Direct control fuel injector with a dual flow rate orifice

The fuel injector includes an injector body 11 that defines a nozzle outlet 23 and a needle control chamber 42 that is in fluid communication with a needle control passage 40. A needle valve member 60 is positioned in the injector body 11, and has a closing hydraulic surface 66 exposed to fluid pressure in the needle control chamber 42. The needle valve member 60 is movable between a first position in which the nozzle outlet is blocked, and a second position in which the nozzle outlet is open. The needle control passage includes a dual flow rate orifice 41. Hydraulic fluid is displaced into the needle control chamber 42 through the dual flow rate orifice 41 when the needle valve member 60 moves from its toward its first position. Hydraulic fluid is displaced out of the needle control chamber 42 through the dual flow rate orifice 41 when the needle valve member 60 moves from its first position toward its second position. A compression spring 67 is operably positioned to bias the needle valve member 60 toward its first position. The dual flow rate orifice 41 facilitates a gradual beginning and an abrupt ending to injection events, thus reducing exhaust emissions.