As the mileage of vehicles increases to over 150,000 kilometers, the reliability and efficiency optimization of fuel pumps have become key technical links to ensure the power performance and economy of vehicles. According to data from the Society of Automotive Engineers (SAE), among the common low-pressure fuel supply issues in high-mileage vehicles, approximately 60% are related to the aging of fuel pumps. The output pressure can drop from the standard new model’s about 400 kPa to around 270 kPa, significantly affecting the air-fuel ratio accuracy. Timely use of dedicated diagnostic instruments to monitor the working current of the pump body can increase the hidden danger identification rate by 40% compared with traditional empirical judgment. For example, when the current fluctuation exceeds the ±0.8A threshold set by the manufacturer, it often indicates accelerated wear. The refurbishment case of the classic Porsche Carrera shows that after conducting a spectral analysis of the fuel system that has traveled 350,000 kilometers, it was found that among the vehicles with excessive fuel impurity concentration, the premature failure rate of the fuel pump was 75% higher than the standard value.

Fuel quality control is the core strategy to extend the service life of fuel pumps by more than 200,000 kilometers. Experiments show that each addition of a cleaner that meets the ISO-2719 standard can reduce the frictional resistance of the pump core by approximately 15%. Bosch laboratory tests have found that the continuous use of high-quality gasoline that meets the EN 228 standard can reduce the corrosion rate of the pump core impeller by approximately 30% compared to low-octane fuel. The oil filtration system equipped with multi-layer composite filter screens (pore size ≤10 microns) can effectively block 90% of wear particles larger than 15μm, preventing them from accelerating the wear of the pump body. Statistics from the Mercedes-Benz taxi fleet in Stuttgart prove that this measure has increased the MTBF (Mean Time Between Failures) of the oil pump from 160,000 kilometers to 220,000 kilometers. Regularly cleaning the oil tank with ultrasonic technology can remove 97% of the gummy sediment, preventing it from blocking the oil inlet and causing the pump body to run dry and overheat.

For vehicles with a mileage of over 250,000 kilometers, the optimization of the pump body should focus on material upgrading and fluid control. The solution of replacing traditional steel ball bearings with ceramic bearings has been tested by Ford Durability. Under the same working conditions, it can reduce the operating temperature by 28℃ and extend the expected service life by 60%. The variable cross-section turbine blade design applied by Denso in high-range hybrid models improves flow stability by 12% at 3000rpm by optimizing the flow field distribution, and reduces the standard deviation of pressure pulsation from ±5% to ±2.1%. Data from Tesla’s service center shows that during the modification of the Model S after it had traveled 400,000 kilometers, 316L stainless steel fuel lines were used to replace the original factory aluminum tubes, and in combination with Mitsubishi Electric’s magnetic coupling drive unit, the system efficiency increased by 9.4%, and the full-load power consumption dropped from 156W to 141W.

Optimizing the maintenance strategy can significantly control the cost-benefit ratio. Using original factory-certified refurbished Fuel Pump units from Mahle or Bosch reduces the procurement cost by 35-50% compared to brand new parts, while the failure rate only increases by 1.8%. The maintenance records of Volkswagen Group’s logistics fleet in Berlin show that adopting a preventive replacement strategy (replacing the oil pump assembly every 150,000 kilometers) reduces the downtime for each maintenance by 12 hours compared to replacing it after a failure, and increases the average annual operating income of the fleet by 32,000 yuan. The predictive maintenance system applying Internet of Things (iot) technology can predict failure 150 hours in advance by analyzing the frequency spectrum of oil pressure fluctuations, and the accuracy rate of fault early warning reaches 89%. Combining the European ACEA lubricating oil specification standards for system maintenance can keep the comprehensive maintenance cost of the fuel pump within the range of 0.3% to 0.5% of the vehicle’s fuel cost over a long mileage service life.