Bosio DLC 520 (ULSD RATED)

Price: $249.00
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Detailed Description
Specifications

Bosio ULSD 520

***ULSD Rated***

Product ID: 520ULSD

 

***Direct replacement for the AFN / ASV Nozzle but with DLC Coatings***

 

OEM style nozzles are 205 µm nominal
Stock replacement for European 110 hp AFN / ASV motors. 

- Optimized spray pattern
- Closer tolerances
- Hardened wear surfaces
- DLC Coated needle for superior wear characteristics with ULSD fuel
- More power than the OEM parts
- More torque than OEM parts
- Less exhaust smoke for the same power output
- Improved economy in many cases

 

Optimized 205 µm Nominal Hole diameter

 

ULSD (Ultra Low Sulfur Diesel) Rated Nozzles 
 
ULSD aka "Ultra Low Sulfur Diesel" has brought about a new set of challenges to the Diesel Injection Systems industry. ULSD specifications more specifically "ASTM-975 §1.1.4- S15". 
 
ULSD Rated Nozzles are unique in that they are literally built around an ultra-hard "Diamond Like Carbon" coating aka "DLC". DLC provide a “Diamond like” surface with superior surface qualities in respect to smoothness and uniformity that greatly reduce sliding friction. This allows the nozzle's needle to cycle faster, with improved fuel quantity control thru better needle response.
 
Another key benefit of DLC is that it results in a 50% or more increase in component life when compared to a non-DLC nozzle type running ASTM 975 USLD fuel. A nozzle is comprised of two precision made pieces, a high nickel alloy nozzle and a high carbon steel needle. A non-ULSD Rated nozzle suffers from the effects of reduced lubricity as a result of the loosely controlled lubricity specifications under ASTM 975. Because of this there is a wide range of actual fuel quality from one retailer to another.
 
Unfortunately, wear is greatly increased due to reduced lubricity on the internal sliding surfaces. More specifically, ULSD fuel increases the wear rates in the needle support regions which over time (3,000-4,000 running hours) leads to decreased nozzle performance. As wear increases, the gap between the needle and nozzle widens and fuel (pressure and volume) leaks back into the injector and power and efficiency are lost due to poor pressure response of the injector nozzle.
 
DLC increases the hardness of the needles sliding surfaces thus increasing its service life by reducing the sliding friction and increasing the hydrodynamic support that the needle utilizes to remain centered in the nozzle bore.  

 

ULSD nozzles carry a small premium over the non-DLC types but with nearly double the service life(or more) of the nozzle your direct savings are realized not only thru greater durability but improved function of the nozzle meaning better fuel economy and lower emissions all of which translate into greater longevity of your diesel engine. 

 

 


ULSD Rated Nozzle
DLC (Diamond Like Carbon) coatings cover all of the internal needles sliding surfaces. The lower portion is not coated since this is a direct contact surface that requires a normal wear characteristic to generate the high pressure seal needed during pressure build up prior to and after injection.
 
 
 
 
 
DLC Coatings at the Nanometer level

The key advantage to a DLC coating is the superior sliding surface it creates between two moving parts. This allows significant reductions in friction, and far greater durabiltiy due to reduced reliance on the lubricity of the fuel.

 

 

Standard Needle and Nozzle

A standard needle is uncoated and relies on the end result of the precision machining. This leaves very slight imperfections in the surfaces that increase the reliance on the fuel to prevent wear. Also this slightly increases the friction and thus lowers the response time of the needle consequently lowering its overall efficiency.

 

 

 

 

 

 

 

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Here's some data on some Genuine Bosio nozzles"

 

Bosio ULSD 1019

***ULSD Rated***

Product ID: 1019ULSD

 

Replaces: Bosch PN#: 0 433 175 291


A higher flowing nozzle than the stock nozzle for the European 150 hp AXG motors!!! With standard flow settings we can net you a 3-5% increase in fuel

economy without sacrificing power or smoke output!


 

Flow Data: 145% Above Stock Flow

Additional Data: 7% more flow and delivered FASTER than the biggest Bosch 1019-764 150hp nozzle

 

 

- Optimized spray pattern
- Closer tolerances
- Hardened wear surfaces
- DLC Coated needle for superior wear characteristics with ULSD fuel
- More power than the OEM parts
- More torque than OEM parts
- Less exhaust smoke for the same power output
- Improved economy in many cases

- 5 year unlimited mileage warranty with installation

 

 ----------------

 

Bosio ULSD 520

***ULSD Rated***

Product ID: 520ULSD

 

***Direct replacement for the AFN / ASV Nozzle but with DLC Coatings***

 

Replaces Bosch PN#: 0 433 175 093

 

Flow Data: 118% Above Stock Flow 

 
Stock replacement for European 110 hp AFN / ASV motors. 

