Upgrade your 4.0 TFSI V8 engine with the Endura Motorsport HPFP Piston Upgrade Kit – specially developed for the 4.0 TFSI block, 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 the fuel capacity by up to 50% compared to OEM.

With 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 parts with aerospace tolerances ensure a perfect fit in the original OEM housing. The included fuel pump tool makes assembly quick and safe.

Advantages

• Up to 50% higher fuel throughput compared to OEM
• Increased fuel pressure thanks to 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 milled with aerospace tolerances for ultimate accuracy
• Perfectly matched piston and cylinder for consistent fuel pressure
• Compatible with E85 and racing fuel
• Inclusive fuel pump tool for easy mounting
• No permanent modifications to the housing are necessary

Technical specifications

• Standard piston diameter: 10.0 mm
• Piston diameter upgrade: 11.6 mm
• Coating: DLC (Diamond-Like Carbon) – reduces wear, friction, and corrosion
• Maximum workload: Tested at 300+ bar
• Tested to: 8,500 RPM
• Fuel flow: up to 50% higher compared to OEM
• Passing: 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.

NB

• ECU tuning is mandatory after installation – without modified software, the extra capacity is not utilized.
• For maximum performance, especially at E85, an upgrade of the entire fuel system is recommended.
• This is a upgrade kit for the existing pumps – no complete replacement pump.
• Assembly 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 mounting

Frequently Asked Questions

Is tuning mandatory?
Yes, one ECU recalibration is necessary to safely utilize the higher flow. This applies when using both petrol and E85.

What is the difference compared to the complete HPFP set?
This kit only replaces the internal parts (piston + cylinder) of the existing pumps. The complete HPFP set consists of two fully pre-assembled pumps based on the original Hitachi – ideal if you do not want 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 ensures significantly higher fuel pressure and up to 50% more throughput.

Can I install this myself?
The included fuel pump tool makes assembly easier, but due to the precision of the HPFP, we recommend installation by a experienced mechanic On.

Is this suitable for E85?
Yes, the upgrade kit supports the higher fuel demand of ethanol setups. The greatest gains are achieved with E85 use in combination with the correct ECU tune.

Can I also drive on regular petrol after the upgrade?
Yes, even when using regular petrol, the upgrade delivers benefits at higher power outputs. However, E85 gets the most out of the increased capacity.