I am interested in the set of nozzles as well... Please let me know !
Unfortunately I have lost connection to the dude who was selling those. Looks like they are out of stock everywhere.
I have bought several sets from santerchips.pt but i think they are out of stock too.


hey. so i m kinda new to this and after some reading still not sure which way to go. Suggestions from you guys: I have a 2002 ake with tiptronic and rear wheel drive. I want to get some more power and suggestions: should I keep the stock housing and go as big as possible in the wheels inside it? What kind of nozzels do you recommend for the stock AKE injectors? Bosio or?
With tiptronic you really dont need that big of nozzles since you are on the tranny limit with smaller nozzles. I would expect short life for the tranny when going far over 500nm. With big enough nozzles fueling needs to be reduced to have control over the high torque numbers
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Unfortunately saunter hips hasnt got any more in stock, it does seems that the stock of race nozzles have been exhausted...
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
Hi guys!
I hope you are all well :)
I am Still looking for a set of Race Nozzles. Or at least one single nozzle since I bought a set of 6 but one was accidentially a 1.9 TDI nozzle branded as a Race nozzle by Bosio and they dont reply to the requests to exchange it.
Thanks!
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
hey. so i m kinda new to this and after some reading still not sure which way to go. Suggestions from you guys: I have a 2002 ake with tiptronic and rear wheel drive. I want to get some more power and suggestions: should I keep the stock housing and go as big as possible in the wheels inside it? What kind of nozzels do you recommend for the stock AKE injectors? Bosio or?
Drop me a pm, I am in Romania too and I can help you...
 

rustybear87

New member
Joined
Feb 11, 2021
Location
High wycombe
TDI
BAU allroad
Ive recently got myself a set of race 683s and a hybrid turbo that popped up on ebay for my BAU allroad. Very lucky find and bought instantly. The seller was a guy from north london who said he got them from you adamss24? He hadnt used them, and said they was all pop tested/set up before he got them and so far they seem to work, had them mapped by a company ive used for pd's before and they really pump some fuel dont they. 259bhp and 427ftlbs....surprise surprise my clutch is slipping, going to go for a sachs sre disc and pressure plate am i ok to use a LUK dmf? Theyre about half the cost of a sachs one! Its only just slipping if i absolutely boot it low down. Feed it in slowly and its fine. Mapper has said theres a bit more in the turbo, so would be good to unlock it. Cheers
 

Princy

New member
Joined
Jul 22, 2017
Location
N. Wales
TDI
A4 2.5tdi cabriolet
If deal doesn't get trough, I am interested in the set of nozzles as well... Please let me know !
If you've any surplus cash Chris, you could always return the £500 deposit you stole off me for work you promised before disappearing.
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
I'm about to order a batch from Bosio directly but I need to order at least 120pcs.
So just checking if there is still a demand for the race nozzles? Price would be around 60€ before import taxes per piece.
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Too much of a niche market there, could probably sell a few off ebay however it might be years before you recoup your investment ! Many folks have moved from v6 tdi to more user friendly 1.9 pd tdi or later CR tdi's...
 

diffas

Veteran Member
Joined
Jun 25, 2008
Location
Finland
TDI
B5q A4 Avant 2.5TDi+, B7q A4 Avant 3.0TDi
Like stated already there isn't that much of market out there. I think something like 5 sets should be able to sell quite easy.
I have been contacted several dudes from eastern part of europe and they have reported somewhat rising trend about tuning 2.5tdis.
There are some decent size oe bosch nozzles available that I have spoted but not tested yet. Will report when more data
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Like stated already there isn't that much of market out there. I think something like 5 sets should be able to sell quite easy.
I have been contacted several dudes from eastern part of europe and they have reported somewhat rising trend about tuning 2.5tdis.
There are some decent size oe bosch nozzles available that I have spoted but not tested yet. Will report when more data
Only trouble the Eastern Europe dudes want to tune them for cheap, when you have 1000 euro car they want to spend a fifth of that ton tuning…they call it “investment”…hard to sell good parts cheap…I have bought 3 sets of firad nozzles and had them professionally fitted at a decent outfit in Romania, none work properly! So when you get a batch of good nozzles and have them fitted by good diesel specialist folk should rip their arm off ! Tuning on the cheap always ends in disaster, many find out the hard way ! I wonder diffas how much you spent/”invested” in your car to get it at the power level you are ? I know I spent tens of thousands…
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
Hi Dudes!

Thanks a lot for your valued feedbacks!
I agree with all of them.
Partickularly tricky might be that there is now a +100% nozzle for 29€ available on ebay and that would be half the cost of the Bosio.
Many people showed their interest in the first request, but now that I was about to buy them, there are just 3 sets preordered.
So I would wait for at least 10 sets to be preordered, otherwise I will also go for the +100% nozzles.
Best regards!
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
If you think that the 30 euro per nozzle is a suitable alternative then I would not want to waste any time buying them ! However the bosio power plus 683 were only able to do 240-260 Bhp…they were +80% nozzles, not much overhead left in them !
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
I'm not considering 30€ nozzles for myself. Just for low budget tuners who then would buy them instead of my Bosio and I would then sit on 100 Bosio Nozzels.
I was about to order the +80% Race nozzles who are capable of 360HP since I drive now 300HP with stage 3 charger and Cummins 8-hole nozzles which just smokes too much.
 
