Abstract: A one-piece cylinder head casting, including reliably located passageways for fuel-air intake, for exhaust and for coolant, is formed by a plurality of interengaging one-piece core elements including a one-piece coolant jacket core, a one-piece exhaust core and a one-piece fuel-air intake core, all reliably positioned and held together in an integral core assembly. Preferably, a further core element having a plurality of core supporting and positioning surfaces provides surfaces that mate interfacing surfaces of the one-piece water jacket core, one-piece exhaust core and one-piece intake core and support such cores in position with respect to one another, and the intake core may be provided with a plurality of interfacing surfaces to lock the plurality of core elements into a unitary core assembly. Such cylinder head casting may also be provided with integral walls forming a long, open intake manifold cavity in the side of the cylinder head.

Abstract: An automatic oil additive injector is disposed over the drain opening in a bottom wall of an engine oil pan and extends into the oil pan. A side port is provided in a housing of the injector for allowing oil to drain therethrough when the oil drain plug is removed. Primary and secondary valve assemblies and a pump operator provided in the housing are activated upon removal of the drain plug to allow a chamber therebetween to fill with a predefined volume of additive, preferably silicone fluid, from a reservoir of the injector and which, upon engagement of the drain plug, dispense the fluid into the oil pan at each oil change to decrease aeration of the oil. In a second embodiment, the additive injector and reservoir are incorporated in the lubricating oil filter header.

Abstract: A high pressure flex fitting comprises a tube assembly which engages within a fitting body. The tube assembly comprises a tube upon which a deformable flanged compression sleeve is disposed adjacent an elastomeric sealing ring which in turn is adjacent a retainer ring, the retainer ring being seated adjacent a flared end of the tube. A nut having an end flange engages over the sleeve and the flange on the nut bears against the radial flange on the sleeve, pushing the sleeve on the tube into the fitting body when the nut is threadedly engaged onto the fitting body. The fitting body includes a large cavity, within which the flared end of the tube is suspended, have a tapered inner entrance section from an entrance diameter larger than the sleeve to an inner diameter smaller than the sleeve to completely fill the area between the cavity wall and the tube adjacent the sealing ring which effects the seal between the cavity wall and the tube to prevent extrusion and fracturing thereof.

Abstract: In a properly calibrated accelerator pedal sensor that provides a signal representative of pedal position to an electronic control module for the engine, the point at which the associated idle validation switch switches to distinguish idle from non-idle lies within a limited range of positions proximate closed throttle. The invention is a method for performing an in-vehicle test that can quickly determine if the switch point is in or out of calibration. A jumper is inserted between the sensor and the vehicle wiring harness that normally connects to the sensor. The jumper comprises several test points to which a voltmeter can be connected to measure certain voltages during the test and two LED's that are observed during the test. A special slide calculator is used to convert certain test data into a form that can be readily compared with other test data to make the determination regarding the idle validation switch.

Abstract: A routing clamp for attaching tubes, hoses, wire harnesses and the like to a vehicle frame comprises an elongate section of spring steel having a center portion and a flange engaging end which is bent back outwardly over the body portion to engage a frame rail flange of a vehicle, such as a truck, and to also engage the web portion of the frame rail. The other end of the section is folded inwardly to create a structure engaging loop within which the tubes, hoses or harnesses may rest. For convenience in opening the structure engaging loop, a terminal finger loop is provided.

Abstract: A cab suspension system comprises an active, computer controlled damping mechanism positioned between the cab and the truck frame, at the rear of the cab. Further, corner mounted high and low level passive damping mechanisms are provided at the front of the cab. Also, a torsion bar is engaged centrally across the frame members beneath the cab, the torsion bar controlling side roll and sway, as well as acting as a radius rod to limited fore-aft travel of the cab.

Abstract: A two-stage shock absorber comprises a casing having a low level damping piston rod therein an end portion of which has two spaced apart flanges thereon with a low resistance fluid path formed therebetween. A floating ring piston is slidingly seated about the piston rod between the flanges and has high resistance throughbores therein. When vibrational forces become excessive to a point where one or the other of the flanges engages against the floating ring piston, the low resistance fluid path is closed off by the floating piston and the high resistance throughbores engage within the fluid flow system to cause a shift from primary low level damping to a high level damping. Once pressure within the system equalizes and the ring piston is no longer in contact with either of the flanges, low level damping resumes.

Abstract: A hose connection element integrally cast as part of a cast structure such as a water outlet conduit for a vehicle engine comprises a tubular structure including a circumferential hose retaining bead with a flawless sealing surface between the bead and a proximal end thereof. A set of three vented tooling elements is used in creating a polystyrene pattern of the cast structure including integral hose connection element including first and second tooling elements to create first and second half-sections of a for a body portion pattern. The first and second tooling elements include a recess at one end thereof to form a socket depression in the body portion. The third tooling element comprises a cylindrical cavity including an outer wall and an inner wall, with the outer wall being uninterrupted by vent openings and including a circumferential area of protruberance near one end thereof, the parting line for the third tooling element being positioned along a crest of the protuberance.

