Abstract: An improved high-pressure fuel pump for a gasoline direct injection system is provided. The fuel pump includes a pump body defining a low-pressure side, a high-pressure side, and a pumping chamber therebetween. The pump body also defines a central bore and a drain port extending from the central bore to the low-pressure side. A slip-fit sleeve is clamped within the central bore, the slip-fit sleeve including upper and lower guide ribs. A plunger is moveable within the sleeve for compressing fuel within the pumping chamber. The plunger and the sleeve define a first diametral clearance, and the guide ribs and the central bore define a second diametral clearance. Fuel diverting around the upper guide rib during pumping operations can recirculate through the drain port to the low-pressure side. To accommodate thermal expansion of the sleeve, the second diametral clearance is at least 75% of the first diametral clearance.

Abstract: An improved high-pressure fuel pump for a gasoline direct injection system is provided. The fuel pump includes a pump body defining a low-pressure side, a high-pressure side, and a pumping chamber therebetween. The pump body also defines a central bore and a drain port extending from the central bore to the low-pressure side. A slip-fit sleeve is clamped within the central bore, the slip-fit sleeve including upper and lower guide ribs. A plunger is moveable within the sleeve for compressing fuel within the pumping chamber. The plunger and the sleeve define a first diametral clearance, and the guide ribs and the central bore define a second diametral clearance. Fuel diverting around the upper guide rib during pumping operations can recirculate through the drain port to the low-pressure side. To accommodate thermal expansion of the sleeve, the second diametral clearance is at least 75% of the first diametral clearance.

Abstract: A fuel pump includes a plunger which reciprocates within a bore of a housing. The plunger extends from a first end proximal to a pumping chamber to a second end distal from the pumping chamber and includes a sealing ring groove between the first end and the second end. The sealing ring groove extends from an upper shoulder proximal to the first end to a lower shoulder distal from the first end and are separated by a first distance. A sealing ring is located within the sealing ring groove and engages the bore in an interference fit. A diametric clearance greater than 12 microns and less than 30 microns is provided between the plunger and the bore such that the diametric clearance extends between the sealing ring groove and the first end for a second distance which is at least four times the first distance.

Abstract: A fuel pump includes a pump housing with a pumping chamber an inlet valve bore. An inlet valve selectively provides and prevents fluid communication between an inlet of the fuel pump and the pumping chamber. The inlet valve includes an inner housing received within the inlet valve bore such that an outer periphery of the inner housing is sealed to an inner periphery of the inlet valve bore. An outer housing circumferentially surrounds the inner housing. An annular chamber is defined radially between the inner housing and the outer housing and axially between the outer housing and the pump housing. A sealing ring is located within the annular chamber such that the sealing ring is compressed axially against the pump housing and the outer housing.

Abstract: A fuel system includes a low-pressure fuel delivery unit and a high-pressure fuel delivery unit which has a low-pressure region and a high-pressure region such that the low-pressure region supplies fuel to the high-pressure region which supplies the fuel to a plurality of high-pressure fuel injectors. A low-pressure fuel rail supplies fuel to low-pressure fuel injectors. A low-pressure fuel injector line is connected at a first end directly to the high-pressure fuel delivery unit and receives fuel from the low-pressure region and is connected at a second end directly to the low-pressure fuel rail, thereby providing fluid communication from the low-pressure region to the low-pressure fuel rail. A device is located between the low-pressure region and the low-pressure fuel rail and reduces fuel pressure pulsations.

Abstract: A fuel pump includes a pump housing with a pumping chamber an inlet valve bore. An inlet valve selectively provides and prevents fluid communication between an inlet of the fuel pump and the pumping chamber. The inlet valve includes an inner housing received within the inlet valve bore such that an outer periphery of the inner housing is sealed to an inner periphery of the inlet valve bore. An outer housing circumferentially surrounds the inner housing. An annular chamber is defined radially between the inner housing and the outer housing and axially between the outer housing and the pump housing. A sealing ring is located within the annular chamber such that the sealing ring is compressed axially against the pump housing and the outer housing.

Abstract: A fuel system includes a low-pressure fuel delivery unit and a high-pressure fuel delivery unit which has a low-pressure region and a high-pressure region such that the low-pressure region supplies fuel to the high-pressure region which supplies the fuel to a plurality of high-pressure fuel injectors. A low-pressure fuel rail supplies fuel to low-pressure fuel injectors. A low-pressure fuel injector line is connected at a first end directly to the high-pressure fuel delivery unit and receives fuel from the low-pressure region and is connected at a second end directly to the low-pressure fuel rail, thereby providing fluid communication from the low-pressure region to the low-pressure fuel rail. A device is located between the low-pressure region and the low-pressure fuel rail and reduces fuel pressure pulsations.

