Abstract: A throttle shaft assembly includes throttle shaft with a cam and shaft portion the shaft portion configured to be inserted in the throttle body, a throttle return spring that is coiled around the throttle shaft with two ends one end engaged to the cam portion and the other end engaged to a spring support on the throttle body, and a throttle spring cover that substantially surrounds the throttle return spring and is slideably mounted on the throttle shaft. The throttle return spring can be preloaded and restrained at both ends on the throttle shaft assembly thus preventing the preload from being released as the throttle shaft assembly is inserted into the throttle body. One end of the spring can be released to engage a portion of the throttle body thus reducing a portion of the preload. The cover had several flexible fingers that engage a groove in the throttle shaft and prevent the cover from sliding off thus exposing the spring.

Abstract: An HVAC motor assembly for mounting to a housing includes a motor having a generally cylindrical portion and a connector extending from the cylindrical portion. The motor also has air flow passages therethrough. The assembly includes a one-piece cover structure including a generally cylindrical section having an opening at one end thereof and a closed end opposite the one end, and an interior between the ends. The motor is disposed in the interior so that one end of the motor is covered by the closed end. A flange structure extends from the cylindrical section. A first passage in the cover structure is in open communication with atmosphere and in communication with the interior. The first passage communicates with a connector opening in the cover structure. The first passage is sized to permit the connector of the motor to pass therethrough and the connector opening receives the connector.

Abstract: An internal combustion engine intake manifold has a wall separating internal manifold space from an external space. An EGR valve for recirculating engine exhaust gases mounts on the wall such that an EGR outlet port of the EGR valve is communicated to the internal manifold space. EGR valves having various mounts for closing valve mounting holes in the manifold wall are disclosed.

Abstract: An air cleaner for purifying air is disclosed. The air cleaner includes a housing having a first shell mounted to a second shell. The air cleaner also includes a filter disposed within the second shell and having a first side and a second side. Also, the air includes a flexible seal disposed between the first side of the filter and the first shell of the housing. At least one cam is rotatably mounted to the second shell and adapted to selectively engage the second side of the filter to compress the seal between the first side of the filter and the first shell of the housing.

Abstract: An internal combustion engine has multiple combustion chambers each having intake and exhaust valves for controlling intake and exhaust flows into and from the combustion chamber, an induction system to the intake valves, an exhaust system from the exhaust valves, and an EGR system for controlling recirculation of exhaust flow to the combustion chambers. The EGR system has an individual electric-actuated EGR valve associated with each respective combustion chamber for controlling the exhaust recirculation to the respective combustion chamber independent of the exhaust gas recirculated to any other combustion chamber. The EGR valves are mounted in an exhaust gas recirculation rail assembly that is assembled to the engine. Each EGR valve is operated according to mapped EGR requirements for the respective combustion chamber.

Abstract: A cooling module 10 of short axial length includes a fan 18 having a plurality of blades 16. A shroud structure 12 is spaced from and generally adjacent to the blades 16. A brushless electric motor 22 rotates the blades 16. The motor 22 includes a heat sink structure 24 coupled to the shroud structure 12 and defines a base of the motor 22. A shaft 32 is fixed to the heat sink structure 24. A rotor 34 is mounted for rotation with respect to the shaft 32. The fan 18 is coupled to the rotor 34. Magnets 48 are fixed in relation to the rotor 34. A lamination core 56 is fixed to the heat sink structure 24. A winding is wound about the lamination core 56 and is operatively associated with the magnets 48.

Abstract: A coupling is disclosed for connecting conduits that carry combustion air to an internal combustion engine. Two conduits are provide, a first one having an associated locking collar with slots and flexible locking fingers, and a second one having several outwardly facing pins and catches located on an outer surface. The pins are received in the slots and the two conduits are rotated with respect to each other. The catches and locking fingers engage to prevent the two conduits from being pulled apart. Both conduits and locking collar are preferably made of plastic, with the second one and its associated locking collar being simltaneously and integrally molded. A resilient seal may be located between the two components to reduce or eliminate air leakage.

