Abstract: A fuel assembly is provided. The fuel assembly includes a fuel supply conduit, an air intake manifold, a fuel injector, and a spacer. The air intake manifold is disposed a predetermined distance from the fuel supply conduit. The fuel injector has a first end disposed in the fuel supply conduit and a second end disposed in the air intake manifold. The fuel injector has a length greater than the predetermined distance. The spacer is disposed about a portion of the fuel injector such that the spacer retains the first end of the fuel injector in the fuel supply conduit and the second end of the fuel injector in the air intake manifold. Methods of installing and removing the fuel injector into and from the fuel supply conduit and the air intake manifold are also provided.

Abstract: A fuel injector assembly for mounting a fuel injector to a fuel rail and permitting alignment of the fuel injector with an engine head. The assembly includes a cup having an upper portion and a lower portion, the upper portion being connected to a fuel rail, the lower portion including an interior, an exterior, and a lower surface. The fuel injector has an inlet, an outlet, and a fuel passageway extending from the inlet to the outlet, the inlet being disposed within the interior of the cup. A collar can be disposed proximate the lower surface of the cup, the collar cincturing the inlet of the fuel injector. A ring cinctures the inlet of the fuel injector. A fastener is secured to the exterior of the cup such that the ring establishes an interference fit between the collar and the inlet of the fuel injector.

Abstract: A fuel supply assembly includes an electrically actuatable fuel injector having a first end, a longitudinal axis, and a fuel channel extending generally along the longitudinal axis. The fuel injector also includes a dielectric overmold including first and second electrical contact rings disposed about an outer perimeter of the overmold. The dielectric overmold extends downstream of the first end. The assembly also includes a dielectric connector shell generally surrounding at least part of the overmold. The assembly also includes an injector cup disposed over the fuel injector upstream of the overmold between the fuel injector and the connector shell. The injector cup includes a first end, a second end juxtaposed from the first end, and a generally longitudinal cup channel extending from the first end toward the second end. The longitudinal channel is in fluid communication with the fuel channel. Methods of installing and removing the assembly are also provided.

Abstract: A fuel supply assembly is disclosed. The assembly includes an electrically actuatable fuel injector having a first end, a longitudinal axis, and a fuel channel extending generally along the longitudinal axis. The fuel injector also includes a dielectric overmold including first and second electrical contact rings disposed about an outer perimeter of the overmold. The dielectric overmold extends downstream of the first end. The assembly also includes a dielectric connector shell generally surrounding at least part of the overmold. The connector assembly has an outer perimeter and a first electrical contact extending generally longitudinally proximal to the outer perimeter. The first electrical contact has a first contact end extends outward from the longitudinal axis and a second contact end electrically engaging the first electrical contact ring. The assembly also includes an injector cup disposed over fuel injector upstream of the overmold between the fuel injector and the connector shell.

Abstract: A fuel injector assembly for mounting a fuel injector to a fuel rail and permitting alignment of the fuel injector with an engine head. The assembly includes a cup having an upper portion and a lower portion, the upper portion being connected to a fuel rail, the lower portion including an interior, an exterior, and a lower surface. The fuel injector has an inlet, an outlet, and a fuel passageway extending from the inlet to the outlet, the inlet being disposed within the interior of the cup. A collar can be disposed proximate the lower surface of the cup, the collar cincturing the inlet of the fuel injector. A ring cinctures the inlet of the fuel injector. A fastener is secured to the exterior of the cup such that the ring establishes an interference fit between the collar and the inlet of the fuel injector.

Abstract: A high pressure direct injection fuel system includes a low pressure fuel supply; a venturi pump including a variable orifice, first and second inlets and an outlet, the low pressure fuel supply connected to the first inlet of the venturi pump; a high pressure pump connected to the outlet of the venturi pump; a fuel rail connected to an outlet of the high pressure pump, the fuel rail including at least one fuel injector and a pressure sensor; a high pressure regulator connected to the fuel rail; a return flow line connected between the fuel rail and the second inlet of the venturi pump; and an electronic control unit connected to the pressure sensor and the high pressure regulator. The variable orifice venturi pump suppresses gas formation in the return fuel flow thereby allowing the use of a lower fuel supply pressure.

