Abstract: The present invention relates to a supplementary lubrication system for an internal combustion engine operable to lubricate the engine and an accessory prior to engine start-up and to lubricate the accessory after engine shut-down. The supplementary lubrication system includes an oil source in fluid communication with a supplemental oil supply conduit, which branches to define two parallel conduits, a prelube branch and a postlube branch. Disposed within the prelube branch is a prelube one-way check valve and disposed within the postlube branch is a postlube one-way check valve. The prelube branch is in fluid communication with a first end of a two-directional pump and the postlube branch is in fluid communication with a second end of the two-directional pump.

Abstract: An EGR valve useful for metering exhaust gas to the intake of an internal combustion engine is disclosed. The EGR valve includes a base member through which exhaust gas passes and in which is disposed a valve member. An actuator housing is constructed with integral, hollow leg members for mounting the actuator to the base and also includes a valve stem passage which sealingly engages an opening in the base to provide a leak-free passage for the valve from the base to the actuator. A solenoid assembly disposed within the housing includes a bottom portion which is configured with openings to support fasteners which pass through the bottom and the hollow housing legs to engage corresponding faster openings in the base to fix the actuator housing to the base by placing the legs in compression thereagainst.

Abstract: An engine assembly is disclosed which includes a cylinder block having cylinders, pistons disposed in the cylinders, and connecting rods connecting the pistons to a crankshaft. The crankshaft rotates to move the pistons reciprocally in the cylinders thereby inducing volumetric changes within the engine and, particularly between axially adjacent pistons. A crankcase disposed below the cylinder block has axial sidewalls extending therefrom to define a crankcase volume in which the crankshaft is disposed for rotation. Crankcase bulkheads extend laterally to connect the axial walls and define cylinder bays therebetween. Each of the crankcase bulkheads includes a crankshaft journal support and a surface configured to rotatably receive a complementary bearing cap for support of the crankshaft therebetween.

Abstract: A fuel system including a fuel nozzle is disclosed. The fuel nozzle is adapted to receive pulsed pressurized fuel from a source and includes a valve seat assembly having a valve seat body with a longitudinally extending passage. The passage of the valve seat body has a valve seat extending thereabout and interfaces with a downstream opening valve element which is disposed within the longitudinally extending passage and operates to move into and out of sealing engagement with the valve seat to regulate the flow of pressurized fuel though the passage. The valve element has a spherically configured upstream surface for sealing engagement with the valve seat which includes an annular drag groove extending thereabout. The drag groove functions to increase viscous drag force, in the downstream opening direction, which is imparted on the valve element by fuel flow over the spherical upstream surface. The nozzle also has an annular, fuel directing orifice disc which is disposed downstream of the valve seat.

Abstract: A valve assembly is disclosed for metering exhaust gas to the intake manifold of an internal combustion engine. The valve assembly has a base which includes a passage communicating between the intake manifold and the exhaust manifold of the engine. The passage has a valve seat which is operable with a valve member to meter the flow of exhaust gas through the passage to the intake manifold. An actuator assembly is mounted to the base and is operably connected to the valve member to move the valve member into and out of engagement with the valve seat. The actuator assembly includes a solenoid having a magnetic circuit comprising stationary primary and secondary pole pieces and a moveable armature.

Abstract: The present invention is directed to a split bearing assembly and the method of manufacturing the same which substantially reduces material yielding and deformation during fracture. The bearing assembly includes a saddle-like main body with first and second legs and a removable saddle-like bearing cap with first and second legs. The ends of the cap are secured in end-to-end engagement with mating ends of the first and second legs of the body to define a journal receiving opening. The mating ends are defined by a portion of rough uneven mating surfaces formed by fracturing the cap from the body and a slot or saw-cut portion which operates to reduce the cross-sectional area of the first portion. The reduction in cross section of the mating ends, through the use of the saw-cut, operates to minimize the magnitude of the force which is required to initiate the fracture of the bearing cap from the body of the bearing assembly thereby limiting the deformation of the material in the fracture area.

Abstract: A valve lifter has a cam follower body with a closed end, or head from which depends concentric inner and outer cylinder surfaces. The inner cylinder surface defines a hollow cylinder having a first, closed end and a second, open end configured to receive a hydraulic lash adjuster, for engagement with the valve of an internal combustion engine. Additionally the inner and outer cylinder surfaces define laterally spaced recesses therebetween for receiving cam engaging rollers supported on transverse shafts extending therein. The shafts are supported at their radially outer ends in openings in the outer cylinder surface and at inner radial ends by abutment with the inner cylinder surface. The cantilevered shafts are thus supported against bending under loads applied by the rollers through the fixing of outer ends in the openings and through frictional interaction of the inner radial ends of the shaft against the inner cylindrical surface of the follower.

