Abstract: A method of assembling a spill valve of a high-pressure fluid pump includes disposing an inlet valve sleeve on an assembly tool such that the inlet valve sleeve contacts a fixture surface of the assembly tool. A pole piece is disposed within a cavity of a spill valve body. An open end of a spill valve body with the pole piece therein is inserted into the inlet valve sleeve that is on the assembly tool. The spill valve body is welded to the inlet valve sleeve to form a body sub-assembly. Subsequent to welding the spill valve body to the inlet valve sleeve, the body sub-assembly is removed from the assembly tool and inserted into a bore in an outer surface of a fuel pump housing. The inlet valve sleeve of the body sub-assembly is then welded to the fuel pump housing adjacent the bore.

Abstract: A method of assembling a spill valve of a high-pressure fluid pump includes disposing an inlet valve sleeve on an assembly tool such that the inlet valve sleeve contacts a fixture surface of the assembly tool. A pole piece is disposed within a cavity of a spill valve body. An open end of a spill valve body with the pole piece therein is inserted into the inlet valve sleeve that is on the assembly tool. The spill valve body is welded to the inlet valve sleeve to form a body sub-assembly. Subsequent to welding the spill valve body to the inlet valve sleeve, the body sub-assembly is removed from the assembly tool and inserted into a bore in an outer surface of a fuel pump housing. The inlet valve sleeve of the body sub-assembly is then welded to the fuel pump housing adjacent the bore.

Abstract: An overmolded coil assembly is provided and includes a body having a generally hollow cylindrical shape and including a central aperture and an inner surface defining a recess. A spool is received in the recess of the body. The spool includes an annular barrel and has opposite first and second ends. The first end is adjacent the central aperture of the body. A coil of electrically conductive wire is disposed in and circumferentially surrounds the annular barrel of the spool. A washer having inner and outer surfaces is adjacent the second end of the spool. An overmold made of an electrically insulative material covers the spool, the coil, the washer, and the body to seal around the spool, the coil, the washer, and the body. A fuel pump including the overmolded coil assembly and a method of sealing a coil assembly are also provided.

Abstract: An overmolded coil assembly is provided and includes a body having a generally hollow cylindrical shape and including a central aperture and an inner surface defining a recess. A spool is received in the recess of the body. The spool includes an annular barrel and has opposite first and second ends. The first end is adjacent the central aperture of the body. A coil of electrically conductive wire is disposed in and circumferentially surrounds the annular barrel of the spool. A washer having inner and outer surfaces is adjacent the second end of the spool. An overmold made of an electrically insulative material covers the spool, the coil, the washer, and the body to seal around the spool, the coil, the washer, and the body. A fuel pump including the overmolded coil assembly and a method of sealing a coil assembly are also provided.

Abstract: A fuel pump includes a pump housing with a pumping chamber an inlet valve bore. An inlet valve selectively provides and prevents fluid communication between an inlet of the fuel pump and the pumping chamber. The inlet valve includes an inner housing received within the inlet valve bore such that an outer periphery of the inner housing is sealed to an inner periphery of the inlet valve bore. An outer housing circumferentially surrounds the inner housing. An annular chamber is defined radially between the inner housing and the outer housing and axially between the outer housing and the pump housing. A sealing ring is located within the annular chamber such that the sealing ring is compressed axially against the pump housing and the outer housing.

Abstract: A fuel rail assembly includes a hollow fuel rail extending along a fuel rail axis and includes at least one outlet for dispensing fuel from the fuel rail. A fuel rail damper is disposed within the fuel rail and extends along a fuel rail axis from a first fuel rail damper end to a second fuel rail damper end for damping pressure pulsations within the fuel rail. A fuel rail damper support is included for positioning the fuel rail damper within the fuel rail. The fuel rail damper support includes an attachment section for fixing the fuel rail damper support to the fuel rail damper and a biasing section that applies a biasing force to prevent axial movement of the fuel rail damper within the fuel rail.

Abstract: A fuel rail assembly includes a hollow fuel rail extending along a fuel rail axis and includes at least one outlet for dispensing fuel from the fuel rail. A fuel rail damper is disposed within the fuel rail and extends along a fuel rail axis from a first fuel rail damper end to a second fuel rail damper end for damping pressure pulsations within the fuel rail. A fuel rail damper support is included for positioning the fuel rail damper within the fuel rail. The fuel rail damper support includes an attachment section for fixing the fuel rail damper support to the fuel rail damper and a biasing section that applies a biasing force to prevent axial movement of the fuel rail damper within the fuel rail.