Abstract: A clip retention arrangement for a fuel injector inserted in a fuel rail seat, in which a U-shaped clip has tabs engaging an injector groove and also has slots captured on ears projecting from opposite sides of the socket. Each of the ears are configured to engage their associated slot to restrain relative rotation and to assist in properly orienting the fuel injector in the seat.

Abstract: A fuel injector includes a housing having a differential piston surrounded by a coil, the differential piston carrying and surrounding an armature carrying a needle valve element. The valve seat for the needle valve is carried for movement with the differential piston. An air chamber in the injector housing communicates with the intake manifold and a fuel inlet to the fuel injector includes a check valve. At the beginning of the combustion chamber intake stroke, the differential piston is moved by a spring toward the combustion chamber, enabling the check valve to open and fuel to enter the injector fuel passages. Upon increasing pressure within the combustion chamber on the compression stroke, the differential piston is displaced to pressurize the fuel in the injector. Near the top of the compression stroke, the coil is energized and the fuel control valve is opened to inject pressurized fuel into the combustion chamber. Upon deenergization, the fuel control valve closes.

Abstract: A spring clip includes a first portion including a bridge connecting spaced elongate fingers adapted to straddle a body portion of the fuel injector and be receivable in a receiving portion of a fuel rail cup. The elongate fingers include a reverse bend at a midpoint therealong and terminate in a bridging portion. The bent elongate fingers define finger segments on each side of the reverse bend. The finger segments diverge from the reverse bend part way toward the bridge and bridging portions and converge thereafter to form generally diamond shaped spring elements. A second portion of a generally planar shape having spaced legs engages slots in the injector body. The second portion includes a wall portion extending generally perpendicular to the spaced legs and connects with the bridging portion. When the injector is mounted in the fuel rail cup, the legs are received in slots in the injector body and the elongate finger segments are compressed between the fuel rail cup and the injector body.

Abstract: A fuel rail damper for use within the fuel rail of an internal combustion engine includes a flexible tubular diaphragm which extends along the center of the fuel rail. The distal end of the tubular diaphragm is closed and the proximal end of the tubular diaphragm is open and connected to a diagnostic fitting at one end of the fuel rail. This fitting includes a diagnostic valve core and a cap which permit external servicing. The diagnostic fitting is removable which permits the fitting to be easily installed or removed, thus facilitating replacement of the fitting, if necessary. The diagnostic fitting is sealed after the tubular diaphragm is pressurized to a pressure below the operating pressure within the fuel rail.

Abstract: A damper device has a sealed damper chamber defined by a flexible diaphragm and an upper cap. The damper chamber is filled with a pressurizing agent that creates a pressurized condition in the damper chamber by a phase transformation to the gaseous state from a solid or liquid state. To form the pressurized damper, the pressurizing agent is placed in the upper cap of the damper chamber in a solid or liquid state. The diaphragm is then positioned across the opening of the upper case and sealed in position, as for example by crimping the edges of the diaphragm between the upper cup and the lower base of the damper. As the solid or liquid pressurizing agent transforms to a gas, the pressure in the damper chamber increases to a predetermined level.

Abstract: An arrangement and method for recirculating highly pressurized fuel from a fuel rail back to a high pressure pump inlet in which a fuel outflow is controllably allowed from the fuel rail into a nozzle to form a high pressure stream of fuel directed into a port connected to the inlet of the high pressure pump and a flow of fuel from a low pressure supply pump is merged into the stream by a surrounding annular flow pattern. This uses the energy of high pressure fuel to increase the pressure at the inlet of the high pressure pump and greatly reduces the tendency for the fuel vapor to form.

