Abstract: A fuel system has a fuel injector directly mounted with a fuel rail. The fuel rail includes a first portion and a second portion that form a body. The body has an interior surface defining a volume, an exterior surface surrounding the interior surface, and at least one aperture disposed between the interior and exterior surfaces in fluid communication with the volume. The at least one fuel injector has an inlet tube with an inside surface defining a flow path through a portion of the fuel injector and an outside surface surrounding the inside surface. The fuel injector is disposed such that the flow path is in fluid communication with the volume. A rigid connection is disposed between the interior surface of the fuel rail and at least one of the outside surface and the inside surface of the inlet tube. The rigid connection secures and hermetically seals the fuel rail with the at least one fuel injector.

Abstract: A fuel injector having a fuel inlet, a fuel outlet, and a fuel passageway extending along an axis between the fuel inlet and the fuel outlet. The fuel injector includes a body having an inlet portion, an outlet portion, and a neck portion disposed between the inlet portion and the outlet portion. An adjusting tube is disposed within the neck portion of the body. A spring is disposed within the neck portion of the body, the spring having an upstream end proximate to the adjusting tube and a downstream end opposite the upstream end. A filter and an O-ring retainer assembly are disposed proximate the upstream end. An armature having a lower portion is disposed within the neck portion of the body and displaceable along the axis relative to the body. The downstream end of the spring is disposed proximate to the armature, the spring applying a biasing force to the armature. A valve seal is substantially rigidly connected to the lower portion of the armature.

Abstract: A method for making a valve assembly is disclosed. The method includes providing a first work piece having a longitudinal axis and a first end and providing a second work piece having a surface. The method also includes disposing the first work piece and the second work piece axially between a pair of aligned elements that are relatively movable toward and away from each other along the longitudinal axis of the first work piece. Additionally, the method includes relatively moving the pair of aligned elements toward each other to axially clamp the first work piece and the second work piece and actuating the pair of aligned elements and delivering to the first work piece and the second work piece a controlled clamping force that acts to coin a zone of surface contact between the first end and the surface. Further, the method includes repeating the actuating of the pair of elements a plurality of times.