Ko3 to Ko4 conversion. Hpfp question

[Raj2212]

Hi wondering if someone can help.
Apologies if asked before. My freinds in the middle of a ko4 conversion

When doing the ko3 to ko4 conversion, would I need to change the hpfp to an uprated one or one from an s3 8p, or can I make do with the original.

So far, we’ve swapped the turbo, relocated the dv, it now has the s3 injectors.
Do we also need the rs4 fuel return valve too and map sensor from an s3 for it all to function ?

Sorry for the many questions. Appreciate the help

[Raj2212]

Sorry forgot to add we’ve also swapped to an s3 intercooler.

[ROH ECHT]

OK...regarding the fueling aspect of the intake cam; The S3 has a trilobe on the intake cam with slightly taller peaks and the HPFP is the same. 

K03 intake cam - 06F 109 101 J __ K04 intake cam - 06F 109 101 K
K03 2.0t HPFP - 06F 127 025 M __ K04 2.0t HPFP - 06F 127 025 M

Without the HPFP internals upgrade...it will drive without any tuning. Just not going to be making all it's got. And without upgrading the intake cam or HPFP...even tuning will leave it low on performance for the lower rail pressure it will have.

Most who do the K04 tune and S3 injector; opt for 'not' replacing the intake cam and choose upgrading the HPFP instead.

[colesey]

I thought it was just the cdl block whose cam had more lift on the fuel lobe but could be mistaken

[Raj2212]

OK...regarding the fueling aspect of the intake cam; The S3 has a trilobe on the intake cam with slightly taller peaks and the HPFP is the same. 

K03 intake cam - 06F 109 101 J __ K04 intake cam - 06F 109 101 K
K03 2.0t HPFP - 06F 127 025 M __ K04 2.0t HPFP - 06F 127 025 M

Without the HPFP internals upgrade...it will drive without any tuning. Just not going to be making all it's got. And without upgrading the intake cam or HPFP...even tuning will leave it low on performance for the lower rail pressure it will have.

Most who do the K04 tune and S3 injector; opt for 'not' replacing the intake cam and choose upgrading the HPFP instead.

Thanks for replying, so the easy method would be to get an uprated fuel pump instead of using one off an s3.
So am I correct in saying it’s just the rs4 fuel return valve, 3 bar map sensor , 200bar Fuel Rail Pressure Sensor and a map to get it all up and running. Or is the car drivable without these parts as I wait for them to come. The map sensor and rs4 fuel return valve are on order at the moment. 

Does anyone have a part number for the 200bar Fuel Rail Pressure Sensor ?

I thought it was just the cdl block whose cam had more lift on the fuel lobe but could be mistaken

[ROH ECHT]

I thought it was just the cdl block whose cam had more lift on the fuel lobe but could be mistaken

You are right in that the CDL has taller peaks. The CRZA (here - US) does and not sure what else with a K04 does. I just didn't have the time to search for who has it all posted.

[ROH ECHT]

OK...regarding the fueling aspect of the intake cam; The S3 has a trilobe on the intake cam with slightly taller peaks and the HPFP is the same. 

K03 intake cam - 06F 109 101 J __ K04 intake cam - 06F 109 101 K
K03 2.0t HPFP - 06F 127 025 M __ K04 2.0t HPFP - 06F 127 025 M

Without the HPFP internals upgrade...it will drive without any tuning. Just not going to be making all it's got. And without upgrading the intake cam or HPFP...even tuning will leave it low on performance for the lower rail pressure it will have.

Most who do the K04 tune and S3 injector; opt for 'not' replacing the intake cam and choose upgrading the HPFP instead.

Thanks for replying, so the easy method would be to get an uprated fuel pump instead of using one off an s3. Correct, because both HPFPs are the same.
So am I correct in saying it’s just the rs4 fuel return valve, 3 bar map sensor , 200bar Fuel Rail Pressure Sensor and a map to get it all up and running. Or is the car drivable without these parts as I wait for them to come. The map sensor and rs4 fuel return valve are on order at the moment. The 3 bar MAP and the rail pressure sensor are both dependent upon requirements of your tuner. I have a 145 bar FPRV(fuel return valve) with a 140 bar max rail target and currently have the 2.55 bar MAP. I did have a 3 bar MAP when I ran one tune for two years (2014 to 2016) and boost for the tune was more than 26 psi. But I went back to my original K04 tune. I wouldn't install the 3 bar MAP until you find out if your tuner requires it and it is about to be tuned. Or just before the drive to the tuner...and drive gently getting there.

Does anyone have a part number for the 200bar Fuel Rail Pressure Sensor ?

High Pressure Sensors are here; https://www.ecstuning.com/Volkswagen-Golf_V--2.0T/Engine/Fuel/Sensor/

If 2007 or later...it may already have the correct G247 (high pressure sensor). Mine is early 2007 and did come with the higher pressure sensor and never required anything else. Forget the third column. This list is a Bosch cross-reference list and they did not accuratley know which VW were installing. And because you can see; mine is the BPY and my G247 was not those listed for it. My G247 was listed below with the higher limit sensors. Remember this is an old list and newer revisions may be available. Here is a list of Bosch G247 sensors and their pressure limits. I believe the latest G247 with higher limit is 06J 906 054 B...not on the list except for the ...051 B is now ...054 B. You can read the part number on the current sensor and check this list for its limits;

[Raj2212]

Thank you @ROH ECHT