Abstract: In at least some implementations, an assembly includes a float having a void with an inlet leading into the void in a first direction, and at least one retention surface that is not parallel to the first direction and a hinge received at least partially within the void. The hinge has at least one retention feature that cooperates with the at least one retention feature of the float to inhibit removal of the hinge from the float in a second direction opposite to the first direction, and the hinge is formed from a polymeric material. In at least some implementations, the hinge has a melting point similar to or lower than the melting point of the material of the float, and the hinge is formed separately from and is pressed into the void in the float.

Abstract: A fuel pump for a fuel system includes a nozzle, a venturi, a pump inlet and a flow controller. The nozzle has an orifice through which fuel is ejected and the venturi is downstream of the nozzle and has an inlet through which fuel discharged from the orifice flows, a passage downstream of the venturi inlet through which fuel flows to create a drop in pressure in the area of the venturi, and an outlet through which fuel is discharged from the venturi. Fuel is drawn through the pump inlet by the drop in the pressure created in the area of the venturi and the flow controller is downstream of the outlet and has a chamber in which fuel from the venturi outlet is received. The flow controller causes fuel to fill the venturi to ensure performance of the fuel pump.

Abstract: In at least some implementations, a liquid and vapor separator includes a body and a cover, a fuel inlet, a fuel outlet and a vent passage. A fuel pump has an inlet in communication with the interior volume and an outlet in communication with the fuel outlet. A fuel pressure regulator has an inlet in communication with the fuel pump outlet, an outlet in communication with the interior volume and a valve between the fuel pressure regulator inlet and the fuel pressure regulator outlet. The fuel pressure regulator is carried by the cover and the cover defines at least part of a fuel passage between the fuel pump outlet and the fuel outlet. An inlet valve is received within the interior volume and associated with the fuel inlet. A wall at least partially separates the area of the fuel pump from the area of the inlet valve.

Abstract: In at least some implementations, a fluid level sensor assembly includes a housing, a sensor element carried by the housing, an arm that moves relative to the sensor element, a saddle coupled to at least part of the arm to retain the position of the arm relative to the sensor element, and a retainer. The retainer is coupled to the saddle and overlies a portion of the saddle, the arm or both, to inhibit decoupling of the arm from the saddle.

Abstract: An in-tank fuel pump assembly may have a mounting flange with a plurality of first coupling features, a fuel pump, a carrier connected to the fuel pump, a plurality of second coupling features on at least one of the carrier and the fuel pump, and a plurality of supports each connected to one or the first and second coupling features to locate the pump relative to the mounting flange. In some embodiments, at least one coupling feature is movable.

Abstract: In at least some implementations, an assembly includes a float having a void with an inlet leading into the void in a first direction, and at least one retention surface that is not parallel to the first direction and a hinge received at least partially within the void. The hinge has at least one retention feature that cooperates with the at least one retention feature of the float to inhibit removal of the hinge from the float in a second direction opposite to the first direction, and the hinge is formed from a polymeric material. In at least some implementations, the hinge has a melting point similar to or lower than the melting point of the material of the float, and the hinge is formed separately from and is pressed into the void in the float.

Abstract: In at least some implementations, a liquid and vapor separator includes a body and a cover, a fuel inlet, a fuel outlet and a vent passage. A fuel pump has an inlet in communication with the interior volume and an outlet in communication with the fuel outlet. A fuel pressure regulator has an inlet in communication with the fuel pump outlet, an outlet in communication with the interior volume and a valve between the fuel pressure regulator inlet and the fuel pressure regulator outlet. The fuel pressure regulator is carried by the cover and the cover defines at least part of a fuel passage between the fuel pump outlet and the fuel outlet. An inlet valve is received within the interior volume and associated with the fuel inlet. A wall at least partially separates the area of the fuel pump from the area of the inlet valve.

Abstract: An in-tank fuel pump assembly may have a mounting flange with a plurality of first couplings, a fuel pump, a carrier connected to the fuel pump, a plurality of second couplings on at least one of the carrier and the fuel pump, and a plurality of supports each connected to one or the first and second couplings to locate the pump relative to the mounting flange.

Abstract: An in-tank fuel pump assembly may have a mounting flange with a plurality of first coupling features, a fuel pump, a carrier connected to the fuel pump, a plurality of second coupling features on at least one of the carrier and the fuel pump, and a plurality of supports each connected to one or the first and second coupling features to locate the pump relative to the mounting flange. In some embodiments, at least one coupling feature is movable.

Abstract: In at least some implementations, a fluid level sensor assembly includes a housing, a sensor element carried by the housing, an arm that moves relative to the sensor element, a saddle coupled to at least part of the arm to retain the position of the arm relative to the sensor element, and a retainer. The retainer is coupled to the saddle and overlies a portion of the saddle, the arm or both, to inhibit decoupling of the arm from the saddle.

Abstract: An in-tank fuel pump assembly may have a mounting flange with a plurality of first couplings, a fuel pump, a carrier connected to the fuel pump, a plurality of second couplings on at least one of the carrier and the fuel pump, and a plurality of supports each connected to one or the first and second couplings to locate the pump relative to the mounting flange.