Abstract: A spring clip for retaining together a fuel injector and a fuel rail cup includes first and second parallel spaced side walls and a third side wall resiliently connecting the first and second side walls to form a generally U-shaped body with an open side. The first and second parallel spaced side walls include flanges extending inwardly toward one another from opposed lower edges of the side walls. The flanges are configured to coact with an exterior surface of an associated fuel injector to locate the injector axially relative to the clip. The first and second parallel spaced side walls also include slots arranged to receive a flanged portion of the fuel rail cup such that the clip is located axially relative to the cup, thereby locating said injector axially relative to said cup. An aperture in the third side wall receives both a radially protruding orientation key of the injector and a corresponding orientation key of the fuel rail cup to fix the injector against rotational motion in the cup.

Abstract: A fuel system is provided for supplying a second fuel different from a first supplied fuel substantially simultaneously to a plurality of injectors. In one form, an inner tube within an outer housing has a plurality of openings spaced from inlets to the fuel injectors for supplying the second fuel substantially simultaneously to each of the injectors, the number of outlets being less than the number of inlets. In a second form, the inner tube within the housing has a plurality of differently sized orifices increasing in size with increasing distance relative to the fuel inlet to the inner tube for supplying fuel substantially simultaneously to fuel injectors in registration with the orifices. In a further form, multiple inner tubes are used.

Abstract: An air assist atomizer is used for obtaining a desired air flow through a fuel injector, the fuel injector having an injector valve stem, and the injector valve stem movable over a displacement. The air assist atomizer has an air passage via which atomizing air enters and a fuel passage via which atomized fuel exits. An injector seat is mounted on a spring for holding the injector seat to the injector valve stem over the displacement. The injector seat is allowed to travel part of the displacement of the injector valve stem, whereby when the injector seat moves, the air passage is opened allowing bypass air to atomize the fuel. A mechanical stop is provided for halting movement of the injector seat, while the injector valve stem moves the remaining distance of the displacement, opening up the fuel passage.

Abstract: A fuel rail has a series of contact strips extending along each side of a molded plastic inner fuel rail, each contact strip having a hook shaped end engaging a contact pocket in a fuel injector to establish an electrical connection. Oppositely located pairs of hook ends retain each fuel injector within a seat in the fuel rail. An overmold over the fuel rail encloses the inner fuel rail and the contact strips, and is formed with openings, each receiving an injector which is hermetically sealed therein.

Abstract: A fuel rail including an electrical strip is utilized to electrically couple fuel injectors to an external electrical connector situated on an outside surface of the fuel rail. The fuel rail is preferably made from plastic and includes injector cups situated in fuel injector attachments for mechanically receiving the fuel injectors. The fuel injectors are electrically and mechanically coupled to the fuel rail by an upward mechanical motion. The fuel injectors include clip-like electrical connectors which receive connector fingers of the electrical strip which are disposed in the injector cups. The fuel rail was preferably molded in a manifold.

Abstract: A fuel rail assembly is disclosed with internal electrical connectors for the solenoids of each fuel injector, the fuel injectors having pin contacts inserted into a connector seated in a recess formed in an internal wall of the fuel rail. A common external connector allows the electrical leads from the internal connectors to be connected to an electronic controller. An air assist version features a simplified construction enabled by the internal connectors, and has an air jacket surrounding each fuel injector, with compressed air received from an air supply passage defined within the fuel rail. The internal connectors are located offset from the fuel injector axes to allow an even sealing pressure to be exerted by manifold mounting bolts.

Abstract: A fuel rail crossover hose connection is disclosed for spaced apart fuel rail segments for V engines, the connection including a separate hose barb fitting installed in each end fuel rail segment in lieu of a conventionally configured end cap, and the crossover hose fit to the projecting ends of the fittings.

Abstract: The fuel pressure regulator is disposed in an off-engine mounting that is fastened to a wall of the engine compartment. The mounting is a body of synthetic material having a socket within which the fuel pressure regulator is disposed. Nipples for fluid-connecting flexible fuel conduits to the body are integral formations of the body. Protective walls that are also integral formations of the body circumferentially surround the nipples. Levers are pivotally connected with the protective walls, and when operated to force-applying positions, they pinch the sides of the conduits against the nipples.