Abstract: An electric motor driven fuel pump for a motor vehicle includes a tubular metal housing, a pump in the housing at an inlet end thereof, an electric motor in the housing adjacent the pump, a plastic end cap in the housing near a discharge end thereof, and a plastic RFI module in the housing over the end cap. Brushes for the motor are disposed in brush passages in the end cap and connected to brass terminal studs press fitted into the open ends of the brush passages. The plastic RFI module completely shrouds the terminal studs on the end cap to minimize corrosion and contamination and has a pair of flat metal contact plates embedded therein. An edge of the tubular housing is crimped over the outside diameter of the RFI module and overlaps the metal contact plates so that the plates reinforce the RFI module against forces urging dislodgment of the RFI module and the end cap from the tubular housing.

Abstract: A fuel system for a motor vehicle wherein an electric motor-driven two-stage fuel pump has a motor with a cylindrical flux carrier having a pair of segmented permanent magnets disposed therein in a manner to provide a pair of axial fuel flow paths intermediate said magnets and interior to the flux carrier. The motor armature has a drive shaft with a D-shaped section which supports a pair of pump impellers each having a central D-shaped aperture complementary to the D-shaped section of the drive shaft. The shaft has a single bearing intermediate the armature and impellers so that the impellers are supported by the D-shaped drive connection in a manner which permits axial alignment of the impellers relative to the stationary elements of the pump.

Abstract: A push rod and tappet assembly for a cam actuated pump in which a tappet having a barbed shank is lightly press fitted, during assembly, part-way into the hollow end of the push rod so that during the initial operating cycle of the pump, as the cam on which the tappet rides rotates through the first cycle of rotation, the pump piston to which the push rod is connected bottoms out and the shank of the tappet will then be forced further into the push rod to a position to thereafter provide substantially zero clearance in the pump.