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Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Power Enhancements

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 14th, 2005, 09:10   #1
Ynot
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Default 6/10/05 updated*Newbies Cumulative Info Links

This is meant to be a brief and not all INCLUSIVE over view of Chipping, Injector nozzle air box questions.

For more Newbie information go here:

http://forums.tdiclub.com/showflat.p...;page=0#570711

http://forums.tdiclub.com/showflat.php?C...&PHPSESSID=

Terms:
Stage I usually refers to a chip upgrade or nozzles only.
Stage II usually refers to chip AND nozzles.
Stage III usually refers to hybred or non-stock turbo, nozzles and chip. .

There are "Custom" programmed chips out now that use a number designation to identify it and it may or may not mean there is a non-stock turbo or nozzles in combination with them.

A boost gauge and Exhaust Temp. Gauge should be installed before any engine modifications. This gives you visible engine health indications and can save alot of heart ache later. It also helps when asking questions in the fourm as you can give data for others with experience to work with.

If you do a web search for "EGT" and diesel, you should find yourself a few vendors selling gauges. If not check the link farther down the page for parts.

Two places you do not really want to waste you money on in increasing your performance of the TDI is putting in a fancy intake system or exhaust system. The word mufflerectomy is used alot and that means the muffler is taken out and the exhaust is run straight. Not to loud for most, your turbo may spool up a little faster with this set up. The filter box gives good performance as it is, some take out the snow screen and some have removed the snorkle. The snow screen being clean or removed makes a good move due to the snorkle picking up cold air from behind the head light. One exception to this might be installing a "Old Man Intake" this may improve air flow to the turbo and has been reported by forum members to help cut down on excesive smoke.

"if you want to order a OMI email send an e-mail to,blubyu@ameritech.net, the price is set at ~$105 shipped in the U.S just tell him if you want it black or grey and with or without the ccv hole. if you have any questions he normally respondeds that day."


The best source for parts is to check the TDI club registerd vendor list and contact them for info and web site or here provided by Blackenedbora. http://forums.tdiclub.com/showflat.p...;Number=911797

http://www.lubricationspecialist.com...roducts_id=127



I understand that programmers USUALLY recommend nozzles first over chipping as you may need to chip again if you add nozzles later. The choice is yours to make.

Auto trans guys like me: you have from the factory smaller nozzles than the manual transmission cars and also come with an 11 mm fuel pump.

Manual trans you have from the factory larger nozzles than the automatic transmission cars, some modifiers will up grade to the 11mm pump or use a kit to get more fuel to feed the bigger holed upgraded nozzles since the manual transmission cars do not have the 11mm fuel pump.


Injectors with new nozzles should be pop tested as some may need to be shimmed to make them all work the same. Better to find this out before putting them in. Also they do have a break in period. Make sure you get quality and the proper copper seals to go with the injectors for the install. This will save you some grief later.

Chipping again check the TDI registered vendor list or do a web search. There are quite a few programmers out there now.

Nozzles alone will give a significant performance increase, but not mind bending and in some cases may need some program changes using a Vag-Com. The chip changes the stock program and dials in fuel, boost and some other things, so usually it is the most impressive first up grade. The biggest bang for the buck is a combination of nozzles and chip. What combination is a personal choice and should be discussed either with your nozzle vendor or the chip vendor. Of course the fourm will more than happily voice their oppions.

Finally, auto trans owners, do not worry, the FAQ is conservative in it's nozzle recommendation. I use the .215's with what is considered a stage II chip and my trans has not complained yet. There are beefing up things that should be done to the drive train, but that is another thread.

Manual trans cars should be aware you may experience clutch slippage at some point and the probability increases with more aggressive modding. Which makes sense I hope.

It has been reported by some that upgrading your FMIC helps to cut down turbo lag time and in some cases to nil. EGT also appear to drop significantly, but each will experience their own results based on design and implementation.

YOUR MILE PER GALLON WILL NOT BE AFFECTED BY A CHIP, NOZZLE UP GRADE! Milage is a function of how you drive. When you up grade, the power will over take you , and the more you stomp the throttle, the more fuel you use. If you drive with sanity , you will get as good if not better mpg.

Enjoy your TDI, we are a special group, let us enjoy our cars no matter what level of modification you are at.


Ynot
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Old March 14th, 2005, 09:43   #2
Smog
 
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Default Newbies/Basic Chip and Injector answers

Quote:
This is meant to be a brief and not all inclusive over view of Chipping and Injector nozzle questions. This is a non-bias summation by me of the percived concensous of this forum. Those who do not agree will chime in I am sure.

