Abstract: An electric power generation system (20) is disclosed, which includes an electric power generator (22) driven by a four-cycle internal combustion engine (30). The engine (30) includes a plurality of reciprocating cylinders (C1-C6) each rotatably coupled to a crankshaft (34), which drives the electric power generator (22). A controller (90) is included that is operable to control fueling to start the engine (30) as a function of engine temperature and determine initial engine start-up as a function of rotational engine speed. This controller (90) regulates engine acceleration until a target engine speed is reached from initial start-up. Once this target speed is reached, the controller (90) provides a speed governor function.

Abstract: An engine cylinder piston connecting rod subassembly, for use in an engine, includes a piston (53), a piston pin (52) and a connecting rod (51). The connecting rod has a piston end portion with a piston pin bore (62). The piston pin is inserted through the piston pin bore and oppositely disposed portions of the piston, for securing the piston and the connecting rod together. Opposite ends of the piston pin bore are machined or profiled with relief portions (60, 61), to allow for piston pin deflection and thereby maximize the load carrying capacity, by providing a greater area of contact. The relief portions can be a curved surface (65) machined as part of the bore, or a plurality of end-to-end angled frustoconical surfaces (66a, 66b, 66c). The relief portions are shaped to correspond to the shape of the corresponding piston pin when under load during normal engine operation.

Abstract: A fuel injector having a nozzle with improved cooling including a retainer and a nozzle housing received therein. The nozzle housing includes a nozzle shank, an outer peripheral surface and at least one injection hole at a tip of the nozzle shank. The nozzle shank is positioned in a nozzle support portion of the retainer. In one embodiment, the outer peripheral surface of the nozzle shank is tapered, and the inner peripheral surface of the nozzle support portion is correspondingly tapered and sized to engage the outer peripheral surface of the nozzle shank along a tapered interface. In another embodiment, the inner peripheral surface of the nozzle support portion has a diameter smaller than a diameter of the outer peripheral surface of the nozzle shank so that an interference fit exists at a seal interface.

Abstract: An internal combustion engine system is disclosed that improves regulation of engine speed relative to a speed setpoint. The system controls ignition timing, throttle plate actuation, fuel valve actuation or a combination thereof in accordance with maintaining a setpoint speed. The system also includes a transient air flow estimation for further improving setpoint speed accuracy.

Abstract: The present invention provides a mechanism of retaining a rocker lever ball socket on a rocker lever ball. The mechanism provided is a retaining cap which is adapted to fit over and securely engage to the socket through a tab and groove arrangement and is made of a slightly elastic material and includes a restricted opening sized smaller than the fullest diameter of the rocker lever ball. During assembly, the retaining cap first interlocks with the socket by a tab and groove arrangement, and the lever ball is then pushed through the restricted opening. The restricted opening, being slightly elastic, enlarges to allow passage of the ball and retracts to a size smaller than the ball so that it is retained thereon.

Abstract: A novel and improved engine data system for collecting, displaying and analyzing engine/vehicle data is provided. The system have advantageously results in a more effective, convenient, portable and low cost method of monitoring and processing vehicle data. The vehicle data system includes a handheld computer containing operating system software adapted to operate the handheld computer in accordance with a data protocol different from a vehicle bus protocol and a handheld microprocessor for executing the operating system software. The system importantly includes an adapter for creating a data pathway between a vehicle bus connector and an external data port provided on the handheld computer which is physically incompatible with the engine bus connector.

Abstract: According to the method of the present invention, the ball plug is press fit into the counterbored passage of a fuel injector nozzle assembly prior to hardening of the fuel injector nozzle assembly. A core hardening and gas nitriding process is then applied to the assembly, causing the ball plug to expand and the passage diameter to shrink. This results in a greatly increased seal between the ball plug and the passage, and substantial elimination of the gaps experienced therebetween in prior art fuel injector nozzle assemblies.

Abstract: In one embodiment of the present invention, a system is disclosed for monitoring the backpressure produced by a particulate filter of an internal combustion engine. When the backpressure of the engine exceeds a predetermined threshold, indicating that the particulate filter should be serviced soon, an input to the electronic control module (ECM) indicating the intake manifold boost pressure is shunted to ground, thereby giving the ECM a false indication that no boost is being applied to the intake manifold. This will cause the ECM, according to its normal engine management software, to derate the engine performance to a “no air torque setting”, thereby limiting the amount of torque that the vehicle operator can extract from the engine. This decreased performance of the engine provides a very high incentive to the vehicle operator to bring the vehicle in for servicing, at which point the particulate filter can be serviced.

Abstract: A method and apparatus for the manipulation of a fuel injector in association with an internal combustion engine. In one form a fuel injector tool is pivotally coupled to a cylinder head and rotated to apply a removal or installation force to a fuel injector. The tool is adapted to be installed within the tight confines of a cylinder head.

Abstract: An apparatus is disclosed including an internal combustion engine, a number of sensors configured to detect operating parameters of the engine, and art engine control system responsive to the sensors to regulate engine operation. The control system includes a controller operatively coupled to a nonvolatile memory and has an interface capable of receiving operator input to customize aspects of a diagnostic data collection routine embedded in the control system. The routine responds to this input to selectively establish a data collection trigger, the nature of the information to be stored in the nonvolatile memory in response to this trigger, and the rate of storage of this information in the memory. The trigger may be externally generated with an operator-controlled triggering device coupled to the control system or internally generated as a function of one or more of the operating parameters.