Abstract: An evaporative emission control system for a fuel system of an internal combustion engine of an automotive vehicle has a purge flow path through which an evaporative emission containment space of the fuel system for containing volatile fuel vapors is purged to an intake system of the engine. A purge valve controls purge flow through the purge flow path. When the intensity of intake system vacuum falls below a threshold, an electric-motor-driven blower operates to creates a pressure rise in the purge flow path upstream of the purge valve and downstream of the containment space. A differential pressure sensor senses pressure differential across the purge valve, and the purge valve includes an integral valve position sensor, both sensors providing feedback signals to a controller than controls operation of both the purge valve and the blower.

Abstract: A module for an on-board evaporative emission leak detection system that detects leakage from an evaporative emission space of an automotive vehicle fuel system. A pump disposed within interior space of the module has an inlet in communication with the interior space and a flow passage through which the evaporative emission space is pressurized by the pump. A vent valve within the interior space is selectively operable to a first state that vents the flow passage to the interior space of the module and to a second state that does not vent the flow passage to the interior space. An electromechanical actuator within the interior space operates both the pump and the vent valve. A first lever for operating the pump is mounted for pivotal motion on a wall of the enclosure, and a second lever for operating the vent valve is mounted for pivotal motion on a wall of the enclosure. The material of the parts that provide the pivotal mountings is polymeric.

Abstract: A field replaceable unitary manifold housing for providing combustion air and combustion fuel to an internal combustion engine is disclosed. The housing includes an air purification cavity having a spaced apart air intake and air discharge. The housing also includes a filter for purifying air disposed in the air purification cavity intermediate the air intake and the air discharge. The housing also includes a hollow elongate member having a first end coupled to the filter and a second end coupled to a plenum chamber for directing the air, the plenum chamber being integral with the air purification cavity. The housing also includes a plurality of channels, each channel integral with the housing and having a first end integral with the plenum chamber and a second end coupled to a cylinder head of the engine.

Abstract: A throttle valve for throttling the combustion air flow for an internal combustion engine is disclosed, having a body with a throat, a butterfly in the throat to throttle flow, and a shaft connected to the butterfly to operate it. The shaft has an arm that abuts a throttle stop to maintain the butterfly in an almost-closed (or idle) position. The arm has an opening that permits access to the head of the throttle stop to adjust the throttle stop when the throttle valve is in the almost-closed position. The opening is located so that a tool such as a hex wrench can pass through the opening and engage a socket in the head of the throttle stop, pemitting it to be rotated and adjusted. The throttle shaft and arm are preferably integrally molded of plastic, and the throttle stop head is preferably larger than the threaded shaft of the throttle stop.

Abstract: An EGR module has a valve containing a main flow passage having a valve member that controls exhaust gas flow through the passage. An internal pressure sensing passage communicates pressure at one side of an orifice in the main flow passage to a pressure sensor. The pressure sensor and an EVR valve are integrated with the body of a fluid pressure actuator that operates the valve member. Various embodiments are disclosed.

Abstract: An exhaust gas recirculation valve for an internal combustion engine (16). A one-piece adapter part (10; 10′) contains a combustion air passageway (34) through which combustion air can enter the engine and a coolant passageway (18) through which engine coolant can flow. The adapter part also has an exhaust gas recirculation passageway (22) through which engine exhaust gas can be introduced into the combustion air passageway. An electric-operated exhaust gas recirculation valve (12) for controlling the recirculation of engine exhaust gas through the engine has a valve member (28) that is positionable with respect to a valve seat (26) that circumscribes the exhaust gas passageway in the adapter part.

Abstract: An engine cooling system includes an engine 14; a radiator assembly including a radiator 16 and a fan 19 driven by an electric fan motor 21; a coolant circulation circuit 12 interconnecting the engine and the radiator for circulating coolant; a by-pass circuit 24 connected to the coolant circulation circuit so that coolant may by-pass the radiator; an electrically powered variable speed coolant pump 28 disposed in the coolant circulation circuit to pump coolant through the coolant circulation circuit; control valve structure 26 constructed and arranged to control mass flow of coolant through the radiator; an engine temperature sensor 54 to detect a temperature of engine coolant; a radiator temperature sensor 58 to detect a temperature of air exiting the radiator or a temperature of coolant at an outlet of the radiator, and a controller 36 operatively connected with the electric fan motor, the coolant pump, the control valve structure, the engine temperature sensor, and the radiator temperature sensor.

