0.216 Injector Nozzles: Pressure Settings & Tuning

Hello.
I purchased the BOSCH 2437010060 fuel injectors with a size of 0.216mm.
These are now going to be installed and adjusted at the Bosch Diesel Center for my AFN engine with its VP37 fuel injection pump.
Okay, so the question is...
The 0.216 nozzles should be adjusted to 230 bar and are used in the 5-cylinder diesel engine of the T4.
The original 0.205 nozzles should be adjusted to 190 bar.

Now, I would like to know if the VP37 pump can consistently achieve 230 bar, or what pressure the 0.216 injectors should be set to.

Best regards, Denis.

Incorrect. 230 bar is not a standard setting for these nozzles anywhere.

The opening pressure is indicated on the outside of the nozzle holder assembly. It's easy to read. The pressures of the first stage are 190 or 220 bar, and they should generally be set as before.

The standard pressure for nozzle holders in the AFN system is 190 bar.

Best regards, Rainer.

Hello.
I know about the 190 bar pressure with the standard 0.205 injectors for the AFN engine.
I plan to take the original Bosch 0.216 injectors to the Bosch Diesel Center and have them installed into the injector holder combination designed for the AFN engine.
Now, the people at Bosch Dieselzentrum didn't know how to adjust the 0.216 injectors.

I was only told that these nozzles are for the 5-cylinder diesel engine in the T4, and that the adjustment pressure is 220-230 bar.
Then they said that if they only set the 0.216 nozzles to 190 bar, it could cause a significant increase in pressure.

Therefore, I would now like to know if the opening pressure of 190 bar is sufficient for the 0.216 injectors, or if they should be adjusted to 220 bar, as with the T4, without causing excessive soot. Otherwise, I would have to pay again if they were to change the pressure from 190 to 220 bar, or vice versa.

I've been using your 0.216 injectors for about 8 years and 200,000 km, and now it's time to replace them.

Best regards, Denis.

Hello,

It's unfortunate that you didn't mention that your vehicle appears to already have different nozzles and/or different software installed!

Adjust the nozzles to the pressure indicated on the nozzle holder!

Quote:

they also said that it might be the case that if they only set the 0.216 nozzles to 190 bar,

it would then produce a very strong rush.
It only makes sense if the vehicle is already "producing a lot of black smoke" and has 220 bar injector holders installed. But then, something is broken.

How many kilometers are on the engine? I can hardly imagine that this whole thing makes any sense, because the car was already old 8 years ago.

IMPORTANT: After approximately 220,000-300,000 km, depending on the driving conditions and the type of fuel used, the fuel injection timing of the VP37 injection pump may no longer function correctly. This results in delayed fuel injection under load, causing the vehicle to produce excessive smoke (and potentially leading to mid-term damage to the pistons).

It would be more helpful for you to troubleshoot potential issues, such as leaks in the charge air system or problems with the fuel injection timing.

Best regards, Rainer.

I have been using other software from TCM Marcus, located in Bergen near Munich, since 2003.
"Then, in 2006, I bought the 0.216 injectors from you, and at the same time, I installed the VTG17 turbocharger."
In August 2007, the VP37 fuel injection pump failed at 260,000 km, and it was replaced with a new Bosch unit.
Then, in October 2011, at 372,000 km, I experienced an engine failure where one piston had a hole in it, and a small corner had broken off from another valve (the same piston).
"I bought an AFN engine from a scrapyard for about 6 months, but it consumed roughly 3-4 liters of oil every 1000 km. After that, I had the entire engine completely overhauled, including boring and honing the cylinders, new pistons, a new cylinder head, a new oil pump, etc."
The engine repair specialist (BK-Motorentechnik) said that there are two possible causes for the damage.
1. Excessive combustion temperature due to a faulty valve.
2. The injector nozzle is now completely clogged with carbon buildup, which has caused a hole to burn through the piston.

For cost reasons, I bought the injectors for the new engine from DPC.
Now I've bought the Bosch injectors, as they unfortunately no longer offer them.

Are the original injector holders installed (or are there differences between A4 and Passat AFN engines)?

Okay, I'm now setting the 0.216 nozzles to 190 bar.

The intercooler system is in good condition, and the injection timing is set just before the upper maximum point on the diagram.


How can the injection adjustment be checked?

"Last winter, I had a problem where the diesel line (supply line) on the underside of the car was crushed. However, I only noticed it when the car started to stutter while driving on the highway at over 160 km/h after about 3-4 minutes. Otherwise, there were no other noticeable issues."

Best regards, Denis.

Sounds like a terrible construction site.

Quote:

How can you check the injection adjustment?

The forum search and the expert articles are your friend.

For cost reasons, I bought the injectors for the new engine from DPC.

I unfortunately read that the nozzles are for much too late, and therefore I have now bought original Bosch nozzles and am having them installed and adjusted.
"I'm already using the 'old' injectors that I bought with the used engine from the scrapyard."
The DPC injectors are in the garage, and the new Bosch injectors are going to be installed.

Hello,

"I also have an AFN engine with 0.216 Bosio injectors. I had them adjusted to 220 [presumably a setting value]. I've been driving like this for 3 years, but it's almost stock performance, maybe 10-15 horsepower more. I don't have any soot problems with this setup, and it starts very well. The only issue is that it sometimes hesitates a bit when starting warm, which is typical for AFN engines."

Since then, I've been using the 1749va, and it provides better low-end performance.