Abstract: The fuel injector includes a solid state actuator that operates through an actuator motion amplifying lever to directly control the needle valve motion. Hydraulic forces, which act along the axes of the needle valve and the motion amplifying lever, are compensated by using a control piston, or other biasing means, to reduce the required amplitude of the control current/voltage and to reduce the required strength of the spring biasing the needle valve closed. The fuel injector may also include a control fuel inlet that is separate from the injection fuel inlet port.

Abstract: A torque sequence template includes a head gasket backing that is constructed and arranged to support a head gasket when packaged with the backing. The head gasket backing has a plurality of tightening sequence punch-outs arranged thereon in positions corresponding to head bolt locations. The cylinder head bolts are used to secure an engine head to the block. The head gasket backing has sequence indicators provided next to the punch-outs that indicate the sequence in which the bolts are to be tightened.

Abstract: An engine crankcase gas blow-by sensor. In a closed crankcase ventilation system, crankcase gases are caused to flow through a venturi which includes high pressure and low pressure taps. The high and low pressure taps are coupled to a differential pressure transducer which produces an output that is proportional to the volumetric flow of crankcase gases through the venturi. The use of a venturi in conjunction with a differential pressure sensor offers a low resistance path for the flow of crankcase gases and allows continuous monitoring of blow-by without exceeding the operating pressure limitations of various oil seals. Such a sensor is particularly suited for closed crankcase ventilation (ccv) systems, as it doesn't require venting of crankcase gases to the atmosphere, but works well in open crankcase ventilation systems also.

Abstract: An improved closed nozzle injector assembly for injecting high pressure fuel into the combustion chamber of an engine is provided which includes a first needle valve element associated with a first set of injector orifices, a first needle valve control device for controlling the opening and closing of the first needle valve, a second needle valve associated with a second set of injector orifices and a second needle valve control device for controlling the opening and closing of the second needle valve. Each needle valve control device includes a control volume positioned at one end of the respective needle valve, a control volume charge circuit for supplying high pressure fuel to the respective control volume and the respective injection control valve for controlling the flow of high pressure fuel from the respective control volume to a low pressure drain thereby controlling the movement of the respective needle valve.

Abstract: A fuel injection system is disclosed for an internal combustion engine that has multiple combustion chambers and a camshaft which cyclically imparts pressurization energy to and recovers pressurization energy from fuel being supplied to the engine. The fuel injection system includes a plurality of unit injectors, a camshaft linkage which simultaneously reciprocates pressurizing plungers of a set of at least two unit injectors and an interconnecting line which allows selective fluid interconnection between fuel pressurization chambers formed within the unit injectors. The interconnection line allows fluid linkage of the volume of fuel which is simultaneously pressurized and depressurized within the interconnected fuel pressurization chambers of a first set of unit injectors.

Abstract: Manufacturing imperfections and component failures in the fuel system of an engine, can lead to non-uniform torque production among the cylinders. Non-uniform cylinder torques can be observed as small engine speed fluctuations about the average engine speed at any given operating point. Engine speed data contains fluctuations at different frequencies. The amplitude of fluctuations at some known frequencies tell about the health of the fuel injectors and the engine. In the present invention, the instantaneous engine speed data is filtered by discrete second-order band-pass filters to find the engine speed fluctuations at particular frequencies. The output of the filters is identical to power spectral density of speed signal at those frequencies. The amplitude of each filter output is then compared to a predetermined threshold value. If the amplitude is bigger than this threshold, it indicates the existence of low fueling or high fueling fuel injectors.

Abstract: A kit of tooling components for use in facilitating the removal as well as the installation of a crankshaft seal includes a housing assembly which is constructed and arranged for attachment to a crankshaft seal during the removal procedure and for pushing the crankshaft seal into position during the installation procedure. The kit further includes a guide pin which is constructed and arranged for insertion through the crankshaft seal and into one of the crankshaft seal mounting holes in order to establish proper alignment for the crankshaft seal as it is pulled off during the removal procedure and as it is pushed on during the installation procedure. The kit further includes a plurality of self-tapping screws which are used during the removal procedure for attaching the housing assembly to the crankshaft seal.

Abstract: The present invention relates to an engine diagnostic system for detecting malfunctions in an engine system having a variable geometry turbine exhaust system. The engine diagnosis system includes an electronic control module adapted to periodically initiate a preprogrammed variable geometry turbine diagnostic routine.

Abstract: A fastener for venting gas around the shank of the fastener. The present invention includes various embodiments for venting gases such as combustion gases that seep from a head gasket of an internal combustion engine to the area around the shank of a cylinder head bolt, as one example. The various vent paths include vent paths directly through the bolt, past the bearing surface of the bolted member, or past a washer between the fastener and the bolted member. These vent paths prevent gases from building up in the chamber between the fastener shank and the clearance hole of the bolted member.

Abstract: A kit of tooling components for facilitating removal of a gear from a shaft includes a plurality of jaw members that are adapted to fit through blanking holes defined in the gear. The jaw members are further adapted to engage the gear. The kit further includes a set of studs with each of the studs adapted to engage one of the jaw members and a plate adapted to couple to the studs. The kit further includes a jack adapted to engage and fit between the plate and the shaft. Included as a part of this disclosure is a method of removing a camshaft gear by use of the kit of tooling components.