Upgrade your 4.0 TFSI V8 engine with the Endura Motorsport HPFP Piston upgrade kit – specially developed for the 4.0 TFSI engine, where the standard high-pressure fuel pump becomes the limiting factor in serious tuning builds. This kit replaces the original pistons in the existing pumps and increases fuel capacity by up to 50% compared to OEM.
Featuring an enlarged 11.6 mm piston and DLC coating, the kit delivers significantly higher fuel pressure and flow – essential when using E85, racing fuel or an aggressive petrol tune. The precision-machined components, manufactured to aerospace tolerances, ensure a perfect fit within the original OEM housing. The included fuel pump tool makes installation quick and safe.
Benefits
-
Up to 50% higher fuel flow
compared to OEM
- Increased fuel pressure thanks to a larger piston (from 10.0 mm to 11.6 mm)
-
Reliably tested up to 300+ bar
and 8,500 RPM
-
Perfect fit
– designed for the original OEM HPFP housing
-
DLC coating
reduces wear, friction and corrosion for a longer service life
-
Precision-machined
to aerospace tolerances for ultimate accuracy
-
Perfectly matched piston and cylinder
for consistent fuel pressure
-
Compatible with E85 and racing fuel
- Includes fuel pump tool for easy installation
- No permanent modifications to the casing required
Technical specifications
-
Standard piston diameter:
10.0 mm
-
Coating:
DLC (Diamond-Like Carbon) – reduces wear, friction and corrosion
-
Maximum operating pressure:
tested to 300+ bar
-
Tested up to:
8,500 RPM
-
Fuel flow:
up to 50% higher than OEM
-
Fit:
designed for original OEM HPFP housing
-
Application:
essential upgrade for Stage 2+ and Stage 3 setups
-
Warranty:
12 months
Compatibility
This HPFP piston upgrade kit is suitable for the 4.0 TFSI models:
Not suitable for: engines outside the 4.0 TFSI platform or standard vehicles without tuning.
Please note
-
ECU tuning is mandatory
after fitting – without modified software, the additional capacity will not be utilised.
- For maximum performance, particularly when using E85, an upgrade of the entire fuel system is recommended.
- This is an upgrade kit for fitting into existing pumps – not a complete replacement pump.
- Fitting requires experience – installation by a specialist is recommended.
Contents
-
2x HPFP piston upgrade kit
– set of matched pistons and cylinders (for both pumps)
-
1x fuel pump tool
for fitting
- Installation instructions
Frequently asked questions
Is tuning mandatory?
Yes, an ECU recalibration is necessary to safely utilise the higher flow rate. This applies to both petrol and E85.
What is the difference compared to the complete HPFP set?
This kit only replaces the internal components (piston + cylinder) of the existing pumps. The complete HPFP set consists of two fully pre-assembled pumps based on the original Hitachi design – ideal if you do not wish to convert the pumps yourself.
What is the difference in piston diameter?
The standard OEM piston has a diameter of 10.0 mm. The Endura upgrade piston measures 11.6 mm, which provides significantly higher fuel pressure and up to 50% greater flow rate.
Can I fit this myself?
The fuel pump tool supplied makes fitting easier, but due to the precision required for the HPFP, we recommend installation by an experienced mechanic.
Is this suitable for E85?
Yes, the upgrade kit supports the higher fuel demand of ethanol set-ups. The greatest benefit is achieved when using E85 in combination with the correct ECU tune.
Can I still run on regular petrol after the upgrade?
Yes, even when using regular petrol, the upgrade delivers benefits in terms of increased power. However, E85 makes the most of the increased capacity.
