Digital Injector Calibration & Nozzle Mounting, VE Injectors

What it is
This is KermaTDI's digital injector calibration and nozzle mounting service for VE-pump TDI injectors. It's the required setup step for properly running any new Genuine Bosio nozzle, not an optional add-on, since a nozzle's spray pattern and pressure settings only deliver their designed performance and efficiency when the injector is calibrated to match.

Two ways to use this service

• Send your injectors in: Mail your existing injectors to KermaTDI for calibration and nozzle mounting.
• Hot Swap Injector Program: Buy a set of Genuine Bosio ALH nozzles and pay for mounting, calibration, and flow balancing. KermaTDI ships you a pre-mounted, calibrated set of VE injectors first, so your car isn't down waiting on parts, and you send your own injectors back afterward as the core.

Pressure setting options

• Stage 1, Low Smoke: Cleanest operation. Best for stock or lightly modified vehicles, or for modified vehicles prioritizing fuel economy.
• Stage 2 (+5% main injection volume): Raises flow above standard/OEM settings, opening up a wider performance range for the same nozzle at the cost of a small EGT increase, since fuel delivery occurs over a slightly longer window. If you need more performance than the higher stages can give, the next step up is a larger-flow nozzle rather than a higher stage.

These pressure settings are mechanically set during the injector overhaul, not controlled by the ECU, and KermaTDI can raise or lower them later without modifying the nozzle itself.

Why two-stage calibration matters
Modern two-stage injectors meter fuel in two precisely timed pulses per combustion stroke, each as short as 1.5 milliseconds, to soften the pressure rise in the cylinder and cut diesel knock. That precision can't be set with conventional tools; it requires digital pressure sensing accurate to ±0.5% across a 600+ bar range, sampling fast enough to capture the full pressure cycle. Every new nozzle KermaTDI sells is also digitally flow-tested before installation, sampling flow rate up to 400 times per second, so it's verified to spec before it ever goes on your injector.

Hot Swap core deposit and return terms

• A refundable $600 core deposit is charged at purchase (select the Hot Swap deposit option at checkout).
• A complete core set is 4 injectors: cylinders 1, 2, and 4, plus the #3 injector (shipped without its T return nipple and banjo bolt, as expected).
• Injectors must come back unopened, with the nozzles still installed, to avoid losing internal parts.
• "Serviceable condition" means no marring, vice-grip marks, or thread damage, and the #3 injector's sensor wire must be undamaged. Cores that don't meet this standard may forfeit the full deposit.
• Heavily fouled cores (common with WVO or high-concentration biodiesel use) may incur a $50 cleaning surcharge, or may not be usable at all.
• If you want the nozzles pulled from your core injectors and shipped back to you separately, that's a $10 fee.
• Return your cores within 60 days or the deposit is forfeited, unless you've made other arrangements with KermaTDI.
• Extract injectors with a slide hammer, pulling straight up and out, to avoid damaging them during removal. KermaTDI sells the extraction tool if you need one.

If your injectors are damaged
KermaTDI also sells complete new injector sets, ready to install, at competitive pricing.

Order requirement
Specify your vehicle's year when ordering. The #3 injector's wire connector differs by year: 1996-2002 uses a square plug, and 2003 usually uses a D-shaped plug. Confirming this before ordering Hot Swap ensures you get the correct connector.

Common questions

Do I have to buy new nozzles to use this service? No, you can send in your existing injectors for calibration alone, or add any Genuine Fratelli Bosio nozzle to the order if you want an upgrade at the same time.

What's the difference between Stage 1 and Stage 2? Stage 1 prioritizes low smoke and cleanest operation, best for stock or economy-focused cars. Stage 2 raises main injection volume 5% over standard for more performance headroom, with a small EGT tradeoff.

Can I get my deposit back if my cores are in rough shape? Only if they meet the serviceable-condition standard, no marring, no damaged threads, and an intact #3 sensor wire. Heavily fouled cores may cost an extra $50 to clean, or may not be usable.

How long do I have to send my cores back? 60 days from purchase, after that the core deposit is forfeited unless you've arranged otherwise with KermaTDI.