Abstract: A method of making a die cast aluminum based engine block with a closed deck is disclosed. A core assembly having at least one water soluble alkaline metal salt core member is stationed on a bore die of a die casting assembly for the block. The core assembly also preferably comprises an iron cylindrical liner centered within the salt core member by an aluminum mesh collar which dissolves in the cast metal during high pressure aluminum die casting. The salt core member is fabricated by die casting under pressure and heat to form a shaped body which, as a core, cooperated to define a substantially closed chamber to serve as the water jacket for the block. The salt core member is removed from the cast block by water dissolution admitted through small port openings in the closed deck block to form a brine, which brine is then washed out of such port openings.

Abstract: An automotive type exhaust gas recirculation (EGR) cooler or heat exchanger that is constructed for integral mounting to the engine intake manifold, the cooler being flat and having an engine coolant inlet at one end of an oblong casing and a coolant outlet at the other end to flow coolant past a U-shaped tube containing EGR gases to be cooled.

Abstract: An automotive type V-8 engine has an exhaust gas recirculation (EGR) system wholly contained within its intake manifold, and a flat, sandwich type EGR cooler is constructed to be integrally mounted to the underside of the manifold in the valley of the V-8 over the combination valley cover-manifold gasket, without the use of hoses, clamps and other paraphenalia normally associated with externally mounted EGR coolers.