- Optimized spray pattern
- Closer tolerances
- Hardened wear surfaces
- DLC Coated needle for superior wear characteristics with ULSD fuel
- More power than the OEM parts
- More torque than OEM parts
- Less exhaust smoke for the same power output
- Improved economy in many cases

- 5 year unlimited mileage warranty with installation

 ----------

BOSIO POWERPLUS 764

***ULSD Rated***

Product ID: PP764

 

 +25 hp +50 torque

 

Flow Data: 154% Above Stock Flow

 

- Optimized hole geometry for improved flow characteristics 

- closer tolerances
- hardened wear surfaces
- DLC Coated needle for superior wear characteristics with ULSD fuel
- More power than the OEM parts
- More torque than OEM parts
- Less exhaust smoke for the same power output
- Improved fuel economy settings can be set at time of install

- 5 year unlimited mileage warranty with installation

 

------------------------------------------------------------------------------------------------------------------------

 

We flow tested and data logged complete sets of these generic "LA 150P 502" aftermarket nozzles claiming to be on par with the PowerPlus 764 nozzle. The overall quality was on par with a $5 "Made in China" nozzle. The actual flow results were not surprising (to us anyway). We picked the highest flow nozzle of the batches we recieved and graphed the flow data. The flow variations were significant despite the claims that they were "flow matched" using a gun powder measuring tray. We understand that they flowed "3.5 grains" (marked on the injectors) using 25 strokes of their vintage hand pump.

 

What we found using a certified nozzle flow bench was a typical variation to be in excess of 10% using ISO 4113 calibration fluid at 40C. Also, we found the actual flow to be far below the PowerPlus 764 in actual flow volume. This generic nozzle is actually more in line with the much lower flow range 520 nozzle despite having much larger holes bored into them. It's the quality of the nozzle, not the size that differentiates one nozzle from another!

 

Another attribute is the poor sealing characteristics of nozzles. The nozzles had dramatic leakage and failed every leak-down check we performed.

 

 $360.00

 $100.00

 

Bosio Power Plus Stage 2 764 

***ULSD Rated***

Product ID: 2PP764

 

+40 hp +65 torque

 

Flow Data: 173% Above Stock Flow

 

- 7 hole version of the PowerPlus 764 nozzles

- Optimized hole geometry for improved flow characteristics

- Increased flow and improved atomization

- The flow rate of these nozzles is between the R520 and 2R520

  (seven hole) nozzles.
- Closer tolerances
- Hardened wear surfaces

- DLC Coated needle for superior wear characteristics with ULSD fuel

-5 year unlimited mileage warranty with installation


 


-------------------

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Bosio Power Plus 520

***ULSD Rated***

Product ID: PP520

 

No smoke in A4 body 5-speed cars with stock chip
Best choice for most applications besides automatic transmission cars
Approximately +20 hp +40 torque

 

Flow Data: 141% Above Stock Flow

 

NOTE: This is the direct flow replacement for "T4-150hp DSLA150P1019-764" Nozzle but with DLC Coatings***

 

- Optimized hole geometry for improved flow characteristics

- closer tolerances
- hardened wear surfaces

- DLC Coated needle for superior wear characteristics with ULSD fuel
- More power than the OEM parts
- More torque than OEM parts
- Less exhaust smoke for the same power output
- Improved economy in many cases

- 5 year unlimited mileage warranty with installation

 

The PowerPlus 520 outflows other nozzle types thanks to their state of the art design. Despite the PowerPlus 520 having "Smaller holes" than the other generic brands, they outflow thos nozzles accross the full flow range. When it comes to nozzles, Quality means more than size!

 


Bosio nozzles from kerma is the best option for maintenance,, or tdi performance upgrades of VW TDI injectors. kermaTDI started the TDI performance market with Powerplus 520 Bosio nozzles. This was the first breakthrough in VW Diesel performance. 


Add kermaTDI VW TDI turbo upgrades, and TDI ECU or TDI Tuning upgrades with the kerma Q Loader flash programmer ...and we can take the 90 Horsepower VW TDI to 135 , 150, or 175+ Horsepower.  TDI performance with increased fuel economy , that is why kermaTDI is a leader in VW diesel performance .

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