Abstract: Various embodiments of the invention relate to an apparatus and method for assembling a cylinder for an internal combustion engine. The cylinder includes a cylinder liner with a liner wall having an outer diameter and a flange extending radially outward from the liner wall at a superior end of the liner wall. The flange includes a fillet region adjacent to the liner wall having an inferior surface. The inferior surface has a contour defined at least partially by a non-circular profile. The contour defines a minimum diameter that is greater than or equal to an outer diameter of the liner wall. The non-circular profile is optionally defined by a slanted ellipse.

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: An adapter is disclosed for use in mounting an ancillary unit in an engine block which has at one end a lateral flange (10) formed with an aperture for mounting of the ancillary unit. The adapter comprises a casing (112) for mounting on the end face of the engine to overlie the 10 aperture, which casing is provided with an O-ring (130) for effecting a seal between the casing (112) and the aperture in the lateral flange of the engine. The casing has a larger diameter portion separated by a shoulder (131) from a portion of reduced diameter, a retaining sleeve (132) axially slidable over the reduced diameter portion of the casing (112) and a O-ring (130) held captive between the axial end of the retaining sleeve (132) and the shoulder (131).

Abstract: An engine is described having a hole for a dipstick which is closed by a cap from which the dipstick depends. The engine body is formed with an overhanging lip adjacent the mouth of the hole, and the cap comprises a spigot rotatably received in the mouth of the hole and a flange extending radially outwards from the spigot to cover the mouth of the hole. The flange is non-circular so that by rotation of the cap relative to the hole, a radially projecting portion of the edge of the flange may be selectively engaged beneath the overhanging lip to prevent axial displacement of the cap and the dipstick relative to the engine body.

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: A method is disclosed for positioning the crankshaft of an engine. The method comprises the steps of providing a first hole in the flywheel, providing a hole in a stationary part of the engine to line up accurately with the hole in the flywheel once during each crankshaft revolution, manually cranking the engine until the holes in the flywheel and the engine are aligned, and inserting a pin into the aligned holes to lock the crankshaft in a predetermined angular position.

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: A balancer shaft assembly for an engine comprises a housing mountable on the engine block, and rotatably supporting at least one balancer shaft (16,18; 16′,18′) connectable for rotation with the engine crankshaft. The housing is formed in two parts (12,14; 12′,14′) and defines pillar blocks (30) for journalling the or each balancer shaft (16,18; 16′,18′). A groove (28; 28′) is formed in the split plane of at least one of the two mating parts (12; 12′) of the housing, which groove (28; 28′) when the parts (12,14; 12′,14′) are mated to one another defines an oil gallery by way of which lubricant is supplied to the pillar blocks (30) supporting the or each balancer shaft (16,18; 16′,18′).

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: An engine having an electronic engine control unit (ECU) is provided with a temperature management system for the ECU to prevent failure of the ECU through overheating. The temperature management system comprising means for monitoring or evaluating the temperature of the ECU to determine when the temperature of the ECU is approaching a predetermined limit and means for limiting further heating of the ECU to prevent the said limit from being exceeded.

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.