2005*
The best source for nozzles is KERMA hands down, there are others and please check them out. There has not been one complaint against the Bosio nozzles. I use them myself.
For detailed info on them contact KERMA directly, brief summery:
Hey, don't forget me, I don't remember having any complain about the nozzles I sell. So please include me on your list, but everybody should note that I only sell the tdi nozzles to canadians ! (I also have D/TD nozzles from 1974 to 2003)
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Old March 14th, 2005, 10:07   #3
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Default Newbies/Basic Chip and Injector answers

Thanks Ynot--we needed this. [b]If newbs need info on how to contact all chip/nozzle vendors, see this post.
That said, let's get this thread linked into the "starting post for Newbies" thread.
-BB
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Old March 14th, 2005, 12:45   #4
Ynot
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Default Newbies/Basic Chip and Injector answers *DELETED* *DELETED*

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Old March 14th, 2005, 16:21   #5
Big 1
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Default Newbies/Basic Chip and Injector answers

everything I read in this post is biased. Best customer service = rocketchip? Thats purely based on personal opinion. This should not be put as a sticky for newbies IMO.
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Old March 14th, 2005, 16:37   #6
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Default Re: Newbies/Basic Chip and Injector answers

I agree with big 1. Endorsing select vendors based on forum opinion is poor. A good percentage of posts are written by people with little/no experience with what they are advocating/bashing. Personal opinions are great. Opinion representing community is not. There's more than one way to enhance any part of a car that is valid. Smart newbies will figure things out with a vendor list, a phone, and some elbow grease.
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Old March 14th, 2005, 18:11   #7
dsclark
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Default Re: Newbies/Basic Chip and Injector answers

"YOUR MILE PER GALLON WILL NOT BE AFFECTED BY A CHIP, NOZZLE UP GRADE!"
I disagree with that. My nozzle upgrade did affect my mpg- it went up.
WIth standard wett chip, my wife averaged averaged 44mpg. Last check, with the same chip and pp520 nozzles, mpg was 46mpg. We still have winter fuel here and 46mpg is the best my wife has ever gotten. So, I have to "blame" those nozzles!
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Old March 15th, 2005, 04:54   #8
Ynot
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Default Re: Newbies/Basic Chip and Injector answers *DELETED*

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Old March 15th, 2005, 09:22   #9
sportsguy
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Default Re: Newbies/Basic Chip and Injector answers

Well, from this newb, YNOT, thanks.

This is the kind of basic "where to start info" I need. Sure, it's easy to call folks - but who the hell do I know to call?

As with everything on the Internet, you'll need to do your own research.

This is a great asset - I agree it should be sticky (mod?).

After informal all-night searching and reading, I think you summaries are accurate - given the source is these forums and votes counted.

Great work - if someone has a beef with this, they're missing your intent.
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Old March 15th, 2005, 10:40   #10
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Default Re: Newbies/Basic Chip and Injector answers

Lets say, for example, that tdiclub is a newspaper. If someone from the media took a survey of all positive media articles of the last presidential election, published the results based on quantity of replies, and claimed these results were the truth, not only of quantity of responses but also of issues, how objective would that newspaper be?
My point is not to question accuracy, simply that tdiclub's role is better suited to reporting as an open forum than wholy endorsing any corporate product. TDI club recommending a specific product/corp. as voiced by the majority is an endorsement of momentum, not scientific fact, and definately not any more subjective or useful than an opinionated post.
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Old March 15th, 2005, 14:58   #11
Ynot
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Default Re: Newbies/Basic Chip and Injector answers

I have removed all vendor references and stuck to mechanical information. I hope this is still helpful in cutting down on some of the repeat questions.

Ynot Happy motoring
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Old March 15th, 2005, 15:42   #12
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Default Re: Newbies/Basic Chip and Injector answers

Ynot sticky?!
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Old March 16th, 2005, 03:47   #13
Ynot
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Default Re: Newbies/Basic Chip and Injector answers

A sticky has been applied for.

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Old March 17th, 2005, 01:38   #14
Ynot
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Default Re: Newbies/Basic Chip and Injector answers

Updated some basic information:

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Old March 18th, 2005, 18:51   #15
Derrel H Green
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Default Updated *Newbies/Basic Chip, Injector and Air box answers

Quote:
Stock nozzle sizes pre PD are as follows, these numbers were verified by an electron microscope measuring the actual holes of factory nozzles. Somewhere on the web these photos should still be posted. [Where?]
Auto trans guys like me: you have from the factory ~.15x nozzles actual Vs .17x spec and they are not that uniform from nozzle to nozzle. [?]
VW gets away with the smaller holes by using a 11 mm fuel pump. [Wrong!]
For some reason this is automatics only. [?]

Manual trans you have from the factory ~.17x nozzles actual Vs .18x spec and they are not that uniform from nozzle to nozzle. The manual trans VW's have a lower pressure fuel pump and some will up grade to the 11mm or more to get more fuel to feed the bigger holed nozzles. More can be done, but I won't go into it here. Ynot


There are some mistakes here that do need to be addressed. Where did you get this information?
It's too bad you cannot see those GeWilli pictures.
That would help clear this matter up for sure.

Automatic transmission cars are supposed to have 0.158 nm nozzles, but only have a true 0.135 nm.

One of the reasons that VW didn't just make all TDIs with the 11 mm pumps is that the 11 mm pump is considerably harder to turn, hence the earlier required replacement of the T/B, and I suspect that the 11 mm pump being harder to turn is also partially responsible for the approximate 20 percent reduction in fuel economy. Think about it!

VW went to the 11 mm pump to raise fuel pressure and to smaller nozzles
to reduce the fuel flow so as to be able to pass the EPA tests.

You're running actual 0.215s and a chip and you are not smoking? What your I Q reading?

I had PP 520s and an UPsolute chip in my automatic, and it smoked like an old coal burning locomotive
on a grade. Even when I dropped back to the PP357s, it would still smoke quite a bit.

Charlie, give me a hand here please.

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