Hello,

Does anyone know what maximum rail pressure stock k03/k04 engines injectors can handle? When they will stop opening due to too high pressure?

Im chasing some issues with my fuel system on a 2.0 tfsi BWA + 200 bar rail sensor + 190 bar rail valve. Currently im requesting 165 bar of rail pressure, my actual pressure follows it, but as soon as I get past let's say 145 bar Im hitting a wall with fueling:
- Lambda goes to 1.99
- Injection time get's longer
- Lambda correction +25%
- Engine stalls completly

So Im assuming either my injector's are not opening at all, or Im having some issues with calibrating my rail valve (I don't know what it could be).

Are you guys adjusting anything specific regarding that upgraded rail valve besides normal stuff like:
KFPRSOLHKS
KFPRSOLHMM
KFPRSOLHOM
KFPRSOLKH
KFPRSOLOFF
KFPRSOLSCH
KLLFPRSG
KLPRMAX
VHDP
RQUAHDPK
SKHDPMX
PGBDVHDO
KLPROV
PRNL1

Check your injectors. Can be a faulty injector.

Hi guys,
someone solved it this problem ?

I have same problem with similar HW, 2.0 tfsi BWA + 200 bar rail sensor + 165 bar rail valve + RE3 injectors + VIS hpfp and more.
All maps recalibrated and same problem, until 140bar clear run and over 145bar lambda goes to 1.99 and lambda correction +25%, engine jerks and not run up.

I always change more maps. For example..

165 rail valve:
PRMXNL 19 bar
PRNOESAB 20 bar

and more...

It's either your injectors going static (seen this before but not at 145 bar) or the PRV going wide open and leaving the injector right in front of it with no fuel.