Nozzle Selection Guide
Due to the volume of sales it is possible from time to time that certain nozzles may be temporarily out of stock.
Contact us for availability prior to ordering.
How to order and Purchase:
- Contact us via Email under the "Contact Us" tab to the left. Include details such as
the nozzle type you are requesting and we will respond
with the availability of the nozzle or Injector type you require.
- Payment, due to demand Paypal or personal check are the preferred methods.
Make Paypal payments to: DBWLLC@live.com
- When shipping your injectors for mounting of new Nozzles or for Calibration and
balancing, include a copy of the Repair Order "RO" sheet:
Repair Order sheet "RO"
- This is a fillable .pdf that can be printed once it is filled out on your computer.
Return Policy and Hot-Swap program Rules
All returns are subject to a 30 day full refund policy nozzles must be returned un-opened and in their original packaging.
Injector core requirements for our Hot-Swap program
-Must be received within 30 days of receipt to be eligible for a core refund, no exceptions.
-Injectors must be received in fully serviceable condition as removed from the vehicle.
-On VE series engines, the #3 Injector wire must be undamaged without any visible damage internal or external to be eligible for a core refund.
-Injectors must be returned complete and with the nozzles installed, no exceptions.
Notes and Our advice to you,
Perform your own due diligence before selecting a nozzle for your application. Take into account the power and risk to your engine and it's associated components any modification presents. Even with new OEM nozzles/injectors the risk of failure exists, it is impossible to eliminate all risk with any mechanical application therefore we strongly suggest you base your decision on the level of risk that you the owner are willing to accept.
Nozzle type and description | Nozzle Prices Sold in sets of (4) | Additional Nozzles Sold only in addition to a complete set purchase |
All nozzles can be set with our exclusive Variable Flows. We offer at no additional charge the following settings please check the setting you desire when ordering. -Low Smoke settings for maximum fuel economy (approx. 85% of rated flow) -Standard Flow which is the ideal flow setting for all nozzle types (approx. 87-90% of rated flow) -Custom Flow (your choice of flow from 100% on down) | $N/C | $N/C |
Bosio Race 520 Stage II ***ULSD Rated*** Product ID: 2Race520 The ultimate race nozzle!
Flows can be reduced to as low as a PP764 and increased all the way to the maximum volume capability of this nozzle. This nozzle is ideal for those who are exploring custom built motors with unknown potential.
The negative affect of reducing flows is that you increase the actual fuel economy of the nozzle/injector/engine combination. 3-5mpg increases are not uncommon. We would insist on starting with a conservative flow setting initially, then gradually increase the peak volume to match the motors ability to utilize that level of power. Flow adjustments are performed for a very reasonable charge after the initial build up and we re-issue a new data sheet for your injector set after the changes have been made. Contact us for custom settings and charges for custom race applications. Flow Data: 240% over stock flow [ Off Road Use Only ] | $545.00 | $131.00 |
Bosio Race 520 ***ULSD Rated*** Product ID: R520 One for the crazies!
Max power and max smoke/EGT. You will break your car without upgraded turbo, intercooler and custom tuning!!!
These nozzles provided an additional 20 hp over the TDI-R nozzles in the VWRacingUK race car.
They have supported over 230 hp with the right equipment configuration.
Not recomended for most applications Flow Data: 206% over Stock Flow [ Off Road Use Only ] | $445.00 | $100.00 |
ALH injectors Bodies No nozzles (set of 4)
Product ID: NEWALHINJ Brand new 2-stage injector bodies ready for mounting of a nozzle of your choice for rotary injector pump TDI's. Set of four injector bodies, including three "short" injectors for #1, 2, and 4 cylinders, and #3 injector with the needle lift sensor. The #3 uses the standard "T" fuel return fitting's and sealing washers used on all Pre-2003 TDI injectors. The sensor wire fits all 90/110 hp tdi's from 1996 to 2002. Note: The wiring adapter for 2003 cars can be supplied upon request for an additional charge. Bosch IMPORTANT NOTE: A core deposit (charge based on a per set basis) which is refundable upon receipt of your rebuildable original injectors. Robert Bosch Corporation | $500 + $500.00
Core Charge | N/A |
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
| $440.00 | N/A |
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! 
| $330.00 | $100.00 |
Bosio Power Plus 502 ***ULSD Rated*** Product ID: PP502 The PP502 is similar to a PP764, but it is 3% larger. Flow Data: 149% Above Stock Flow - 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 | $330.00 | $100.00 |
Bosio Power Plus 357 ***ULSD Rated*** Product ID: PP357 Commonly used in:
-- '98-'03 A4 body TDI with automatic transmission
-- Best upgrade choice for A3/B4 cars
-- Other VE PUMP TDI for mild power upgrade and better fuel economy
Approximately +10 hp +30 torque Flow Data: 109% Above Stock Flow - 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 | $380.00 | $100.00 |
| 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 | $360.00 | $90.00 |
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 | $310.00 | $90.00 |
Bosio Sprint 520 ***NOT ULSD RATED*** Product ID: S520 Flow Data: 111% Above Stock Flow Stock replacement for European 110 hp AFN/AHF/ASV motors.
Mild upgrade for 90 hp cars. - 1 year 12,000 mile warranty without installation - 2 year unlimited mileage warranty with installation | $270.00 | $80.00 |
Bosio Sprint 764 (Bosch DSLA 150P 1019-764 direct replacement) ***NOT ULSD RATED*** Product ID: SP764 Flow Data: 137% Above Stock Flow NOTE: This is a slightly higher flow flow replacement for "T4-150hp DSLA 150P 1019-764" nozzle - Optimized hole geometry for improved flow characteristics - closer tolerances than OEM
- hardened wear surfaces - More power than the OEM parts
- More torque than OEM parts
- Less exhaust smoke for the same power output than the Bosch 1019 nozzle
- Improved economy in many cases
- 1 year 12,000 mile warranty without installation
- 2 year unlimited mileage warranty with installation | $240.00 | $80.00 |