K04 conversion 200 bar rail sensor

[muff1991]

Hi all,
Can’t find a definitive answer for why I shouldnt or yes I can fit the 200 bar fuel rail sensor.
My thoughts are the sensor only reads higher than stock (139 bar) this goes to 200 bar.

FYI I’m doing a k04 conversion on my gti

I’ve read, don’t install until you reach the mapper, others say just put it in etc. I have fitted it as it made sense while I was doing the injectors, but if this is going to cause a problem driving it up to the mapper (approx 60 miles) then I’ll need to take inlet back off and swap it... just when I get to the mapper I may have to take the inlet off AGAIN to put it back on.

Can anyone tell me if I’ll be ok to leave it as is or whether I should go through the hag of swapping it?

Advice ASAP would be great please. (While the cars in bits)

The guy who’s mapping said I won’t need the sensor either but I think he may be getting confused with a k04 stock car being mapped vs me turning my k03 into a k04 car. I think they’ll be some difference in these sensors.

Other than the above, I wonder if disconnecting the sensor so the ecu sees no readings and “maybe” runs the fuel pressure on a “basic setting” this would be more than good enough for me to poodle up for a map!

Please let me know your knowledge and thoughts.
cheers.


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[LC5F]

Think of it as the sensor only provides a signal to ECU as a percentage - it is in the ECU scales this to the correct figure.

If you throw in the bigger sensor without correct scale, it will see a smaller percentage of fuel and will attempt to correct by overfueling.

[muff1991]

Thanks LC5F, so I shouldn’t really drive it to the mapper with it fitted?


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[LC5F]

I would only be tempted to swap if the tuner is just a couple of miles down the road and your not driving the car till the remap day.
Otherwise I wouldn't risk it - just do it at the tuners.

[ROH ECHT]

My MK5 was built in mid'06 yet sold as an '07. I replaced my G-247 and was confused by this chart...as my engine is BPY. But I was told to not pre-order the sensor before knowing which I truly needed after having removed it and put eyes on the part number. Bosch made this chart before VW began swapping to the 200 bar sensor. My BPY actually had the 200 bar sensor in it. So, it is best to see which G247 you currently have and replace it with the latest revision.

I agree with the previous statement in that this sensor sends a variable signal to the ECU based on pressure. For the identical rail pressure...each of these sensors may send a different voltage to the ECU causing the ECU to react to an inaccurate pressure. All pressure and temperature sensors are this sort. I encourage you to speak with a custom tuner to see what they can do if you choose to covert it.

This is the older Bosch cross-reference chart for the G247. It should show you which your original is.

[colesey]

For some reason, model years change in the summer. I took delivery of my 2007 chassis car in July 2006.

[muff1991]

My MK5 was built in mid'06 yet sold as an '07. I replaced my G-247 and was confused by this chart...as my engine is BPY. But I was told to not pre-order the sensor before knowing which I truly needed after having removed it and put eyes on the part number. Bosch made this chart before VW began swapping to the 200 bar sensor. My BPY actually had the 200 bar sensor in it. So, it is best to see which G247 you currently have and replace it with the latest revision.

I agree with the previous statement in that this sensor sends a variable signal to the ECU based on pressure. For the identical rail pressure...each of these sensors may send a different voltage to the ECU causing the ECU to react to an inaccurate pressure. All pressure and temperature sensors are this sort. I encourage you to speak with a custom tuner to see what they can do if you choose to covert it.

This is the older Bosch cross-reference chart for the G247. It should show you which your original is.

Thanks for the chart and info Roh Echt.

So my original sensor has the part number:
06D906051A (my engine is BWA 2006) which falls in the top area on your chart.

The orange 200 bar sensor (I fitted) is from the low part of that chart... with part number:
06J906051D

I’m guessing once I have it mapped I’ll be needing something that will read over 140bar, or will my fuel pressures not reach that high? Surely they will and that’s why everyone has to put this sensor in?

I’ll speak to the custom mapper today, last time I spoke to him he advised I didn’t need this sensor. But is he thinking I don’t need it because I’ve already got a 200 bar sensor as standard? Or will my fuel pressures reach no where near 140 bar and therefore I don’t need the sensor?


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[ROH ECHT]

I would just let him know which you have and see which he then recommends...as he will be tuning it and should have a preference to work with. As you see on the chart,, the volt range varies and will make a difference in the accuracy of the pressure report.

Mine has a 145 bar FPRV and the tune has a 140 bar max rail pressure target.

This is one note I found, but I do not know if this only relates to NA (North America) or U.S market: "For vehicles with VIN up to 1K-6-250 000"

As I said, mine is 06J906051D and: "for vehicles with VIN from 1K-7-000 001" ...mine being number-042 000 but built in May or Jun 2006 and sold as 2007 here.

[muff1991]

I spoke to him yesterday, he said it’ll be fine, so happy days for me.. I left it in once mapper up etc it won’t make a blind bit of difference.

I just wanted to know if it would be ok to drive from mine to the mapper, apparently I will be so fingers crossed all is well.

Thanks again for the advice and details.


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[muff1991]

Just to update, the car runs and drives ok with the sensor fitted (ok for a k04 built car being run by K03 software atm) but so you all know, with the different part number and higher pressured sensor.. it runs and drives. I don't drive the car daily (next drive will be to the mapper early next month).

Thought I'd share this outcome for others that may ask the same question!