Engine/Transmission (1998.5 - 2002) Frateli Bosio injector nozzle factory

[Walt-L]

Hi folks, just posted this on the CaTCHER post and thought this is good enough for a post on its own. Check out the extra wide panoramic view of the shop. Looks like we are becoming a bit 3rd world architechterally wise. http://forums.tdiclub.com/showflat.php?Cat=0&Number=602915&page=&fpart=1&vc=1 These injector nozzles can be found at www.kermatdi.com

 

[darkhorse]

That's a fine post, Walt.

 

[d.miner]

Worth the $$$'s ?

This is a nice post... appreciate all the photos.



Has anyone (besides John Holmes) tried these nozzles yet?



From what I've read they seem to be something along the lines of a Bosch RV 275.



Any opinions?

 

[Walt-L]

I hope they still have the $200 special price for the CTD when I get ready for a valve adjustment and injectors later in the year. From what the TDIers say these beat the older bosch style nozzles hands down. In time we should have some hard numbers from some of the good people here at TDR!

 

[Herman8r]

I just received the nozzles from Charlie at kermaTdi. They were very prompt in delivery & also very responsive to the emails I sent prior to the purchase.



I have never changed injectors on the Dodge before so I researched the TDR forums foe articles on injector R&R & found the download by Diesel Dynamics (www.dieseldynamics.com) very helpful. Also- kermaTDI posts directions on their web site for the nozzle change out.



Upon the first inspection of the nozzles I could see these were to be handled with care. A dropped nozzle could damage the ports in the tip of the nozzle.



As I followed the directions I started to second guess myself if doing the nozzle exchange myself was worth it. The injectors came out very easy (remember to remove the high pressure fuel tube that mates sideways to the injector). Next came the removal of the old nozzles. This was easier than I thought. I use the square shank of a medium size screwdriver to fit in the slot of the injector (sorry--no pics--didn’t think about it) and a 15mm wrench to loosen the retaining cap that secures the nozzle to the injector. After the cap is loose I made sure to keep the injector upright so the inner parts of injector remain in place. This is very important. Then I removed the old nozzle & installed the new nozzle. They can only go on one way. It that simple. Installation was the reverse of the removal process. New o-rings & copper shims on the injectors & o-rings on the fuel tubes.



After the air was purged from the system the truck fired right up. The test drive proved the nozzles worked without any failures. Throttle response was quick as was the power. I have not pulled my equipment trailer yet to note any added performance as it relates to towing yet. Soon though.



It took me 3. 5 hours -start to finish to do the R&R--this included doing some extra cleaning (batteries, cables, etc). I sure someone with more experience could do it faster (I am not a practicing mechanic)



Time will tell if the nozzle change out was worth it. As for as the cost--the savings is hard to beat.



Herman Radtke

 

[wicked6]

Herman -



Can you post what the set co$t ya. ?? Ball park, if posting prices gets us in trouble... ... ...



Thx !

 

[Herman8r]

Wicked6---complete cost was $200. 00 --shipping was free & no tax. I don't know how that compares to a set of stock 275's.



Herman

 

[KYLE4]

Charlie sent me a set I will be selling them soon as well, through him of course I was very pleased with performance gained from them as for mileage my driving style is heavy on the pedal so it is tough to asess any gains.

 

[LOtero]

now you guys have me drooling! what kinda power gains are you seeing? maybe this will be a good bomb before going to big honkin injectors?

 

[Marco]

Personally I did not know that company. I've asked a few questions to my buddies in the diesel injection scene here in Italy. All responses I got is that Fratelli Bosio is top notch. BTW. they're about 3 hours from my home...



Just one question from my side. It's my understanding that you only buy the injector nozzels. In other words one keeps it's injector nozzle holder and replaces the tips. Right?



During that process one has to adjust the pop pressure of the injector.

How do you do it?



Marco

 

[Herman8r]

Marco--there are no adjustments to be made--that is if your stock injectors work ok. Just un-screw the nozzle cap--remove the old nozzle & replace with the new nozzle--that's it. If you wish to have the pop pressure--there is a site listed on the home page www.kermaTdi.com that offers to do the testing--oh ya--you only live a few hours from the plant--matbe they will pressure test them for you.



