Fuel Injector Maintenance and Overhaul

The key component that converts your engine’s fuel into energy most efficiently is the fuel injector. Over time, carbon build-up, wear on internal parts, and pressure losses degrade the injector’s spray quality. This situation directly leads to increased fuel consumption, reduced engine power, elevated emission values, and can even cause severe damage to main components like cylinders and pistons. At İntermak, we use state-of-the-art testing and repair equipment to recondition your fuel injectors to perform at factory standards.

• Assessment and Disassembly: The process begins by connecting the injectors that arrive at our workshop to a special test bench. In this initial test, critical performance values such as the injector’s current opening pressure, spray pattern (atomization), sealing (leak-tightness), and dribbling are measured to pre-diagnose the fault condition. Following the assessment, the injector is carefully disassembled, with each part meticulously labeled to prevent damage to its high-precision components.
• Analysis and Component Inspection: All disassembled injector parts are meticulously cleaned in ultrasonic baths to remove carbon and other residues. After cleaning, the most critical parts—the injector nozzle and needle—are subjected to a detailed inspection under a microscope for wear, corrosion, and cracks. All other parts (springs, shims, etc.) are also checked with precision measuring tools for compliance with manufacturer tolerances, and any parts needing replacement are clearly reported.
• Repair and Assembly: Based on the analysis, the surfaces of repairable parts are restored to their original smoothness and sealing capability using special lapping pastes. All critical parts that are worn or have reached the end of their service life, such as the injector nozzle, needle, and sealing elements, are replaced with 100% original or OEM-quality spare parts. The assembly process is carried out in a dust-free, clean-room environment, adhering to manufacturer procedures, with the awareness that even the smallest foreign particle can affect performance.