Abstract: A fuel injector for discharging fuel to an internal combustion engine is disclosed. The injector includes a nozzle body having a solenoid actuator, a pole piece with an axial extending fuel passage, a valve assembly including a reciprocably moveable armature operable against the bias of a spring member, a calibration tube extending through the pole piece fuel passage and operable to load the spring, an axially extending, drawn metal fuel tube having a first end defining an injector fuel inlet and a second end in communication with the axially extending fuel passage of the pole piece. The fuel tube includes features which extend radially inwardly in the wall of the fuel tube to define depressions in the outer surface of the wall which function, with a molded composite jacket to deter rotation of the tube.

Abstract: A fuel injector for discharging fuel to an internal combustion engine is disclosed. The injector has a nozzle body with an annular valve seat surrounding a fuel discharge opening. A valve member is disposed in the internal cylindrical cavity and is moveable between a first, sealing position relative to the valve seat and a second, open position off of the seat. The valve member is guided in its movement, with respect to the valve seat by a valve guide member disposed in the nozzle, closely adjacent the annular valve seat. The valve guide member includes a disc shaped member having an outer perimeter which is configured for placement within the nozzle body and a tubular central portion which defines a central, valve guide opening. The valve guide opening extends through the tubular central portion to open adjacent the annular valve seat and is configured for circumjacent disposition relative to the valve member to guide movement of the valve.

Abstract: A combustion air intake system for an internal combustion engine has an intake manifold which supplies intake air to the engine through pairs of differing length intake runners. A valve assembly is disposed between the intake runners and the engine and includes a molded composite housing having pairs of combustion air through passages which are in flow communication with associate pairs of intake manifold runners. An axially extending valve bore defines an axis through the valve housing and bisects the through passages. Molded integrally within the valve housing is a molded composite valve member having an axial valve shaft, disposed in the valve bore, and integral valve plates, disposed in predetermined through bores. The valve member is rotatable in the valve bore to open and close the valve plates for regulation of air flow through the predetermined through bores and associated intake runners.

Abstract: A fuel injection system is disclosed having a fuel injection nozzle which receives pressurized fuel pulses from a source. The nozzle includes a body having a tubular nozzle body with a longitudinally extending opening extending therethrough. A valve seat is located between the upstream and downstream ends of the longitudinal opening in the valve body for engagement with a valve member to thereby regulate the flow of fuel through the opening. A downstream stop member includes a hollow cylinder with a diametrical member extending across one end. The cylindrical stop member is received over the downstream end of the nozzle body with the diametrically extending member disposed across the downstream end of the longitudinal opening to thereby limit the outward range of movement of the valve member from the opening. As a result, the valve member and the downstream end of the longitudinally extending opening define an annular fuel metering orifice therebetween to regulate the flow of fuel from the nozzle.

Abstract: A piston assembly for an internal combustion engine includes a piston having a pair of opposed piston pin bosses. The bosses include first and second coaxial bores which define a piston pin bore. A connecting rod, having an end including a through-bore, extends into the piston and is connected to the piston by a piston pin assembly. The assembly includes a first journal end for disposition within the first coaxial bore, a second journal end disposed within the second coaxial bore and a spherical journal portion disposed intermediate of the first and said second ends. A bushing is assembled about the spherical journal portion and has a spherical inner surface corresponding to the spherical journal portion and an outer surface corresponding to and disposed in the connecting rod through-bore. The spherical journal portion rotates relative to the spherical inner surface of the bushing so as to facilitate rotational alignment of the piston in an engine cylinder bore.

Abstract: A two-step valve lifter for actuation of a valve member in an internal combustion engine includes an outer cam follower, having a cam-engaging upper surface with a cylindrical body depending therefrom, and an inner cam follower disposed within said cylindrical body. The inner follower includes a hollow cylinder having a first diameter "D", an upper, closed end and a lower, open end. The open end is configured to receive, for disposition between the two-step valve lifter and the valve member, a lash adjusting, hydraulic element assembly. An obround follower foot, having a length "L" normal to said camshaft axis and a width "W" parallel to said camshaft axis and less than said length "L", extends from the upper, closed end of the inner follower to terminate in a cam engaging surface which is extendable through an opening in the cam engaging surface of the outer cam follower. The width "W" of the follower foot is less than the first diameter "D" of the hollow cylinder of the inner follower.

