Detailed nozzle size technical information
The below OEM and aftermarket nozzle size information is specific to VW diesels. Some of the nozzles below were measured with an electron scanning microscope by Geoff Williams "GeWilli", organized by smallest to largest. The "DSLA" means that the nozzle orifice is cut into the needle seating area. The "P" is the needle type that is in the nozzle- a 4mm diameter needle, and the "150" is the spray angle of the orifices. The last number is not the orifice size, it's just the name. Note that the nozzle orifices may be placed asymmetrically around the nozzle tip, some are, some aren't. The stock nozzles have 5 holes around the tip.
.158 injectors:
DSLA 150P 672, OEM on the 90 hp auto transmission mk4 ALH 1998-2003 engine, actual measured
size is .138mm.
.184 injectors:
DSLA 150P 706 OEM on the
90 hp manual transmission mk3 AHU/1Z (post smoke recall for the 1996 passat) 1996-1999 engine and the mk4 ALH 1998-2003 engine, actual measured size is
.170mm. Remember that if you have this size injectors and replace them with ".184" .170mm actual size injectors you will see an increase in power because of the size difference.
.184 injectors:
(Euro market: DSLA 150P 357)/(US market: DSLA 150P 442) (sprint 357/442 or PP357), OEM on the 90 hp manual transmission mk3 AHU/1Z 1996-1999 engine, actual measured size is
.185mm. Similar to the "smaller".184 injectors used in later cars except it has a larger opening and was used in injector bodies with lower opening pressure (190 bar) used with different ecu programming pre-smoke recall in the 1996 passat. PP357 should give about +5hp, +10ft-lbs over comparable sprint nozzles with less smoke.
.205 injectors:
DSLA 150P 520 (sprint 520 or PP520), found on the 110 hp Euro AFN/ASV engine, actual measured size is
.205mm. These are the stock nozzles found on the 110hp Euro cars which also used a larger turbo and different ECU to account for more fuel. PP520 should give about +10hp, +25ft-lbs over stock nozzles and about +5hp, +10ft-lbs over comparable 520 sprint nozzles with less smoke.
.216 injectors: These will give more power than .205 injectors. Note that most people report better results from using later ".216" injectors instead of buying aftermarket .216 nozzles only due to better atomization of the fuel. There were also two different actual sizes for injectors commonly referred to as ".216". See below for more details on actual sizes. You definitely need adjustment of the fueling to control smoke and when used with a chip, advanced modification and a new clutch are probable requirements to be able to burn all the fuel. See 1000q: advanced power modifications for more details. They are not recommended for automatic transmission cars due to smoke.
Earlier 140hp 5 cylinder VW/Audi AEL engine "
DSLA 150 P502" are true
.216mm nozzles. Later 150hp Transporter (eurovan, not available in the US) 5 cylinder AXG engine "
DSLA 150P 1019" are
.203mm nozzles but seem to give better results due to differences in the injector body (nozzles are all interchangeable). The smaller nozzles used a longer duration to achieve the same amount of fuel but since your ecu doesn't know the difference, make sure you know what .216 nozzle you are getting. The actual .216 injector body looks slightly different than your stock smaller nozzle injector bodies but the nozzles are all removable and interchangeable. 150hp nozzles may also be called "
DSLA 150P 764" and use .205 holes.
All pumpe duse injectors: the replacement is more complicated since you have to remove the valve head cover, remove a few bolts and use a puller to remove the injectors. Reinstalling them is more complicated and you have to make sure they went back in exactly the way they were before. If you have a pumpe duse, I would recommend getting a chip and seeing how the car feels at that power level. A chip alone will make about 150hp/250 ft-lbs torque which is quite a bit. Another issue is that you have to have the entire injector body modified at a specialized facility. This requires either car downtime or a core charge for exchanging someone else's injectors. If you still want injectors, kermatdi at
http://www.kermatdi.com/ sells larger or modified pumpe duse injectors. If you don't know if you have a pumpe duse, all North American VW diesels between 2004 and 2006 are pumpe duse. For more details, see 1000q: model year differences - pumpe duse.
