Abstract: A fuel injector assembly with fluid communication cut-outs is disclosed which includes a method of forming a fuel injector that allows weld integrity evaluation between a shell and a body of the fuel injector, the fuel injector having a fuel inlet, a fuel outlet, a fuel passageway extending from the fuel inlet to the fuel outlet along a longitudinal axis, the body having an exterior surface, and the shell having an interior surface, the method including the steps of securing the shell to the exterior surface of the body, and cincturing the exterior surface of the body with the interior surface of the shell such that fluid communicates between the exterior surface of the body and the fuel passageway for particular weld integrities.

Abstract: A fuel injector with a body having an inlet portion, an outlet portion, and a fuel passageway extending from the inlet portion to the outlet portion along a longitudinal axis. An armature proximate the inlet portion of the body. A needle operatively connected to the armature. A seat is located proximate the outlet portion of the body. The seat includes a first surface, a second surface, a seat passage extending between the first surface and the second surface in the direction of the longitudinal axis, and a swirl generator formed in the first surface that communicates with the passage. A flat disk, which is located proximate the first surface, includes an aperture that guides the needle and at least one opening that communicates with the swirl generator of the seat. The flat disk combined with the seat provide a seat, swirl generator, and needle guide combination.

Abstract: A method and fuel injector for precision setting of valve lift, using a valve body shell (42) telescoped over the valve body (60), the shell (42) having a nonmagnetic extension welded to the valve body shell (42) and to the end of an inlet tube (16) providing a solenoid pole piece, with the valve body (60) and shell (42) adjusted to set the valve lift and thereafter welded together. Interference fit portions stabilize the adjusted position of the members preparatory to welding, and displaced material in a locking groove (102) creates a mechanical interlock between the valve body (60) and shell (42) to stabilize the members in their adjusted positions after welding so that the set lift is minimally affected by weld shrinkage. An external radial groove 18 allows radial bending as the weld cools to minimize axial shift of the parts and thus the effect on the set valve lift.

Abstract: Dissipation of vapor bubbles in a top-feed, solenoid-operated fuel injector is enhanced by providing the otherwise circular I.D. of the adjusting tube with at least one axially extending radial slot. Different slot patterns are disclosed.