Abstract: A top feed fuel injector for an internal combustion engine includes a housing; a fuel passage within the housing; an electrically controlled valve mechanism for controlling fuel flow through the fuel passage; and a radially extending protrusion on the housing, the radially extending protrusion configured to mate with a void in a manifold or head in which the fuel injector is inserted such that the fuel injector maintains its orientation with respect to the manifold or head. Another aspect of the invention is a top feed fuel injector for an internal combustion engine including a housing; a fuel passage within the housing; and an electrically controlled valve mechanism for controlling fuel flow through the fuel passage; wherein the housing defines a radially inwardly extending opening, the radially inwardly extending opening configured to mate with a protrusion on a manifold or head in which the fuel injector is inserted such that the fuel injector maintains its orientation with respect to the manifold or head.

Abstract: A manifold for a fuel injected engine has several fuel injectors that are connected to a common air assist passageway for each bank of cylinders. This passageway is preferably supplied with assist air from a central location, between two of the fuel injector pockets that intersect the air assist passageway in each bank of cylinders. This air assist passageway may be formed integral with a manifold, or may be separately formed together with the injector pockets as an air assist rail. The air assist passageway preferably intersects the center line of the fuel injector pockets and is formed by inserting pins that define the interior surface of the passageway into a mold cavity to intersect and pass through bosses that define the fuel injector pockets.

Abstract: A fuel rail for a non-return fuel injection system and a method of breaking-up pressure pulsations in the fuel rail. The fuel rail comprises an inlet, at least one first outlet, and a first tube providing fluid communication between the inlet and the at least one outlet. The inlet is adapted for fluid communication with a source of pressurized fuel. Each at least one first outlet is adapted for fluid communication with a respective fuel injector. The first tube extends along a first axis and includes a first portion and a second portion. The first portion extends a first length along the first axis and has a first cross-sectional shape transverse to the first axis. The second portion extends a second length along the first axis and has a second cross-sectional shape transverse to the first axis. The second cross-sectional shape has a first indentation toward the first axis, and the first indentation disrupts pressure pulsations propagating through the first tube.

Abstract: A top feed fuel injector for an internal combustion engine includes a housing; a fuel passage within the housing; an electrically controlled valve mechanism for controlling fuel flow through the fuel passage; and a radially extending protrusion on the housing, the radially extending protrusion configured to mate with a void in a manifold or head in which the fuel injector is inserted such that the fuel injector maintains its orientation with respect to the manifold or head. Another aspect of the invention is a top feed fuel injector for an internal combustion engine including a housing; a fuel passage within the housing; and an electrically controlled valve mechanism for controlling fuel flow through the fuel passage; wherein the housing defines a radially inwardly extending opening, the radially inwardly extending opening configured to mate with a protrusion on a manifold or head in which the fuel injector is inserted such that the fuel injector maintains its orientation with respect to the manifold or head.

Abstract: A top feed fuel injector for an internal combustion engine includes a housing; a fuel passage within the housing; an electrically controlled valve mechanism for controlling fuel flow through the fuel passage; and a radially extending protrusion on the housing, the radially extending protrusion configured to mate with a void in a manifold or head in which the fuel injector is inserted such that the fuel injector maintains its orientation with respect to the manifold or head. Another aspect of the invention is a top feed fuel injector for an internal combustion engine including a housing; a fuel passage within the housing; and an electrically controlled valve mechanism for controlling fuel flow through the fuel passage; wherein the housing defines a radially inwardly extending opening, the radially inwardly extending opening configured to mate with a protrusion on a manifold or head in which the fuel injector is inserted such that the fuel injector maintains its orientation with respect to the manifold or head.

Abstract: A method of making air assist passageways and injector pockets in a manifold or air assist rail includes providing a mold that can open and close with several bosses extending from an inside surface. These bosses are arranged in a row and define the inside of the injector pockets when the mold is filled. The air assist passageway that couples the fuel injector pockets is provided by inserting a long pin that passes through the row of injector pocket bosses inside the mold cavity. When the cavity is filled with molten material and solidifies, the pin is withdrawn, leaving a long air assist passageway extending between the injector pockets. The mold is then opened, pulling the injector pocket bosses out of the now-formed injector pockets. The resulting structure is a row of injector pockets in a manifold or air assist rail into which injectors can be inserted, that are connected by a long air assist passageway.

Abstract: An air assist fuel injector wherein a shroud member is snapped on the outside of the valve body to provide a path for assist air to atomize the fuel exiting the injector. Located on the bottom surface of the shroud is a belleville washer to preload air deflection disks against the bottom of the valve body. Snap-on connectors cooperate with the valve body to locate and retain the shroud to the valve body.

Abstract: A shroud member for converting an extending tip fuel injector into an air assist fuel injector wherein the air metering is performed at a distance remote from the O-ring seals holding the injector into the engine manifold.