Abstract: According to one embodiment, a vehicle powertrain includes an engine having a first locking feature defining first mating surfaces, and a differential coupled to a transfer case via a driveshaft. The differential includes a second locking feature defining second mating surfaces. The first and second locking features are engaged such that the first and second mating surfaces are disposed against each other connecting the engine and the differential. A fastener is disposed within the engine and the differential.

Abstract: Engine blocks and methods of forming engine blocks are disclosed. The engine block may include a cast aluminum body and a plurality of cast-in liners. Each cast-in liner may include (a) an outer layer of 2xxx-series aluminum molecularly bonded to the cast aluminum body and (b) an inner layer directly contacting the outer layer and forming at least a portion of an engine bore. The inner layer may be a wear-resistant coating, such as a steel coating. The method may include extruding an elongated 2xxx-series aluminum extrusion having an inner cavity bounded by an inner surface and applying a wear-resistant coating to the inner surface. The extrusion may be sectioned into a plurality of cylinder liners and the cylinder liners may be into an aluminum engine block such that each cast-in liner forms at least a portion of an inner surface of an engine bore in the engine block.

Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.

Abstract: Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.

Abstract: An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.

Abstract: An engine includes a cylinder block with first and second saw cuts intersecting a block face on opposed sides of a block bore bridge. A cylinder head has third and fourth saw cuts intersecting a head face on opposed sides of a head bore bridge. A gasket is placed between the block and the head. The gasket defines a cooling passage adapted to fluidly connect the first, second, third and fourth saw cuts and cool the interbore region of the engine. The cooling passage has an inlet and a pair of outlets.

Abstract: Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.

Abstract: According to one embodiment, a vehicle powertrain includes an engine having a first locking feature defining first mating surfaces, and a differential coupled to a transfer case via a driveshaft. The differential includes a second locking feature defining second mating surfaces. The first and second locking features are engaged such that the first and second mating surfaces are disposed against each other connecting the engine and the differential. A fastener is disposed within the engine and the differential.

Abstract: Engine blocks and methods of forming engine blocks are disclosed. The engine block may include a cast aluminum body and a plurality of cast-in liners. Each cast-in liner may include (a) an outer layer of 2xxx-series aluminum molecularly bonded to the cast aluminum body and (b) an inner layer directly contacting the outer layer and forming at least a portion of an engine bore. The inner layer may be a wear-resistant coating, such as a steel coating. The method may include extruding an elongated 2xxx-series aluminum extrusion having an inner cavity bounded by an inner surface and applying a wear-resistant coating to the inner surface. The extrusion may be sectioned into a plurality of cylinder liners and the cylinder liners may be into an aluminum engine block such that each cast-in liner forms at least a portion of an inner surface of an engine bore in the engine block.

Abstract: An engine includes a cylinder block with first and second saw cuts intersecting a block face on opposed sides of a block bore bridge. A cylinder head has third and fourth saw cuts intersecting a head face on opposed sides of a head bore bridge. A gasket is placed between the block and the head. The gasket defines a cooling passage adapted to fluidly connect the first, second, third and fourth saw cuts and cool the interbore region of the engine. The cooling passage has an inlet and a pair of outlets.

Abstract: An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.

Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.

Abstract: An engine includes a cylinder block with first and second saw cuts intersecting a block face on opposed sides of a block bore bridge. A cylinder head has third and fourth saw cuts intersecting a head face on opposed sides of a head bore bridge. A gasket is placed between the block and the head. The gasket defines a cooling passage adapted to fluidly connect the first, second, third and fourth saw cuts and cool the interbore region of the engine. The cooling passage has an inlet and a pair of outlets.

Abstract: A tool and a method of using the tool are provided for forming an engine component. The engine has a block defining a first cylinder and a second cylinder spaced apart by a bore bridge. The bore bridge defines a first cooling passage spaced apart from a deck face and extending transversely, and a second cooling passage positioned between the first passage and the deck face and extending transversely. The first and second passages are formed by a casting skin. In forming the engine component, a die is provided that defines a locator recess and at least one core. An insert is positioned into the recess on the die. The insert has a cast shell surrounding a lost core. The component is die cast with the die and the insert to form a cooling jacket. The insert is adapted to form the cooling passages for the bore bridge.

Abstract: Embodiments may provide an engine knock monitoring system that may include an engine block including an engine block body and a cylinder wall defining at least a portion of a combustion chamber. A space may be defined between a top of the cylinder wall and a top of the engine block body. An engine knock sensor may be mounted to the engine block. A pressure pulse transmissive element may be disposed in the space and may be disposed in contact with an outside surface of the cylinder wall and an opposite inside surface of the engine block body.

Abstract: An engine has a cylinder head with a deck face defining first and second chambers adjacent to one another and separated by a bore bridge. The body defines a first cooling jacket and a second cooling jacket configured to operate at a lower pressure than the first cooling jacket. The first cooling jacket is positioned substantially between the deck face and the second cooling jacket. The first cooling jacket has a series of passages intersecting the deck face and configured to receive coolant from a cylinder block cooling jacket. The second cooling jacket has an inlet passage intersecting the deck face adjacent to the bore bridge and configured to receive coolant from the cylinder block cooling jacket to cool the bore bridge.

Abstract: An engine includes a cylinder block with first and second saw cuts intersecting a block face on opposed sides of a block bore bridge. A cylinder head has third and fourth saw cuts intersecting a head face on opposed sides of a head bore bridge. A gasket is placed between the block and the head. The gasket defines a cooling passage adapted to fluidly connect the first, second, third and fourth saw cuts and cool the interbore region of the engine. The cooling passage has an inlet and a pair of outlets.

Abstract: A tool and a method of using the tool are provided for forming an engine component. The engine has a block defining a first cylinder and a second cylinder spaced apart by a bore bridge. The bore bridge defines a first cooling passage spaced apart from a deck face and extending transversely, and a second cooling passage positioned between the first passage and the deck face and extending transversely. The first and second passages are formed by a casting skin. In forming the engine component, a die is provided that defines a locator recess and at least one core. An insert is positioned into the recess on the die. The insert has a cast shell surrounding a lost core. The component is die cast with the die and the insert to form a cooling jacket. The insert is adapted to form the cooling passages for the bore bridge.

Abstract: An engine has a cylinder head with a deck face defining first and second chambers adjacent to one another and separated by a bore bridge. The body defines a first cooling jacket and a second cooling jacket configured to operate at a lower pressure than the first cooling jacket. The first cooling jacket is positioned substantially between the deck face and the second cooling jacket. The first cooling jacket has a series of passages intersecting the deck face and configured to receive coolant from a cylinder block cooling jacket. The second cooling jacket has an inlet passage intersecting the deck face adjacent to the bore bridge and configured to receive coolant from the cylinder block cooling jacket to cool the bore bridge.

Abstract: Embodiments may provide an engine knock monitoring system that may include an engine block including an engine block body and a cylinder wall defining at least a portion of a combustion chamber. A space may be defined between a top of the cylinder wall and a top of the engine block body. An engine knock sensor may be mounted to the engine block. A pressure pulse transmissive element may be disposed in the space and may be disposed in contact with an outside surface of the cylinder wall and an opposite inside surface of the engine block body.