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TDI Fuel Economy Discussions about increasing the fuel economy of your TDI engine. Non TDI related postings will be moved or removed.

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Old November 6th, 2019, 08:55   #1
peteguenther
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TDI(s): 2003 Jetta
Fuel Economy: 40 in the hils 50 on the highway
Default 11mm pump and injectors on a manual

So I have an 03 ALH TDI manual trans and I plan to put an 11 mm pump on it. Iím considering switching to the injectors that go with that pump. I realize i would be reducing nozzle size and fuel flow and losing hp but anyone know if i might gain mpg and reduce emissions?
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Old November 6th, 2019, 09:21   #2
scooperhsd
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Why don't you put the 11mm pump on, but keep your manual injector nozzles ? You will get a modest boost in power.


When I did my 5 speed manual conversion, I basically had what you want - and the car was just fine.
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Old November 6th, 2019, 13:50   #3
Andyinchville1
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Hi

I just did an 11 mm pump on mine but with dlc 520 injectors and over the last 5000 miles i have not had 1 tank below 50 mpg ... power is better too but i normally drive regularly...
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Last edited by Andyinchville1; November 7th, 2019 at 09:42. Reason: Typos
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Old November 6th, 2019, 15:42   #4
IndigoBlueWagon
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I've been running an 11mm pump in my manual Jetta forever. Works great. I prefer the way it responds to the accelerator compared to the 10mm.
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Old November 10th, 2019, 15:08   #5
peteguenther
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Fuel Economy: 40 in the hils 50 on the highway
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OK thanks for the input. I definitely plan to put the 11mm pump in -probably re seal it first. But back to nozzles. I'm noticing a decline in my mpg ( from high 40s to high 30s ) and a noticeable though brief fuel cloud on cold starts. I'll run some purge through but I'm wondering if any of you have tried any of the cheap ebay nozzles? I'm sure it's not a long term solution and not at all the same as having Kerma or some one do it right but it might get me by and boost mpgs. My timing's good, intake clear, turbo ok no code and running really well otherwise. Any thoughts?
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Old November 10th, 2019, 16:02   #6
scooperhsd
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Part of the economy drop is the changeover to winter D2, plus the colder temps uses some more fuel until the engine warms up.
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Old November 10th, 2019, 18:53   #7
peteguenther
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Right, and it's cold here. Can I check the cold start system to be sure it's functioning properly and registering the actual temps?
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Old November 10th, 2019, 20:42   #8
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white smoke on start is just the combustion chamber being way too cold
it's totally normal and has been a 'feature' of diesels for like a hundred years now
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Old November 14th, 2019, 14:31   #9
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Quote:
Originally Posted by peteguenther View Post
I'm wondering if any of you have tried any of the cheap eBay nozzles?
One of the great things about the TDI Club is that practically every dumb mistake has been thoroughly debriefed, so the rest of us don't have to make them.

Buying cheap eBay nozzles would be a mistake, especially when there are some really excellent ones available that will last you for the life of your ALH engine, and then you can swap them into your next ALH.
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Old November 14th, 2019, 15:09   #10
Rrusse11
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https://www.cascadegerman.com/produc...t-wuzetem-205/


Get a set of these.
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Old November 15th, 2019, 21:25   #11
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Sprint 520ís are still available, and a very inexpensive upgrade. Iíve run dlc520ís, and 1019ís on different cars. I like the 1019ís better, but itís hard to beat the price of the sprint 520ís. I wouldnít hesitate to run them.
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Old November 15th, 2019, 21:28   #12
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$170 for the set. You canít beat that
https://www.tunemyeuro.com/genuine-f...r-vw-audi-tdi/
Paired with an 11mm pump is a great combo.
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Old November 16th, 2019, 06:44   #13
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Just be aware you will smoke like a train at higher RPM, especially when you combine these with a tune. I had my tune (RC2) tailored so daily driver RPM it doesn't smoke much, but once I hit 3500-4000 RPM the smoke (and power) really pickup, pulling power until 5000 RPM (and beyond - I don't usually run it that hard).
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Old November 16th, 2019, 10:50   #14
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Quote:
Originally Posted by scooperhsd View Post
Just be aware you will smoke like a train at higher RPM, especially when you combine these with a tune. I had my tune (RC2) tailored so daily driver RPM it doesn't smoke much, but once I hit 3500-4000 RPM the smoke (and power) really pickup, pulling power until 5000 RPM (and beyond - I don't usually run it that hard).
What was your IQ set at. Smoke shouldnít be an issue, unless you wanted it to smoke. With my current dlc1019ís and a stage 3 tune, I get a light haze at wot. If I dropped my IQ, it would smoke like a chimney, without any extra power.
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Old November 16th, 2019, 15:31   #15
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I have no idea, but since it smokes only on high output demand - I don't really care. I suppose if I found someone with a VCDS and knew how to adjust it, it would be nice to optimize it.
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