Fuel Pump Overhaul and Timing Adjustments

The Power to the Engine's Heart: Precision Fuel Pump Overhaul and Synchronization

The high-pressure fuel pump, the heart of the fuel injection system, directly affects your engine’s power, efficiency, and health. This precision mechanical unit is responsible for delivering the correct amount of fuel, at the right pressure, and most importantly, at the exact right time in the piston’s cycle. Over time, worn pump elements (plunger & barrel) and incorrect timing adjustments can lead to insufficient engine power, increased fuel consumption, high exhaust temperatures, and even severe mechanical damage such as knocking. At İntermak, we perform both the mechanical overhaul of your fuel pumps and their critical synchronization with the engine with the highest precision.

Assessment and Disassembly: The process begins by examining the fuel pump’s performance and timing settings on the engine. When necessary, the pump is brought to our workshop and systematically disassembled. Each critical component, such as plunger-barrel sets, delivery valves, springs, and the camshaft, is carefully removed, labeled, and prepared for detailed inspection in accordance with manufacturer procedures.
Analysis and Component Inspection: After being meticulously cleaned in ultrasonic baths, all disassembled parts are subjected to a detailed analysis by our expert technicians. The plunger and barrel surfaces are inspected under a microscope and with precision measuring tools for scratches, wear, and corrosion. The operating clearance between these two parts is measured with extreme care, as it is the most critical factor in the pump’s ability to generate pressure. The sealing of the delivery valves and the camshaft surfaces are also inspected with the same precision.
Repair and Assembly: Based on the analysis, all parts that have out-of-tolerance wear or have lost their structural integrity, especially the plunger & barrel sets and delivery valves, are replaced with 100% original or OEM-quality spare parts. The assembly is carried out with great care in a dust-free environment, appropriate for the pump’s sensitive nature, ensuring all clearances and torque values are in full compliance with manufacturer data.

Testing and Delivery: Before being installed on the engine, the overhauled fuel pump is connected to a special test bench. On this stand, critical performance values such as the pump’s fuel delivery quantity, pressure stability, and internal sealing are measured and calibrated under various speed and load scenarios. After the pump successfully passes these tests, it is mounted on the engine, and the most critical phase, the timing adjustment, is performed. Our expert team uses specialized equipment to ensure the injection is perfectly synchronized with the piston’s position, guaranteeing the engine operates at its most efficient and safest.
Comprehensive Reporting: At the end of the process, a two-stage report is presented to the customer. The Overhaul Report details all procedures performed on the pump, the list of replaced parts, and the calibration data obtained from the test bench. The Timing Report documents that the final timing adjustment made on the engine is set precisely to the specific values designated by the manufacturer. This holistic reporting provides a complete assurance for the health and performance of your fuel system.

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for Critical Failures