Injectors - Performance - VAG 1.9 Lt. TDI

Bosch VE Performance Injectors – Flow Rates

Years of experience in setting up of Bosch Two Stage TDI injectors for both the 1.9L and 2.5L engines have led to the establishment of a series of different parameters depending on application. Please remember that part numbers and part names associated with various nozzle manufacturers will only relate to the delivery of the individual nozzle. The final fuel flow is dependent on the set up of the unit as a whole. The flow rates below thus describe the flow of the injector, not the individual nozzle.

We have learned that all the part numbers and so called nozzle identification numbers like .216 don't mean a lot as it all depends on the flow rate of the complete injector once set up. Also we have found that nozzle manufactures are all different and if the injector is not calibrated once a nozzle has been fitted you will not get optimum performance and even run the risk of damaging your engine.

All injectors that we supply have been calibrated and set up to the following specifications. We flow test and set up each injector. All flow rates have been tested using a Hartridge Two Stage Test Master and the flow rate is measured in “liters per minute” this is not the actual delivery but a measurement used to flow test the injector. All Bhp quoted will depend on engine condition and “engine build” in the case of modified systems.

Moderate Flow: nozzle hole size is between .216mm – .220mm with a flow rate of 1.45 to 1.55 L/min (litres per minute). A great injector used to revitalize your 1.9lt or 2.5lt TDI. No mods, no turbo’s, inter coolers or any remaps needed, just fit and enjoy. This set of injectors will improve response, torque and drivability with an increase in power of 20 to 30 Bhp, at a very affordable price. If you are thinking of getting your injectors reconditioned and don’t want to get involved in any other engine modifications this is the way to go.

Enhanced Flow: nozzle hole size between .230mm - .240mm with a flow rate of 1.55 to 1.65 L/min, just fit and expect an increase in power of approximately 35 Bhp and with a tune you should achieve about 50 Bhp. Great low down torque also noticeable.

High Flow: nozzle hole size between .250mm -. 260mm with a flow rate of 1.65 to 1.80 L/min these injectors are normally fitted as part of an engine tune sometimes with more efficient intercoolers, hybrid turbo’s and a few other minor modifications. Again with a tune you should see improvements in Bhp of about 100 Bhp

Super High Flow: nozzle hole size between .270mm. – .300mm with a flow rate of 1.90 to 2.10 L/min - even bigger turbo’s, more comprehensive engine modifications and a injector pump up-rate will increase power to about 250 – 300 Bhp

Extreme Flow: nozzle hole size .320mm – .350mm with a flow rate of 2.10 to 2.50 L/min this can only be used by an experienced engine tuner. A more comprehensive engine mod will be required with even bigger pump uprate. Power achievable of 350 – 400 Bhp

Pump Mods.

Standard mod is a pump overhaul including a higher lift cam plate with performance calibration.

High mod is a pump overhaul including a higher lift cam plate, larger head/rotor and performance calibration.

11,5mm rotor is good for 280hp with 0.280 nozzles and even more with bigger nozzles. No RPM limit for this size of rotor if an eye is kept on fuel temp. Fuel cooler recommended but not really needed.

12,5mm rotor for around 320hp with 0.320 nozzles and more with bigger nozzles. Fuel cooler highly recommended plus RPM limit at 4000RPM (DSSR recommendation)

Basically, with exactly the same configuration, the upgrade from stock 10mm to 12,5mm head gives you 50hp gain.

The 14mm head is a monster! This is good for around 400hp with 0.350 nozzles or bigger but RPM limit at 3500 on that one