Herman

 

[crawler]

Nozzles only and they are $200. Not bad but I'll do you one better.



How about EDM 8 hole injector nozzles. 50-75-100-125-150 HP Levels With a price ranging from 216-325.



Later,

Wes

(903) 355-4475

 

[AKAMAC]

I did the nozzle switch to my stock injectors. Pretty straight forward. Have yet to exchange them for the RV275's currently in my truck. I got a 10% discount from KERMATDI. I will probably do the install next weekend.

 

[KERMA]

Personally I did not know that company. I've asked a few questions to my buddies in the diesel injection scene here in Italy. All responses I got is that Fratelli Bosio is top notch. BTW. they're about 3 hours from my home...



Just one question from my side. It's my understanding that you only buy the injector nozzels. In other words one keeps it's injector nozzle holder and replaces the tips. Right?



During that process one has to adjust the pop pressure of the injector.

How do you do it?



Marco

Marco- you should give Giuseppe a call, he is very busy, but if he can find the time, I am sure he will be happy to show you around. I am proud to know that family, never known better people in my life, you will see this also. 011-960-6222 Bring your truck and give him a ride!



A couple of hints for doing the nozzle swap- USE A VISE or else you are going to drive yourself crazy. After you get them open, cleanliness is the most important thing. A little piece of carbon can mess with the seal between the nozzle and the holder if it gets in there. You can use an old toothbrush and some diesel fuel to clean up the hardened soot and it won't scratch anything. A puff of compressed air can clean up the "crumbs". Clean is also imprortant to ensure accurate torque on the nut so be sure the threads are nice and clean to spin freely. 30 degrees past hand tight is sufficient.



You can pop test them if you want, but it is not absolutely neccesary. Any diesel shop can do it and usually they won't charge much if anything. SOme people do it for the peace of mind, but if you followed the instructions on the web site, all it will prove is that they don't need to be shimmed after all.



VW TDI crowd likes the Bosio stuff, so we figured why not the Dodge? Had to start somewhere. There is nothing groundbreaking about these particular nozzles, the nozzle swap will simply convert your stock injectors into "RV275" injectors, everyone knows it's "only" a 40 hp gain. The difference is the quality of the workmanship, which I think the aftermarket is not used to seeing (I must admit I've never seen DonM's work) Only 7 holes, (for now ) but for sure it is certainly better made than the "made in China" stuff.



Interest seems to be picking up, it looks like we will advertise in the TDR after all.

 

[Alphacowboy]

Kerma,



do you plan on any more advanced injectors for the CTD... maybe a 80 and 120hp set? Just curious. I am very interested in the 40hp ones for now, hopefully if the funds provide, I will order a set in the next few months.

 

[KERMA]

Not much emphasis on developing 24v stuff currently. That market is saturated with everything from DonM to cheap "8-hole" unlabeled chinese nozzles that cost the manufacturer more to ship than to make.

Right now the development focus is on the common rail both 03-04 and newer types. We have the stock ones, and some been honing them since August. Some people with upgraded 3rd gen injectors have our stuff that's been honed by a shop and don't realize it. As far as I know they are currently the only ones using "new" unused nozzles for the common rail, everyone else uses exchange nozzles because it's cheaper (but also risky from a reliability standpoint. ) Bosch has not made them available.

There's a large company signing on to distribute the "POWERPLUS" version(s) of our nozzles in their own injectors, so we don't intend to offer the CR stuff at retail. Besides, the CR stuff is a little more critical than previous injectors and nozzles. Remains to be seen if the backyard guys should be swapping their own nozzles for 3rd gen CR.



We made the 40 hp ones for 24v to begin because it's a well known item and the starting point for most of the honed and EDM ("Stage X") injectors out there. It is a common "low risk" upgrade and generally won't cause EGT or transmission issues with towing or a box. We prefer to make a "modest" output nozzle to a very high manufacturing and durability standard instead of a ton of different "stages" that make headline-grabbing power but won't balance easily and wear out after 10k miles. If we do produce something more than these 40 hp version, it will be maybe one other version. But the 24v ship has largely sailed, common rail is the future.