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An innovative diesel injection pump was created, and during the testing of the initial prototypes, the performance of the prototypes was incongruent to expectations. To investigate this, each prototype was fully measured and converted into a digital twin in the Amesim system simulation software. With the virtual prototypes at hand, their hydraulic performance was simulated under the same conditions of the physical tests. The models from each prototype could explain why they presented inconsistent results. A full factorial DOE was created to evaluate the most significant geometric contributors. Then, three design proposals were evaluated and two designs were discarded with these results. A sensitivity study was conducted for the original design and the best design achieved. Design improvements to the valve were suggested using these results. Finally, new prototypes were produced according to the new design, they were tested and measured and again converted into a digital twin. The models presented the same performance as the measurements, being considered validated. Both the nominal design as well the digital twins of the prototype presented results within the targeted performance of the design, so the issue was considered solved.