Abstract: A solenoid actuated fuel injector includes an elongated ferromagnetic inlet tube having a major outside diameter portion and a reduced outside diameter portion and a step between the major and reduced outside diameter portions. A two-ended non-magnetic shell including an elongated tubular portion and a valve body shell engaging portion is fittable over the inlet tube reduced diameter portion and abuts the step in the inlet tube at one end. A coil is mountable around the elongated tubular portion of the non-magnetic shell and seated on the valve body shell engaging portion. The coil has a length shorter than the elongated tubular portion, at at least one circumferential point of the coil, allowing the inlet tube to be welded to the non-magnetic shell upon rotation relative to the coil without having to move the coil longitudinally.

Abstract: A solenoid actuated fuel injector includes an elongated ferromagnetic inlet tube having a major outside diameter portion and a reduced outside diameter portion and a step between the major and reduced outside diameter portions. A two-ended non-magnetic shell including an elongated tubular portion and a valve body shell engaging portion is fittable over the inlet tube reduced diameter portion and abuts the step in the inlet tube at one end. A coil is mountable around the elongated tubular portion of the non-magnetic shell and seated on the valve body shell engaging portion. The coil has a length shorter than the elongated tubular portion, at at least one circumferential point of the coil, allowing the inlet tube to be welded to the non-magnetic shell upon rotation relative to the coil without having to move the coil longitudinally.

Abstract: A ferromagnetic housing that encloses the electromagnetic coil to form part of the stator is fabricated from uniform thickness sheet metal to have a cylindrical neck that fits onto the ferromagnetic fuel inlet tube of a top feed fuel injector, a shoulder extending outwardly from the neck and a cylindrical body extending from the shoulder to circumferentially bound the electromagnetic coil. A single through-hole is provided in the housing to provide for passage of both electrical terminals from the electromagnetic coil.

Abstract: A clip is used to retain a bottom feed fuel injector in an injector seat cavity of a fuel rail, the clip having a pair of legs engaging the fuel rail and a bridging portion cutout to receive one side of the fuel injector to retain the fuel injector in the seat cavity. Various release devices allow convenient disengagement of the legs with fuel rail protrusions used to secure the legs in a first embodiment of the clip. The clip wraps around the fuel rail in a second embodiment.

Abstract: A non-metallic cylindrical shell is fitted to the exterior of a metallic valve body portion of a solenoid-operated fuel injector to cover otherwise exposed metal that exists between a lower O-ring seal proximate the nozzle and a non-metallic overmold that covers the solenoid and an adjoining portion of the valve body. The shell and the cover come together at a joint where they mutually axially overlap in such a manner that assures both coverage of the exposed metal and retention of the shell on the valve body for the full tolerance stack-up range of the various parts when assembled.

Abstract: The armature has a tubular wall bounding a main axial through-hole. The upper axial end has a larger outside diameter than does the lower axial end. A portion of the tubular wall lying between these upper and lower ends has a frustoconical exterior surface. A single through-hole extends through the tubular wall at this frustoconical surface to non-perpendicularly intersect the main axial through-hole. The upper end of a needle valve is inserted into the lower axial end of the main through-hole, and the two parts are joined there by welding and/or crimping. The inserted end of the needle valve does not obstruct the single through-hole extending through the tubular wall so that fuel entering the armature via the open upper end of the main through-hole will change direction to pass out of the armature through the single through-hole in the tubular wall.

Abstract: A non-ferromagnetic member is disposed between, and joined to, a ferromagnetic fuel inlet tube and a ferromagnetic valve body structure. The valve body structure is fitted to the non-ferromagnetic member by telescoping the upper axial end of the valve body structure over the O.D. of the lower end of the non-ferromagnetic member and by guiding the armature on a cylindrical guide surface in a bore of the valve body structure at a location that is axially below the axial location where the upper end of the valve body structure and the lower end of the non-ferromagnetic member telescopically engage. For given part tolerances and given tolerances in tooling that is used to assemble the parts, closer tolerance in parallelism of the impacting armature end surface to the impacted fuel inlet tube end surface is obtained.

Abstract: When the overall diameter of a solenoid-operated fuel injector is reduced, sections of a pair of electric terminals that are circumferentially spaced apart about, and embedded in an end wall of a bobbin of, an electromagnetic coil assembly of the fuel injector are disposed such that their rectangular transverse cross sections are disposed at an angled relation to each other to provide greater clearance to any electrically conductive parts of the fuel injector in the immediate vicinity. Other sections of the terminals that form blades of standard-sized rectangular transverse cross section for connection to terminals of a mating connector leading to an electric control circuit for operating the fuel injector are in non-angled relationship so that the mating connector and its component parts can remain of standardized dimensions.

Abstract: A non-metallic overmold covers the solenoid and an adjoining portion of a valve body shell, leaving another portion of the valve body shell exposed. This exposed portion contains a circumferential groove in its outside surface that is held by a portion of a mold that molds the cover. This prevents the inside surface of the valve body shell from having to be contacted.

Abstract: The fuel inlet tube of a top-feed fuel injector has a larger O.D. proximate its inlet end than it does at its opposite end where a tubular non-ferromagnetic part is laser-welded to it. The through-hole in the coil's bobbin has a smaller diameter portion and a larger diameter portion, the larger diameter portion being disposed closer to the fuel inlet tube's inlet than is the smaller diameter portion. The larger diameter portion of the bobbin's through-hole and the smaller outside diameter portion of the fuel inlet tube are mutually axially overlapping to an extent that, during the fabrication process, the coil assembly can be disposed axially on the fuel inlet tube to a position allowing the laser-welding to be performed, and thereafter the coil assembly disposed to cover the laser-welded joint.

Abstract: The silicon sensing element of a mass airflow sensor is shielded from direct impact by large dust particles by means of a plastic deflector that is disposed in spaced upstream relationship to the entrance of a by-pass venturi containing the sensor. The deflector is supported on a mesh screen and is arranged such that air can enter the by-pass venturi after having passed by and behind the deflector. In another embodiment the deflector is an airfoil that is part of a probe assembly containing the sensing element.

Abstract: The sensor comprises a silicon sensing element on a ceramic substrate. A slot is provided in the substrate just ahead of the leading edge of the silicon so that some of the airflow that is flowing toward the leading edge surface of the silicon passes through the slot. This promotes a less turbulent flow over the sensing face of the silicon.