Abstract: A diesel engine having a lubricating oil sump and a low pressure lubricating oil pump, is provided with a hydraulically-operated, electronically-controlled unit fuel injector operating system of the type having a unit fuel injector, a high pressure pump, a high pressure lubricating oil supply passage from said pump to said unit injector, a fuel supply to said unit injector, and an electronically controlled valve in said unit injector for controlling the application of the pressure of the lubricating oil to force said fuel to be expelled from said injector, wherein a priming reservoir is operatively connected to the low pressure lubricating oil pump and disposed upstream and above the high pressure supply pump and above the high pressure supply passage, preferably being disposed in the engine front cover and having a restricted return line to the oil sump for venting air from said reservoir, a siphon passage establishes fluid communication between said reservoir and said high pressure passage independently of

Abstract: A convienience feature is added to a DRL circuit to enable the driver to temporarily override the DRL system in situations where it is appropriate, such as when the vehicle is approaching weigh scales or entering a tunnel. The convenience feature is embodied in a convenience circuit that is interposed in the current feed path to the DRL circuit. The convenience circuit comprises a momentary switch that is actuated by the driver and a timing relay module that is responsive to the actuation of the momentary switch.

Abstract: The engine control module incorporates strategy which controls and modulates glow plug activation and also controls activation of a glow plug indicator lamp mounted in the cab of the vehicle. The control functions are separate in action but both are based on first sensing input power. If power is out of a predefined range strategy is provided for maintaining the glow plugs off. Both are secondly based on sensed engine coolant temperature, with out of range coolant temperatures causing activation of the glow plugs so long as input power is within range.

Abstract: A one-piece water jacket core for an internal combustion engine is formed by providing a first core box portion and a second core box portion adapted for assembly and formation of the one-piece water jacket core. The first core box portion includes a first cavity adapted to form a lower portion of the one-piece water jacket core and the second core box portion includes a second cavity adapted to form an upper portion of the one-piece water jacket core. A plurality of movable members are pivotally carried adjacent to, and preferably by, one of the core box portions. Each of the pivotal movable members includes a portion adapted to form a water jacket port and to be pivoted, after assembly of the first and second core box portions, to a position forming one of the water jacket ports in the one-piece water jacket core. The invention is particularly adapted for the formation of one-piece water jacket cores with a cold-cure process.

Abstract: A microprocessor engine control for a diesel engine powered truck is provided with a grade-holder vehicle speed control by another algorithm that is effective to cause the engine operation to move from one horsepower vs. speed curve to another when the vehicle encounters a change in load, such as when the vehicle encounters a change in grade.

Abstract: An aneroid boost modulator briefly restricts mass air flow from a turbocharged diesel engine intake manifold to a fuel injection pump aneroid control during free engine acceleration to inhibit operation of the aneroid controller until the engine and the turbocharger develop sufficient speed to use the increasing fuel supply efficiently. The modulator eliminates emission of black smoke from the engine during free engine acceleration while having no significant affect on acceleration of the engine under a load as in accelerating a vehicle.

Abstract: A feedthrough sleeve and integral support fitting comprises a hollow tubular sleeve and integral planar mounting collar. The sleeve lies in a plane transverse to the plane of the collar which is less than perpendicular thereto. The collar is configured to be engaged in a snap fit manner within an opening in a surface, such as a bulkhead of a truck, with the sleeve being mounted in a manner to allow an elongated member, such as a hose, wire or tubing, to be fed therethrough from one side of the bulkhead to the other, without requiring the need for splicing of or creating a joint in the elongated member to provide feedthrough thereof.

Abstract: An air-isolated fifth wheel system for use in connecting a trailer to a semi-tractor in a manner to isolate vibrational input of the trailer to the fifth wheel from being transferred to the semi-tractor. An inflatable air bag is operably disposed in a centered location beneath the fifth wheel support plate to eliminate vertical fifth wheel load from being transferred to the semi-tractor. The system is light weight and can easily be included into existing fifth wheel assemblies without significant alteration to the chassis of the semi-tractor.

Abstract: A wastegate actuator control valve for a wastegate of a turbocharger of an internal combustion engine is disposed in the intake manifold pressure supply line to the wastegate actuator and has a spring-biassed piston preventing intake manifold pressure from being transmitted through said line until a predetermined intake manifold or boost pressure is reached. The valve housing also has a bleed orifice communicating to the atmosphere to relieve any residual pressure in the actuator when the valve is closed but which bleed orifice is closed upon the piston moving to the open position. Such residual pressure relief results in the full preload of the actuator spring being exerted to completely close the wastegate. Further, the piston is provided with a metering orifice through which the intake manifold pressure flows to the wastegate actuator.