best nozzels for a 96 B4 to get low end power yet keep economy.

akal65

Well-known member
Joined
Aug 1, 2014
Location
Alaska
TDI
B4
I am considering some new injector nozzels for my 96 b4 , I have been told the 205's are not the best for low end torque that they come on in the higher rpm's and I should go to 764's . this was not my understanding as I have seen many opt for the 205 size . what are your opinions ?
 

garciapiano

Veteran Member
Joined
Feb 12, 2018
Location
Los Angeles
TDI
1997 Jetta TDI (1Z)
I have DLC 1019 and they are great for what you are describing on a mostly stock car with some headroom for upgrades. They are .216 size.
 

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
DLC520 may be better for low end power. I think the 1019 may move the power to the upper range. May want to call and ask… been a while since I bought nozzles.

FWIW, I’m running 1019s.

-Todd
 

Mongler98

Top Post Dawg
Joined
Mar 23, 2011
Location
COLORADO (SE of Denver)
TDI
98 Jetta TDI AHU 1.9L (944 TDI swap in progress) I moved so now i got nothing but an AHU in a garage on a pallet.
Fuel isn't the issue so much as it is boost. And the tune. Even if you have a tune written and nozzles pope tuned for lower rpm flow you still need a lot of air to give to any upgraded nozzle or you just end up with more smoke. The best way to get more low end power is to upgrade the turbo. An electric hybrid turbo would be a great upgrade but is custom.
Imo just go with some light upgraded nozzles because it's cheap and see how you like it. If you need more a light tune. You will eventually need a clutch if you do much more.
 

krook

Veteran Member
Joined
Jan 13, 2021
Location
Hungary
TDI
A4 B5 AWX, A4 B5 AFN
I always forget how those engines have a wastegated turbo. In that case a simple vnt15 conversion will do miracles!
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
DLC520s are .205s. I had them in my A3 without a tune and they gave a nice power bump at the low end. Didn't help much at higher revs. That's where more boost is more helpful.
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
How difficult is it to install new nozzles on your injector bodies? I've been thinking about it for a while, I'm closing in on 300k miles and it would probably be a good idea at this point.
 

Mongler98

Top Post Dawg
Joined
Mar 23, 2011
Location
COLORADO (SE of Denver)
TDI
98 Jetta TDI AHU 1.9L (944 TDI swap in progress) I moved so now i got nothing but an AHU in a garage on a pallet.
How difficult is it to install new nozzles on your injector bodies? I've been thinking about it for a while, I'm closing in on 300k miles and it would probably be a good idea at this point.
It’s fairly simple to DIY but there are things you need to consider first.

1: They need to be poptested at 2 stages based on the RPM target for max flow. This is achieved by hydraulically popping them and recording the pressure then adjusting things via shims until all 4 are popping the same and then again at a higher pressure based on the target.
The professionals like Kerma, or Malone and so on all do this with a flow bench and a pulse to ensure its delivering correctly.
On light to stock nozzles you can get away with just assembly and drive them but there is still a small risk they may not be right. You can pop test them yourself simply with a bottle jack and some brake lines and fittings and such.
2: you need a clean environment. if you have a box fan and a merve 18 filter making a down draft setup is good enough with gloves and lint free rags... coffee filters are a good solution for rags as there lint free and cheap. Everything must be clean; you cannot see the dust that will damage things smaller than 30 microns.
3: to have kerma or anyone else do the job is cheap, usually $150 for all 4 with a hot swap option available. They send you the injectors assembled with your new nozzles ready to go and you send them your old cores and they refund the core charge.
Possible damage can be anywhere from bad economy to a melted piston in extreme cases. The tips of the nozzles must not be touched even when assembled.
Spend the few bucks and have them done via hot swap. I do like kerma, others have had issues with them but there are other options I encourage you to research and talk to tuners.
 

TDeanI

Veteran Member
Joined
Oct 14, 2007
Location
Bremerton WA
TDI
'97 Passat TDI Wagon w/ 286K mi.
At 300k your injectors will be very hard to get out. The soot around the injectors is practically diamonds at this point.