Abstract: A fuel pump includes a plunger which reciprocates within a bore of a housing. The plunger extends from a first end proximal to a pumping chamber to a second end distal from the pumping chamber and includes a sealing ring groove between the first end and the second end. The sealing ring groove extends from an upper shoulder proximal to the first end to a lower shoulder distal from the first end and are separated by a first distance. A sealing ring is located within the sealing ring groove and engages the bore in an interference fit. A diametric clearance greater than 12 microns and less than 30 microns is provided between the plunger and the bore such that the diametric clearance extends between the sealing ring groove and the first end for a second distance which is at least four times the first distance.

Abstract: A fuel pump includes a fuel pump housing made of stainless steel and having a pumping chamber therewithin, a plunger bore extending thereinto, an inlet passage extending thereinto, and an outlet passage extending thereinto. A pumping plunger reciprocates within the plunger bore such that an intake stroke of the pumping plunger increases volume of the pumping chamber and a compression stroke of the pumping plunger decreases volume of the pumping chamber. An outlet valve controls fuel flow from the pumping chamber out of the fuel pump housing. The outlet valve includes an outlet valve seating surface formed by the fuel pump housing within the outlet passage such that a nitrided layer extends from the outlet valve seating surface into the fuel pump housing. The outlet valve also includes an outlet valve member within the outlet passage which is moveable between a seated position and an unseated position.

Abstract: A fuel pump includes a fuel pump housing made of stainless steel and having a pumping chamber therewithin, a plunger bore extending thereinto, an inlet passage extending thereinto, and an outlet passage extending thereinto. A pumping plunger reciprocates within the plunger bore such that an intake stroke of the pumping plunger increases volume of the pumping chamber and a compression stroke of the pumping plunger decreases volume of the pumping chamber. An outlet valve controls fuel flow from the pumping chamber out of the fuel pump housing. The outlet valve includes an outlet valve seating surface formed by the fuel pump housing within the outlet passage such that a nitrided layer extends from the outlet valve seating surface into the fuel pump housing. The outlet valve also includes an outlet valve member within the outlet passage which is moveable between a seated position and an unseated position.

Abstract: A fuel system includes a low-pressure fuel delivery unit; a high-pressure fuel delivery unit which has a drive region and a delivery region such that the drive region supplies fuel to the delivery region and such that the delivery region supplies fuel to a high-pressure fuel injector; a low-pressure fuel supply passage which supplies fuel from the low-pressure fuel delivery unit to the drive region of the high-pressure fuel delivery unit; a cooling passage which receives fuel from the drive region of the high-pressure fuel delivery unit; and a low-pressure fuel injector supply passage which is in direct fluid communication with the low-pressure fuel supply passage and which supplies fuel to a low-pressure fuel injector from the cooling passage.

Abstract: A high-pressure fuel pump includes a pump housing which defines a pumping chamber, a fuel inlet which allows low-pressure fuel into the pumping chamber, a fuel outlet which allows high-pressure fuel out of the pumping chamber, and a plunger bore which extends along an axis and opens into the pumping chamber. The high-pressure fuel pump also includes a pumping plunger which reciprocates within the plunger bore along the axis such that reciprocation of the pumping plunger within the plunger bore increase and decreases a volume of the pumping chamber. The pumping plunger includes a sealing ring groove which is concentric with the plunger bore, the sealing ring groove including a sealing ring therein which engages the plunger bore in an interference fit. A diametric clearance greater than 12 microns is provided between the pumping plunger and the plunger bore.

Abstract: A fuel system includes a low-pressure fuel delivery unit; a high-pressure fuel delivery unit which has a drive region and a delivery region such that the drive region supplies fuel to the delivery region and such that the delivery region supplies fuel to a high-pressure fuel injector; a low-pressure fuel supply passage which supplies fuel from the low-pressure fuel delivery unit to the drive region of the high-pressure fuel delivery unit; a cooling passage which receives fuel from the drive region of the high-pressure fuel delivery unit; and a low-pressure fuel injector supply passage which is in direct fluid communication with the low-pressure fuel supply passage and which supplies fuel to a low-pressure fuel injector from the cooling passage.