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adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Probably you don’t have enough air if they smoke that much ? What boost pressure you run your charger at ? Anyway 300 Bhp is not little power anyway so maybe look at shedding some weight ! What car is it you’re driving ?
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
When getting boost, even up to 2,6 Bar, they don't smoke.
But they smoke while idling. Makes me feel guilty when a police car is behind me :D
The cummins nozzles are for common rail engines which have much more injection pressure than our VP44 pumps can bring at idle.
Nozzle opening pressure was raised to 280 Bar but I think even this is too little. 300 and maybe even more could help.
But I think the best will be the Bosio Race nozzles.
It's a 2001 Audi Allroad AKE.
 
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adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
I neg to disagree, vp44 pump can do up to 2000bar of pressure, that’s why they could keep it at euro 4…probably they could have even muster a euro5 norm however it’s a lot more involved to get an euro 5 accreditation as the materials used needs to be in some percentage recycled and recyclable at the same time ! Few diesels of that era had higher than 1600 bar pump pressures, the Achilles heel was dependence of Top Dead Centre of vp44 which the CR could do away with !
 

Knightboat

Member
Joined
Oct 6, 2020
Location
Wien
TDI
2.5 V6 AKE
The 2000 bar are right. But that’s the maximum pressure and at 800rpm (which are 400 rpm for the pump) it is far away from that.
 
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diffas

Veteran Member
Joined
Jun 25, 2008
Location
Finland
TDI
B5q A4 Avant 2.5TDi+, B7q A4 Avant 3.0TDi
I wonder diffas how much you spent/”invested” in your car to get it at the power level you are ? I know I spent tens of thousands…
To be honest I have been tested and errored some but mostly been able to have always more power and performance over the years. My budget has been really small and that usually causes delays on the build. Luckily I have managed to sell my old / tested parts to buy new one so that increases costs of the new build...and also learning to fabricate stuff myself keeps costs down too. But yeah some thousands are spent for sure over the years.

What I've learned over the years is that you really need to start off with the top condition engine. So that been said, you really want to use base engine like bau, bdg, bdh. Those have new roller type of lifters and have little better valve control due just a bit tougher valve spring pressures. And also stronger bottom end atleast compared to akn and afb. That harder springs translates better valve control with higher boost / emp numbers. And not to mention worn out cams with early engines. Also must to do is to clean heads from the egr soot. With just that 300hp numbers with pretty clean output is no joke. Next step is for sure make heads done; some porting and upgraded valve springs.

For fueling. That is the most weirdest thing of these engines. I think somewhat around 2009 or so I was told repeately that these engines cant deliver fuel over 200hp. I had B5 with 150hp AKN engine back then. Ordered Finturbo bolt on hybrid back then, that I believa was build from the gt2056v or so. Few mm bigger wheels both side. Combined with (I believe was called "iveco" nozzles back then) upgraded nozzles it delivered 225hp or so. With some tweaking on the software and I think I ordered new bigger hybrid turbo (basically 2260) from finturbo and it delivered around 250 and stock clutch started to slip. That was agains said max level power these support and i should be lucky with that power. :D
After that I think I upgraded the the heads for mildly ported BDG heads, same ones I use today. On that time I believe I changed nozzles to OE cummins bosch dsla143p970. Power inreased to ~280hp with around 1.8bar . I was pretty happy with that setup. Good responsive turbo and decent power. That wasn't enought after some time so I decided to go over to WG turbos instead and target was 300+. I believe it was 2013 when I installed old good gt3071r (nowdays called gt2971r) and made vp44 upgrade (stock akn pump with ake 3plunger pumphead). Not so responsive turbo but delivered good power 300hp with 2bar and AFR 17.5 - 18.5 on full power. So proved everyone said its not possible wrong again. :D And really that was with the cummins oe nozzles. I think I drove around half a year with that turbo and then garrett came out new gtx series and I switched over to GTX2863R and bigger CPC nozzles. Heh I remember I had a case with CPC and probably are banned from their facebook ever since. :D Nozzles had atomization problem on test bench but cpc told I should use better equipment. Well yes but harder to find better than top notch bosch diesel service. :D Diesel service said you can use them they are adjusted but might cause excessive smoke because not that quality atomization. Car went faster and delivered more power. I belive it was now around 330-340hp and from now on it wasnt giving more power, only more smoke. There started to occur weird advance problems with the pump so it was time to install external lift pump I have had on shelf waiting for install. Immediately on the first pull out of the garage it felt stronger waay less smoke. Went dyno and it gained 40hp with the same ecu mapping and AFR went from 14:1 to 16:1. Made an smoke test video about it. I think it was most powerful 2.5tdi back then in finland. My ourcome was that the vp44 internal lift pump wasnt able to keep up the pressure in the pump case so high pressure dropped and gave really only smoke. So when going past 300 i really recommend to have lift pump, its not a bad thing to have even lower power levels. Something like 100gph/350lph @ 1.2 - 1.5bar

The lift pump didn't solve the advance problem. It was caused by the broken flywheel. And I belive the flywheel also caused the engine crank to vibrate so much it broke the low end. Some pics of it https://evvk.1g.fi/kuvat/Diudi/remppa/vauhtis/


My current build is stage 3 so it has also upgraded cams, and my stage 3 compound three-turbo kit installed and slightly reduced compression.
Funny thing is that I have now stock 2plunger AKN pump and +90% over stock nozzles it gave more power and even cleaner with exactly the same ecu tune that had 380hp years ago. Now 394hp/290kw. I used that ecu maping just for breaking in the engine and have it dynoed and make it all street legal. Surprised me big time.

dang long post :D
 
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