2004 Jetta TDI Injector Nozzles? HELP!

Any idea where to find replacement nozzles for a 2004 PD Injectors?
Son has a 2004 Jetta TDI that he has been working on for months, he was just about to bring it into the shop for a tune when he was told the injectors would need to be upgraded first for the tune.
So he pulled them out of the car and tried to replace them with the nozzles he was sold only to find out that they were wrong and didn't fit. What we discovered is that the shop thought they were dealing with a 2002 car and that was the advice and nozzles they gave him. But the nozzles in this 2004 would have been fine for the Stage 2 upgrade he was trying to do. But when he removed the nozzles he ruined them and now we need to find replacements.

There are very few vendors that can replace nozzles on those injectors, and they aren't inexpensive. You may be better off finding some good used injectors.

Ouch. Sounds like a clueless tuner, unless they were told it was a 2002.

I’d say your best bet is to go to a local auto wrecker.

After removing the injectors you need a new seal kit to install them.

There are three different O-rings and a heat shield that need to be replaced.

Also, the bolts that hold the injectors in, and the rocker shafts all need to be replaced. They are one-time use.

At this point, you might be better off getting a used set of PD150 injectors from Frans in the Netherlands.

You can buy PD nozzles, but you can't install them without some pretty serious equipment, like not at all at home. I'm not sure why the vendors that sell the nozzles do/will since they can't be replaced by too many people.



Your least expensive option would be a used set (of injectors) from Ebay. New seals and bolts like Mike says.



If your junk yards are like mine, you could be waiting a while for anything PD/BEW.


I don't know if anyone else beside DBW works on PD injectors. Even getting them rebuilt is big $. Around half of a new set IIRC.


I would not be returning to the tuner that caused this. You can buy a new set of ALH injectors for less than one new stock PD injector. If you had to buy new ones, they run ~$500 per injector...

Most tuners will tell you there's tons of performance room available on the stock PD nozzles before they are on the critical path for upgrade.

Unless there's something wrong with them in the first place, and the shop thinks they just out-and-out need to be replaced 'cause they are worn out?

Good advice, but they've destroyed their stock nozzles. You might try forum members Franko6 or DriveByWire, they do those sorts of things.

You could talk to www.darksidedevelopments.com in the UK. They sell a lot of PD injectors.

Who knows if my son told them it was 2002 or not, I just know thats the year they were basing everything off of. I'll start hunting based on everyones leads. Very much appreciated.

Here are some sets on eBay.

Entire head including injectors: https://www.ebay.com/itm/Volkswagen...654596?hash=item1a93e8c284:g:lvoAAOSw8~5ebxqL

This is a steal: https://www.ebay.com/itm/1-9-Tdi-Be...344375?hash=item1a948bdf77:g:43wAAOSwPf1efvnz

Just another thread to book mark to my "this is why you wont DIY nozzles" threads
Sorry you had to go though this. What "tunner" was this?