I'm trying to decide which injector nozzles to upgrade to. I recently replaced my mk4 jetta alh turbo to a stage 1, I'm planning to straight pipe it soon, and then will eventually get a custom tune on it by a local shop. I've been reading that some nozzles might smoke more than others or that I might need to upgrade my clutch when I upgrade the nozzles. Any recommendations on nozzles that wont smoke much and won't tank the mpgs much?
The stock clutches in these cars do not hold up well to power add-ons. Not that they explode but they start to slip pretty quickly. So look to change out your clutch regardless of your choice of power add-ons.
Which nozzles smoke? Any thing bigger than stock on an untuned car will smoke, but since you are getting the car tuned anyway you don't have to worry about this. The general consensus is that any nozzle .330 or smaller will work fine so long as you pair it with the appropriate turbo and other supporting mods. Why is .330 the number? Because bigger than that and we begin to see atomization issues.
In general when tuning these engines more=more (rather than less=more). These are not high HP engines so mild mods become very boring rather quickly.
MPG... That depends on the tune and the squishy bit located between the steering wheel and the seat. More power means more fuel, so "using" this new found power will cost you in fuel. However, if you drive sanely then you wont notice a significant change in fuel consumption.