I had to build a slide hammer to get mine out at 230k miles. Piece of 2' of 1/2" iron pipe, 2 - 1/2" pipe couplers, pipe plug, and drilled and tapped the end of the pipe plug to the 18mm (I think) threaded end of the injector. I used a 10# dumb bell weight sliding on the 1/2" pipe shaft. Popped em right out after that.

I used 0.205 nozzles and it added quite a bit of low end power. I might still have the 18 mm threaded pipe end piece that fits the injector. I will look for it.

I took my injectors to a big rig diesel injector place and they pop tested within specs.
 

Steve Addy

Top Post Dawg
Joined
Aug 7, 2002
Location
Iowa
TDI
97 Mk3
At 300k your injectors will be very hard to get out. The soot around the injectors is practically diamonds at this point.

I had to build a slide hammer to get mine out at 230k miles. Piece of 2' of 1/2" iron pipe, 2 - 1/2" pipe couplers, pipe plug, and drilled and tapped the end of the pipe plug to the 18mm (I think) threaded end of the injector. I used a 10# dumb bell weight sliding on the 1/2" pipe shaft. Popped em right out after that.

I used 0.205 nozzles and it added quite a bit of low end power. I might still have the 18 mm threaded pipe end piece that fits the injector. I will look for it.

I took my injectors to a big rig diesel injector place and they pop tested within specs.
Part of it is presoaking the injectors to help loosen the crap in the bores.

I'd suggest getting injector work done at a professional shop so as to avoid all the problems with doing your own nozzles.

Steve
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
How hard they are to remove also depends on how the car was driven. They came out of my B4 fairly easily at 290K miles.
 

Mongler98

Top Post Dawg
Joined
Mar 23, 2011
Location
COLORADO (SE of Denver)
TDI
98 Jetta TDI AHU 1.9L (944 TDI swap in progress) I moved so now i got nothing but an AHU in a garage on a pallet.
#1 thing to use for carbon soot holding them down is like has been said, to soak them the night before. the #1 best thing against that carbon is choke cleaner but for soaking is Berryman 0996-ARM B-9 Chem Dip Parts Cleaner. you can get it on amazon in a bucket to soak parts in. this stuff takes a while but is the #1 best stuff i have ever found to dissolve diesel carbon other than oven cleaner and you do not want to use oven cleaner on your aluminum head!
#2 for penitents is ATF fluid and Acetone mixed 1:1 it may not be the best at lubricating or dissolving but it penetrated the deepest.
food for thought!
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
It’s fairly simple to DIY but there are things you need to consider first.

1: They need to be poptested at 2 stages based on the RPM target for max flow. This is achieved by hydraulically popping them and recording the pressure then adjusting things via shims until all 4 are popping the same and then again at a higher pressure based on the target.
The professionals like Kerma, or Malone and so on all do this with a flow bench and a pulse to ensure its delivering correctly.
On light to stock nozzles you can get away with just assembly and drive them but there is still a small risk they may not be right. You can pop test them yourself simply with a bottle jack and some brake lines and fittings and such.
2: you need a clean environment. if you have a box fan and a merve 18 filter making a down draft setup is good enough with gloves and lint free rags... coffee filters are a good solution for rags as there lint free and cheap. Everything must be clean; you cannot see the dust that will damage things smaller than 30 microns.
3: to have kerma or anyone else do the job is cheap, usually $150 for all 4 with a hot swap option available. They send you the injectors assembled with your new nozzles ready to go and you send them your old cores and they refund the core charge.
Possible damage can be anywhere from bad economy to a melted piston in extreme cases. The tips of the nozzles must not be touched even when assembled.
Spend the few bucks and have them done via hot swap. I do like kerma, others have had issues with them but there are other options I encourage you to research and talk to tuners.
Thanks for the tip! The hot-swap option sounds great if available. The biggest thing holding me back was the thought of not having my car for potentially over a week while I wait for shipping.
 
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