It's been August since I looked in on this thread... I haven't forgotten you, Mr. Tift. As a matter of fact, another of your TDI soul mates is asking for similar treatment.
If I remember right, the nozzles set were Bosio 764's, with which I have some of the most problem (assuming you understand I never will install the Race 520's), as they tend to vary a great deal. There are years past I swore off using Bosio, as quality was in the tank. We had been accepting a loss ratio of 1:10, then it increased. I believe they were outsourcing the bodies.
Since then, the quality has rebounded, but I still stand on my previous comments about Bosio.
'They are CAPABLE of producing good nozzles.'
However, when re-working Nero Morg's, I was given permission to replace them, but found that was not necessary, or the issue. I have several methods to 'repair' nozzles that are incorrectly flowing or spraying. When I reworked the nozzles, they all fell into range, with just a little effort. It was the #3 body that was the culprit.
That falls to the issue of why we do not perform 'instant gratification' nozzles any more. We had too many core nozzles that were damaged or destroyed. We don't like to send replacements with broken wires or that are badly corroded. Instead of coating injector bodies black, where you can't see any pitting or corrosion, we clear-coat, so the quality of the injector is plainly visible. So, if you send a bad #3 injector or injector bodies that look like they came out of the 'Great Salt Belt', you get the rust polished off, but they are the same ones you sent. I'd say 95% of all injectors are reusable.
The control of installing in a perfect running car eliminates the possibility of sending out a injector that is flowing poorly, but even if your engine is running just as well, does not mean you have the Injection Quantity (IQ) set correctly. At least 10 years ago, we developed a method of driving the car in 3rd gear, starting at 35 mph. Fuel in applied to Wide Open Throttle (WOT). When speed hits 40mph, turbo kicks in. Count 3 seconds and check speedometer. If the initial IQ is set low enough, the exhaust will show smoke. Raise the IQ (See Hammer Mod) and repeat WOT runs until the some performance (Loss of speed) is noted. Revert to the last IQ number that did not lose performance speed run. By doing this you will have optimized your IQ to acceleration and minimized your smoke.
I think Nero Morg has been explained this method and it is worth the try to increase FE if it has not been attempted.
It has been a pleasure to work with you Nero. I hope you continue your improvement.