Abstract: A fuel injector includes a nozzle body to be inserted into a fuel injector receiving bore along a nozzle body axis; a valve housing; and a locating pin extending from the valve housing along a locating pin axis. The locating pin axis is eccentric to the nozzle body axis. The locating pin has a width in a first direction radially relative to the nozzle body axis and through the locating pin axis and a length in a second direction perpendicular to the width such that the width is less than the length. The locating pin includes a first crush rib and a second crush rib which are diametrically opposed at the length of the locating pin and such that the first crush rib and the second crush rib plastically deform when inserted into the locating bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector includes a nozzle body configured to be inserted into a fuel injector receiving bore of the internal combustion engine along a nozzle body axis; a valve housing held in fixed relationship to the nozzle body; and a first locating pin and a second locating pin each extending from the valve housing. The first locating pin extends from a first locating pin fixed end which is fixed to the valve housing to a first locating pin free end. The second locating pin extends from a second locating pin fixed end which is fixed to the valve housing to a second locating pin free end. The first locating pin and the second locating pin elastically deform when inserted into the bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector includes a nozzle body to be inserted into a fuel injector receiving bore along a nozzle body axis; a valve housing; and a locating pin extending from the valve housing along a locating pin axis. The locating pin axis is eccentric to the nozzle body axis. The locating pin has a width in a first direction radially relative to the nozzle body axis and through the locating pin axis and a length in a second direction perpendicular to the width such that the width is less than the length. The locating pin includes a first crush rib and a second crush rib which are diametrically opposed at the length of the locating pin and such that the first crush rib and the second crush rib plastically deform when inserted into the locating bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector includes a nozzle body configured to be inserted into a fuel injector receiving bore of the internal combustion engine along a nozzle body axis; a valve housing held in fixed relationship to the nozzle body; and a first locating pin and a second locating pin each extending from the valve housing. The first locating pin extends from a first locating pin fixed end which is fixed to the valve housing to a first locating pin free end. The second locating pin extends from a second locating pin fixed end which is fixed to the valve housing to a second locating pin free end. The first locating pin and the second locating pin elastically deform when inserted into the bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector retention arrangement includes a fuel rail socket interior space defined within a fuel rail socket body along a fuel rail socket axis; a fuel injector retention groove defined on a fuel injector upper housing of a fuel injector; a first retention bore defined in the fuel rail socket body along a first retention bore axis that is substantially perpendicular to the fuel rail socket axis; a second retention bore defined in the fuel rail socket body along a second retention bore axis that is substantially perpendicular to the fuel rail socket axis; a first retention pin disposed within the first retention bore and the fuel injector retention groove; a second retention pin disposed within the second retention bore and the fuel injector retention groove; and a retention pin retaining member which retains the first and second retention pins in the first and second retention bores respectively.

Abstract: A fuel injector retention arrangement includes a fuel rail socket interior space defined within a fuel rail socket body along a fuel rail socket axis; a fuel injector retention groove defined on a fuel injector upper housing of a fuel injector; a first retention bore defined in the fuel rail socket body along a first retention bore axis that is substantially perpendicular to the fuel rail socket axis; a second retention bore defined in the fuel rail socket body along a second retention bore axis that is substantially perpendicular to the fuel rail socket axis; a first retention pin disposed within the first retention bore and the fuel injector retention groove; a second retention pin disposed within the second retention bore and the fuel injector retention groove; and a retention pin retaining member which retains the first and second retention pins in the first and second retention bores respectively.

Abstract: In a method for forming an injection molded manifold, the portion of the mold that forms a septum is modified to provide a substantially thicker septum, preferably about 8.5 mm or greater. In the molding operation, one or more removable slides are inserted through this region of the mold, each slide being preferably about 2.5 mm thick and about 30 mm wide. The septum is cast around the slides which are then withdrawn from the septum after the polymer composite is set, resulting in a septum that is substantially thicker than a prior art septum, comprising first and second plates, each about 3 mm thick, and a plurality of open core voids about 2.5 mm high and about 30 mm wide between the plates. The improved septum is stiffer than a single 4 mm thick prior art septum, has a higher natural frequency, and improves suppression of engine noise.

Abstract: A valve to shaft assembly includes a butterfly-type valve, a pair of bushings receiving the valve and holding the valve in axial position within a housing, and a shaft engaging the valve and the bushings and rotating the bushings in the housing. The bushings include features to hold the valve in position in the bore prior to assembly of the valve and, furthermore, act as rotating bearing surfaces for the valve. The valve to shaft assembly process may be simplified, especially where multiple valves are assembled to a single common drive shaft, such as in a port face charge motion control valve. Furthermore, the valve to shaft assembly provides an axial degree of freedom between valve, drive shaft, and bore, which allows the valve to float on the axis of the drive shaft, to facilitate self centering of the valve in the valve housing.

Abstract: In a method for forming an injection molded manifold, the portion of the mold that forms a septum is modified to provide a substantially thicker septum, preferably about 8.5 mm or greater. In the molding operation, one or more removable slides are inserted through this region of the mold, each slide being preferably about 2.5 mm thick and about 30 mm wide. The septum is cast around the slides which are then withdrawn from the septum after the polymer composite is set, resulting in a septum that is substantially thicker than a prior art septum, comprising first and second plates, each about 3 mm thick, and a plurality of open core voids about 2.5 mm high and about 30 mm wide between the plates. The improved septum is stiffer than a single 4 mm thick prior art septum, has a higher natural frequency, and improves suppression of engine noise.

Abstract: An improved air intake manifold for a V-style internal combustion engine comprising three individual injection molded sections joined by friction welding of flanged mating elements. Each section is formed of a high-melting temperature composite polymer. The welds are all on the exterior of the manifold. The mating surfaces are formed to be directly accessible to welding apparatus and are so oriented that friction welding may be carried out by relative motion between the components in the axial direction. When joined, the lower and middle sections form the individual air distribution runners from the plenum to the intake ports in the engine heads. The lower and middle sections are so configured that each such runner crosses the valley of the engine, providing great strength and rigidity to the module. All runners are identical, so that air flows from the plenum to the individual cylinders are substantially identical.

Abstract: An improved air intake manifold for a V-style internal combustion engine comprising three individual injection molded sections joined by friction welding of flanged mating elements. Each section is formed of a high-melting temperature composite polymer. The welds are all on the exterior of the manifold. The mating surfaces are formed to be directly accessible to welding apparatus and are so oriented that friction welding may be carried out by relative motion between the components in the axial direction. When joined, the lower and middle sections form the individual air distribution runners from the plenum to the intake ports in the engine heads. The lower and middle sections are so configured that each such runner crosses the valley of the engine, providing great strength and rigidity to the module. All runners are identical, so that air flows from the plenum to the individual cylinders are substantially identical.