Abstract: A method of making air assist passageways and injector pockets in a manifold or air assist rail includes providing a mold that can open and close with several bosses extending from an inside surface. These bosses are arranged in a row and define the inside of the injector pockets when the mold is filled. The air assist passageway that couples the fuel injector pockets is provided by inserting a long pin that passes through the row of injector pocket bosses inside the mold cavity. When the cavity is filled with molten material and solidifies, the pin is withdrawn, leaving a long air assist passageway extending between the injector pockets. The mold is then opened, pulling the injector pocket bosses out of the now-formed injector pockets. The resulting structure is a row of injector pockets in a manifold or air assist rail into which injectors can be inserted, that are connected by a long air assist passageway.

Abstract: A housing for abating noise and receiving an air cleaner is disclosed. The housing is configured for separable coupling to an internal combustion engine of an automobile. The engine includes a plurality of belt driven accessories driven by a crankshaft. The housing includes an internal air cavity disposed in the housing. The cavity provides an air induction chamber adjacent an intake for inducing air into the air induction chamber from an external source and a filtering chamber adjacent an air discharge for venting air from the filtering chamber. The filtering chamber is configured to receive a filter for purifying air disposed intermediate the intake and the discharge. The engine further includes a shroud integral with the exterior of the housing. The shroud provides a peripheral wall defining a recess configured to at least partially surround at least a portion of at least two belt driven accessories. The shroud substantially reduces noise generated by the engine.

Abstract: A brushless electric motor 26 includes a stator assembly 32 defining an interior chamber 38. The stator assembly includes a stator core 34 and windings 36. The windings and at least a portion 44 of the stator core are in open communication with the interior chamber. A rotor assembly 42 is provided in the interior chamber. An electronic control unit 60 is coupled to the stator assembly and has an upper surface 62 in communication with the interior chamber. A fluid flow path structure 64 is constructed and arranged to permit fluid to pass from an inlet in the stator assembly and enter the interior chamber so that the rotor assembly, the windings, and the portion of said stator core are submerged in the fluid for cooling the rotor assembly, the windings, and the portion of the stator core. Fluid also contacts the upper surface of the electronic control unit to cool the electronic control unit. Fluid isolating structure 74′ prevents fluid from contacting an end 81 of the windings.

Abstract: An air cleaner that locks two shells together by a cam action is disclosed having two shells with interlocking fingers staggered along at least one length of the joint between the first and second shells. A cam is inserted between the interlocking fingers and when rotated pulls the fingers apart and pulls the two shells together.

Abstract: An apparatus and method for incorporating a plurality of various fuel and emission components generally located on the top or outside of an internal combustion engine into a completed sub-assembly that can be delivered to an engine assembly line and installed as a unit on the engine. The air-fuel system components are assembled in a unitized or integrated air-fuel module which is then assembled to the engine. Also disclosed is a method of assembling an engine including providing an intake manifold base having at least one valve cover integrally molded in a bottom of the intake manifold base and having integral intake manifold runners; assembling an integrated air-fuel module at a first location; and then attaching the integrated air-fuel module to the engine at a second location.

Abstract: A combined air cleaning and flow rate sensing system for the combustion air of an internal combustion engine is disclosed. The system includes a housing providing an inlet and a filter at least partially disposed in the housing. The air cleaner system also includes a conduit adjacent the housing and providing a flange and an outlet. The air cleaner system also includes a compressible seal disposed between the filter and the flange. The air cleaner system also includes a locking mechanism adapted to selectively secure the conduit to the housing such that the seal may be compressed between the conduit and the filter. The air cleaner system also includes an accessory mounted to the conduit. The air entering the inlet exits through the outlet.