Abstract: Methods of swaging fuel injector pump components are provided. A method of securing an armature plate to a control valve of a solenoid-actuated fuel injector pump comprises: (1) providing a control valve stem extending from the control valve, the stem having a body with a body width, a head with a head width narrower than the body width, and a neck with a neck width narrower than the head width, the neck forming an annular groove between the head and body; (2) providing a central aperture formed in the armature plate having an aperture width between the head and body widths; and (3) forcing the stem into the central aperture in a manner to cause a portion of the armature plate to deform into the groove to secure the armature plate to the stem.

Abstract: A solenoid stator assembly for electronically actuated fuel injectors is disclosed as having an E-shaped stator core including a top portion and three parallel pole pieces extending orthogonally therefrom. The outer pole pieces each have an outermost side, and each of the three pole pieces has a distal end, a face being formed across the distal end. Each of the outer pole pieces has an attachment slot formed across its outermost side proximate its distal end. A coil of electric wire is disposed around an insulating spool disposed on the central pole piece, and leads from the coil are connected to terminals. A flange on one end of the spool exerts outward forces on the outer pole pieces, prestressing them to resist further flexing caused by outwardly directed forces applied by errant fuel under pressure. An insulating cover is molded around the solenoid stator assembly, enveloping it except for portions of the terminals and the faces of the pole pieces, the cover being bonded to at least the stator core.

Abstract: A common rail fuel system is described which consists primarily of a high-pressure fuel pump, nozzles and a rail or rails having a substantially constant rail pressure situated between the fuel pump and the nozzles, the necessary connecting fuel lines and electronic control system. The pump is constructed to add leakage fuel to each stroke output without the necessity for routing this leakage fuel through the primary supply. This reduces the total amount of fuel pumped and improves metering accuracy.