Abstract: An anti-coking bushing assembly for sealing a pintle shaft of an EGR control valve, comprising a bushing carrier disposed in the valve body and supportive of close-fitting pintle shaft bushing liners formed of a polyimide such as Vespel. The bushing carrier and bushing liners are installed into a carbon shield extending into the exhaust flow space within the valve. Within the carbon shield, between the gas flow space and the bushing carrier, is a ring seal on the pintle shaft and a gas expansion chamber to cool exhaust gas escaping along the pintle shaft, allowing contaminants in the exhaust gas to precipitate in the gas expansion chamber. The carbon shield, ring seal, bushing carrier, and bushing liners are conveniently pre-assembled as an anti-coking bushing assembly for subsequent installation into a valve body during final valve assembly.

Abstract: An anti-coking bushing assembly for sealing a pintle shaft of an EGR control valve, comprising a bushing carrier disposed in the valve body and supportive of close-fitting pintle shaft bushing liners formed of a polyimide such as Vespel. The bushing carrier and bushing liners are installed into a carbon shield extending into the exhaust flow space within the valve. Within the carbon shield, between the gas flow space and the bushing carrier, is a ring seal on the pintle shaft and a gas expansion chamber to cool exhaust gas escaping along the pintle shaft, allowing contaminants in the exhaust gas to precipitate in the gas expansion chamber. The carbon shield, ring seal, bushing carrier, and bushing liners are conveniently pre-assembled as an anti-coking bushing assembly for subsequent installation into a valve body during final valve assembly.

Abstract: A rack and pinion gear train actuator for a pintle valve. A motor shaft has a pinion gear that engages a large reduction gear having an integral hub gear. The hub gear is a planet gear for a ring gear segment that pivots on a shaft and includes a pinion gear segment that engages a linear rack. The rack is attached to a valve pintle shaft, causing the valve to be opened and closed in response to rotation of the motor shaft. The pintle shaft, return spring, rack, and gears are all assemblable by slip fit. The actuator has a high actuation force, a fast response time, and compact design by virtue of a rack and internal gearing. The stroke of the rack may be changed for use with pintle valves having differing strokes by varying the angle through which the motor operates.

Abstract: A dual-poppet valve comprising a valve body having spaced-apart coaxial valve seats and being arranged such that first and second poppets both open into the primary chamber. A first pintle shaft engages the first poppet, and a second pintle shaft engages the second poppet. A motorized actuator having a gear transmission includes a pinion gear. The pintle shafts include opposing gear racks, and the pinion gear engages both racks. Thus, rotation of the pinion gear in a first direction causes both poppets to be lifted from their seats simultaneously, in opposite directions; and counter-rotation engages each poppet with its respective seat. In closing, one poppet engages its seat slightly before the other poppet engages the other seat. The first pintle slides through the first poppet until the second poppet is fully seated by the actuator. The force of the spring fully engages the first poppet with the first seat.

Abstract: A bearing module for a pintle valve including a pintle bearing, bearing spring, and two-part housing. The bearing has an axial face for sealing against an inner axial surface of the housing. The bearing diameter is less than the diameter of the housing, permitting the bearing to float radially. The housing fits into a port in the valve body and also extends over an axial surface of the body, thus forming a seal against the wall of the port and the surface of the body. The bearing spring, preferably a wave washer, is compressed within the housing as the two housing parts are assembled to form the module. In a currently preferred embodiment, the housing further comprises a coking shield extending along the surface of the pintle shaft within the valve port to reduce the tendency for coking gases to enter the bearing module.

Abstract: A motorized cam actuator for linear actuation of an apparatus. An actuating motor shaft is fitted with a bushing having first and second opposed flats and a threaded portion at an outer end thereof. With the motor mounted to a pedestal, the bushing is rotated on the shaft to a predetermined angular position such that assembly stack up is cancelled. The bushing is then fixed to the shaft by welding. A cam with a central opening is mounted onto the bushing, the opening having flats for mating with the flats on the bushing. The cam is mounted onto the bushing and is secured thereto by a nut. This arrangement eliminates any relative motion between the bushing and the motor shaft and prevents stress on the weld joint from reaching failure levels.

Abstract: A dual-coil outwardly-opening fuel injector including a fuel tube connected at a lower end to a lower injector housing. Within the fuel tube are a lower (opening) solenoid pole piece, a specially-formed armature, and an upper (closing) solenoid pole piece. A seat assembly including an injector nozzle, swirler, and valve seat are adjustably threaded into the lower housing. A pintle assembly, including a solid pintle portion supporting a valve head and a tubular portion welded thereto, is axially disposed within the fuel tube and is welded to the armature which is spaced from the lower pole piece by a distance equal to the opening stroke of the valve. A return spring adjustment mechanism disposed on the upper pole piece engages the upper end of the pintle assembly for varying the closing force of the return spring. Opening and closing solenoid preassemblies are mounted external to the fuel tube for magnetically engaging the pole pieces and armature within in known fashion.