A scheme of high-pressure common rail injectors with low-return fuel was proposed by changing the control plunger structure in order to reduce the pressure of the control chamber connected to the fuel return orifice to reduce the quantity of returned fuel. The key structural parameters of the new scheme was optimized with one-dimensional simulation tool AMESim. Results show that the delay of closing the needle valve decreases with the decrease of the diameter of the seal ring

but too small diameter of the seal ring will cause the needle valve to continuously jump

resulting in the pulsation of the injection rate and weakening the effect of reducing the quantity of returned fuel. The quantity of returned fuel decreases with the decrease of the diameter of the orifice

but too small diameter will deteriorate the closing response. The new scheme was simulated under different common rail pressures. Compared with original high pressure common rail injectors

the quantity of returned fuel of the new scheme reduces significantly by up to more than 41% and the characteristic of closing response is not affected

which proves that the proposed scheme is effective.