Modular fuel injector having a terminal connector interconnecting an electromagnetic actuator with a pre-bent electrical terminal

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 a first inlet tube end and a second inlet tube end;
• a non-magnetic shell having a first shell end connected to the second inlet tube end at a first connection and further having a second shell end;
• and
• a valve body having a first valve body end connected to the second shell end at a second connection and further having a second valve body end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• a member biasing the armature assembly toward the seat;
• an adjusting tube located in the tube assembly, the adjusting tube engaging the member and adjusting a biasing force of the member;
• a filter located in the tube assembly;
• and
• a first attaching portion;
• and a coil group subassembly including:
• at least one electrical terminal;
• a solenoid coil operable to displace the armature assembly with respect to the seat, the solenoid coil being axially spaced from the at least one electrical terminal;
• a terminal connector axially connected to the at least one electrical terminal, the terminal connector electrically connecting the at least one electrical terminal and the solenoid coil;
• and
• a second attaching portion fixedly connected to the first attaching portion.

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;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly;
• a member biasing the armature assembly toward the seat;
• an adjusting tube located in the tube assembly, the adjusting tube engaging the member and adjusting a biasing force of the member;
• a filter located in the tube assembly;
• and
• a first attaching portion;
• providing a coil group subassembly including:
• at least one electrical terminal;
• a solenoid coil operable to displace the armature assembly with respect to the seat, the solenoid coil being axially spaced from the at least one electrical terminal;
• a terminal connector axially connected to the at least one electrical terminal, the terminal connector electrically connecting the at least one electrical terminal and the solenoid coil;
• and
• a second attaching portion;
• and
• inserting the coil group subassembly over the valve group subassembly.