Abstract: A rocker arm and hydraulic lash adjuster assembly is disclosed. The assembly includes a shaft mounted rocker arm having a valve actuating arm portion which includes a stepped bore for slidingly receiving a hydraulic element. The bore has an open end, a cylindrical wall and a closed end having a spot face formed therein, and fluidly connected via a passage in the rocker arm to a source of pressurized fluid. The stepped bore is configured to receive a flat wear plate in abutment with the closed end and the hydraulic element such that the wear plate and the hydraulic element cooperate to define a fluid reservoir therebetween for pressurized fluid. The wear plate includes a centrally located through-bore operable to fluidly connect the fluid reservoir and the spot face formed integrally with the closed end of the stepped bore to define a passage from the source of pressurized fluid to the fluid reservoir to thereby fill the hydraulic element with pressurized fluid.

Abstract: A valve actuation assembly for an internal combustion engine is disclosed in which a rotatable rocker arm assembly is actuated by an engine driven camshaft to move a poppet valve reciprocably. The rocker arm assembly includes a hydraulic lash adjuster for disposition between the rocker arm and the valve stem. The lash adjuster includes an actuator at one end having an axially extending neck which terminates in an enlarged head. The enlarged head engages a foot assembly which includes a disk having a socket in which the head is positioned. A retainer ring is disposed in the socket and includes a wall portion which operates to establish an interference fit with the socket so as to fix the ring in the socket and a radially inwardly extending flange member which operates to define an opening through which the actuator neck extends but having a diameter less than that of the enlarged head portion of the actuator to thereby prevent removal of the head from the socket.

Abstract: A hydraulic lash adjuster for an internal combustion engine, and a method of its construction is disclosed. The lash adjuster has a cylindrical follower body in which a tubular plunger is slidingly disposed. The plunger cooperates with the follower body to define a high pressure chamber therebetween which is supplied with fluid through a valved port. A low pressure chamber which operates to supply fluid to the high pressure chamber through the valved opening, is defined by an axial passage through the plunger. Fluid flows into and out of the low pressure chamber through a port in the wall of the plunger. Intermediate of the port and the valved opening is a radially inwardly extending annular shelf which is integral formed with the axial passage of the plunger using a mechanical shaving step to plow a portion of the plunger material from the wall of the axially extending passage.

Abstract: An exhaust gas recirculation valve meters exhaust gas to the intake of an internal combustion engine. The valve includes an electromagnetic solenoid actuator having a magnetic circuit defined by a primary and a secondary pole piece. The pole pieces define an axial chamber in which is disposed an axially moveable armature and an associated valve member. The primary pole piece has a center pole member including a cylindrical inner wall which is open at a first end for receiving the armature. The armature and the cylindrical inner wall establish a fixed, radially extending primary air gap for flux passage while the outer wall extends in an outward taper from the first, open end of said center pole member and operates to increase the mass of the pole piece through which the magnetic circuit operates as the armature moves from the first, open end of the center pole member towards the second end.

Abstract: A valve assembly is disclosed for metering exhaust gas to the intake manifold of an internal combustion engine. The valve assembly has a base which includes a passage communicating between the intake manifold and the exhaust manifold of the engine. The passage has a valve seat which is operable with a valve member to meter the flow of exhaust gas through the passage to the intake manifold. An actuator assembly is mounted to the base and is operably connected to the valve member to move the valve member into and out of engagement with the valve seat. The actuator assembly is constructed of an extruded housing having sides a bottom and support members extending from the bottom to position the actuator relative to the base. A stepped extension also extends from the bottom of the actuator housing and is press fit into an opening in the top of the base member to define a sealed passage for the valve stem between the base member and the actuator.

Abstract: A planetary cam phaser for varying the timing of an engine camshaft is provided with oppositely tapered teeth on the planet gear(s) and the mating ring and sun gears and biasing means for urging the mating gears axially into lash free engagement. The tapered teeth may be formed on constant pitch circles or on conical pitch circles of conical gears and the teeth of at least one of a pair of mating gears may be crowned to control loading and wear. The taper angles of the teeth and/or the conical pitch circles of the conical gears are preferably made small enough to avoid gear drive forces from developing gear separation forces greater than restraining friction forces.

Abstract: A fluid level detector for determining the level of fluids in motor vehicle components such as engines and transmissions includes a cylinder mounted in parallel to the surface of the fluid. The cylinder has a diameter which spans the fluid range to be monitored and includes a first, open end and a second closed end. A piston is disposed within the cylinder and is biased towards the first end where fluid is admitted to the cylinder interior and can be moved towards the second end under the influence of an actuator. When moved, the openings in the cylinder are blocked by the piston to thereby trap the fluid in the cylinder. As the piston continues to move towards the closed end of the cylinder, air above the fluid surface is exhausted through an orifice. Once the air is exhausted from the cylinder, fluid exits the orifice resulting in an increase in operator effort required to move the piston.