Modular fuel injector and method of assembling the modular fuel injector

1. A method of assembling a fuel injector, comprising:

providing a valve group subassembly including:

a tube assembly having a longitudinal axis extending between a first end and a second end, the tube assembly including an inlet tube having an inlet tube face;

a seat secured at the second end of the tube assembly, the seat defining an opening;

an armature assembly disposed within the tube assembly, the armature assembly having a closure member disposed at one end of the armature assembly and an armature portion disposed at the other end of the armature assembly, the armature assembly having an armature face;

a member biasing the armature assembly toward the seat;

a filter assembly disposed within the tube assembly;

an adjusting tube disposed within the tube assembly proximate the second end;

a non-magnetic shell extending axially along the axis and coupled at one end of the shell to the inlet tube;

a valve body coupled to the other end of the non-magnetic shell;

a lifting setting device disposed within the valve body;

a valve seat disposed within the valve body and contiguously engaging the closure member; and

a first attaching portion;

providing a coil group subassembly including:

a housing;

a bobbin disposed partially within the housing, the bobbin having at least one contact portion formed thereon;

a solenoid coil operable to display the armature assembly with respect to the seat,

the solenoid coil being electrically coupled to the contact terminals;

at least one pre-bent terminal electrically coupled to the contact portion; and

at least one overmold;

inserting the valve group subassembly into the coil group subassembly;

aligning the valve group subassembly relative to the coil group subassembly on the basis of predetermined reference points on the valve group subassembly and the coil group subassembly; and

affixing the valve group subassembly to the coil group subassembly.

2. A fuel injector for use with an internal combustion engine, the fuel injector comprising:

a valve group subassembly including:

a tube assembly having a longitudinal axis extending between a first end and second end, the tube assembly including an inlet tube having an inlet tube face;

a seat secured at the second end of the tube assembly, the seat defining an opening;

an armature assembly disposed within the tube assembly, the armature assembly having a closure member disposed at one end of the armature assembly and an armature portion disposed at the other end of the armature assembly, the armature assembly having an armature face;

a member biasing the armature assembly toward the seat;

a filter assembly disposed within the tube assembly;

an adjusting tube disposed within the tube assembly proximate the second end;

a non-magnetic shell extending axially along the axis and coupled at one end of the shell to the inlet tube;

a valve body coupled to the other end of the non-magnetic shell;

a lift setting device disposed within the valve body;

a valve seat disposed within the valve body and contiguously engaging the closure member; and

a first attaching portion;

a coil group subassembly including:

a housing;

a bobbin disposed partially within the housing, the bobbin having at least one contact portion formed thereon;

a solenoid coil operable to displace the armature assembly with respect to the seat, the solenoid being electrically coupled to the at least one contact portion;

at least one pre-bent terminal being electrically coupled to the at least one contact portion;

at least one overmold, the overmold further including:

a first insulator portion generally surrounding the second end of the inlet tube; and

a second insulator portion generally surrounding the first end of the inlet tube, the second insulator portion being bonded to the first insulator portion; and a second attaching portion fixedly connected to the first attaching portion.

3. A fuel injector for use with an internal combustion engine, the fuel injector comprising:

a valve group subassembly including:

a tube assembly having a longitudinal axis extending between a first end and second end, the tube assembly including an inlet tube having an inlet tube face;

a seat secured at the second end of the tube assembly, the seat defining an opening;

an armature assembly disposed within the tube assembly, the armature assembly having a closure member disposed at one end of the armature assembly and an armature portion disposed at the other end of the armature assembly, the armature assembly having an armature face;

a member biasing the armature assembly toward the seat;

a filter assembly disposed within the tube assembly;

an adjusting tube disposed within the tube assembly proximate the second end;

a non-magnetic shell extending axially along the axis and coupled at one end of the shell to the inlet tube;

a valve body coupled to the other end of the non-magnetic shell;

a lift setting device disposed within the valve body, the lift setting device includes a lift sleeve;

a valve seat disposed within the valve body and contiguously engaging the closure member; and

a first attaching portion;

a coil group subassembly including:

a housing;

a bobbin disposed partially within the housing, the bobbin having at least one contact portion formed thereon;

a solenoid coil operable to displace the armature assembly with respect to the seat, the solenoid being electrically coupled to the at least one contact portion;

at least one pre-bent terminal being electrically coupled to the at least one contact portion;

at least one overmold; and

a second attaching portion fixedly connected to the first attaching portion.

4. A fuel injector for use with an internal combustion engine, the fuel injector comprising:

a valve group subassembly including:

a tube assembly having a longitudinal axis extending between a first end and a second end, the tube assembly including an inlet tube having an inlet tube face;

a seat secured at the second end of the tube assembly, the seat defining an opening;

an armature assembly disposed within the tube assembly, the armature assembly having a closure member disposed at one end of the armature assembly and an armature portion disposed at the other end of the armature assembly, the armature assembly having an armature face;

a member biasing the armature assembly toward the seat;

a filter assembly disposed within the tube assembly;

an adjusting tube disposed within the tube assembly proximate the second end;

a non-magnetic shell extending axially along the axis and coupled at one end of the shell to the inlet tube;

a valve body coupled to the other end of the non-magnetic shell;

a lift setting device disposed within the valve body, the lift setting device including a crush ring;

a valve seat disposed within the valve body and contiguously engaging the closure member; and

a first attaching portion;

a coil group subassembly including:

a housing;

a bobbin disposed partially within the housing, the bobbin having at least one contact portion formed thereon;

a solenoid coil operable to displace the armature assembly with respect to the seat, the solenoid coil being electrically coupled to the at least one contact portion;

at least one pre-bent terminal being electrically coupled to the at least one contact portion;

at least one overmold; and

a second attaching portion fixedly connected to the first attaching portion.