Abstract: In at least some implementations, a seal for a wire includes a body having at least one opening adapted to receive at least one wire therethrough, and an axially extending engagement surface disposed around at least a portion of each of said at least one openings. The engagement surface has at least a portion that is not parallel to an axis of the opening and is disposed at an acute included angle relative to the axis so that, when the engagement surface is contacted by another component, the size of the adjacent opening tends to be reduced.

Abstract: In at least some implementations, a seal for a wire includes a body having at least one opening adapted to receive at least one wire therethrough, and an axially extending engagement surface disposed around at least a portion of each of said at least one openings. The engagement surface has at least a portion that is not parallel to an axis of the opening and is disposed at an acute included angle relative to the axis so that, when the engagement surface is contacted by another component, the size of the adjacent opening tends to be reduced.

Abstract: A fuel pump for a fuel system includes a nozzle, a venturi, a pump inlet and a flow controller. The nozzle has an orifice through which fuel is ejected and the venturi is downstream of the nozzle and has an inlet through which fuel discharged from the orifice flows, a passage downstream of the venturi inlet through which fuel flows to create a drop in pressure in the area of the venturi, and an outlet through which fuel is discharged from the venturi. Fuel is drawn through the pump inlet fuel by the drop in the pressure created in the area of the venturi and the flow controller is downstream of the outlet and has a chamber in which fuel from the venturi outlet is received. The flow controller causes fuel to fill the venturi to ensure performance of the fuel pump.

Abstract: A carburetor includes a body, a fuel metering system carried by the body to regulate fuel flow to the body, and a fuel-and-air mixing passage in fluid communication with the fuel metering system. The mixing passage extends through the body and is partitioned into a rich mixture passage, and a lean mixture passage positioned between the rich mixture passage and the fuel metering system.

Abstract: A housing for a fuel pressure regulator includes a body having a fuel inlet, a fuel outlet, a plurality of retention members, a bypass fitting, and preferably an electrical fitting and a ground fitting. Each retention member includes a catch that is constructed to engage and securely hold the fuel pressure regulator in the housing, while the fuel inlet, the fuel outlet and the bypass passage permit fuel routing as pressurized fuel passes through the fuel pressure regulator. The regulator housing preferably is made of an electrostatic charge dissipative material and is formed in one piece using a single manufacturing process such as injection molding.

Abstract: A pass-through electrical connector assembly with a body having at least one through-hole formed therein. A pin is forced into the through-hole and held by the body. The pin has a shank with opposed ends, each with a blind hole to receive a wire and a solid center portion that seals the wires and the pin. The pin has a tip with a barb at one end and a head with a shoulder at the other end which captures the pin in the body after the pin is forced into the through-hole when the shoulder engages the body. The shank has a circumferential surface that is press-fit within the through-hole to form a seal between the pin and the body. The body can then be sealed to a mating flange of a fluid-holding tank.

Abstract: A cosmetically attractive fuel tank assembly preferably for a motorcycle application has a fuel pump subassembly inserted into the fuel chamber of the tank through bottom access hole thus preserving the overall appearance of the tank itself. The flange of the fuel pump subassembly covers the bottom access hole and sealably months to a bottom wall of the fuel tank. Various fuel pump subassembly components, such as a fuel pressure regulator, an outlet fuel filter, an electrical connector and a fuel outlet mount directly to the flange along with a tripod like vibration absorbing bracket which supports the fuel pump and preferably a fuel level sensor. The bracket is flexible and resiliently contacts an internal surface of a bottom wall of the fuel tank via a resilient pad, and is threadably engaged to the flange and spaced therefrom by a vibration damping member.

Abstract: A level sensor and fuel pump assembly insertable through an access hole of a fuel tank so that an elongated fuel pump is disposed substantially completely within the fuel tank, and so that a flange of the assembly covers the hole and is engaged sealably to the wall of the fuel tank. The fuel level sensor has an arm which projects generally laterally when in a biased operating position from the elongated fuel pump to a float at a distal end. During insertion of the fully pre-assembled fuel sensor and pump assembly through the access hole of the fuel tank, the fuel level sensor is pivoted from the biased operating position to a collapsed position by an external force thus pivoting the fuel level sensor generally parallel, and closely orientated, to the fuel pump. This temporary orientation permits insertion of the fuel pump assembly through the relatively small access hole of the tank.

Abstract: A pass-through electrical connector assembly with a body having at least one through-hole formed therein. A pin is forced into the through-hole and held by the body. The pin has a shank with opposed ends, each with a blind hole to receive a wire and a solid center portion that seals the wires and the pin. The pin has a tip with a barb at one end and a head with a shoulder at the other end which captures the pin in the body after the pin is forced into the through-hole when the shoulder engages the body. The shank has a circumferential surface that is press-fit within the through-hole to form a seal between the pin and the body. The body can then be sealed to a mating flange of a fluid-holding tank.