Abstract: A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.

Abstract: A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.

Abstract: A cylinder head assembly for an internal combustion engine includes a main body, a valve seat insert, and at least one flow passage extending through the main body. The main body may be formed from a first material and defines a recess configured to cooperate with an associated cylinder bore and piston to form a combustion chamber. The flow passage may extend through the main body from the recess. The valve seat insert may be disposed within the recess proximate to an end of the flow passage. The valve seat insert includes a thermally conductive layer of powdered metal having an upper side disposed adjacent to the main body, a hardness layer of powdered metal, and a machining layer of powdered metal.

Abstract: A sealed t-joint includes a first component having a first sealing surface, a second component having a second sealing surface, and a third component including a channel characterized by a channel height, channel width, and a channel depth. The t-joint also includes a gasket having a thickness and a protrusion characterized by a protrusion height, a protrusion width, and a protrusion depth. The protrusion height is less than the channel height, the protrusion width is less than channel width, and the protrusion depth is less than the channel depth. The t-joint additionally includes a polymer sealant. The gasket is compressed between the first and second sealing surfaces to generate a first and second component sub-assembly. Additionally, the polymer sealant is applied into the channel. The third component is subsequently assembled with the first and second component sub-assembly such that the protrusion extends into the channel to seal the t-joint.

Abstract: A sealed t-joint includes a first component having a first sealing surface, a second component having a second sealing surface, and a third component including a channel characterized by a channel height, channel width, and a channel depth. The t-joint also includes a gasket having a thickness and a protrusion characterized by a protrusion height, a protrusion width, and a protrusion depth. The protrusion height is less than the channel height, the protrusion width is less than channel width, and the protrusion depth is less than the channel depth. The t-joint additionally includes a polymer sealant. The gasket is compressed between the first and second sealing surfaces to generate a first and second component sub-assembly. Additionally, the polymer sealant is applied into the channel. The third component is subsequently assembled with the first and second component sub-assembly such that the protrusion extends into the channel to seal the t-joint.

Abstract: An engine assembly may include an engine structure, a first camshaft housing assembly and a first camshaft assembly. The first camshaft housing assembly may be supported by the engine structure and have a first portion providing a first plurality of bearing support surfaces on a first side and a second portion coupled to the first portion and providing a second plurality of bearing support surfaces on a second side opposite the first side. The first camshaft assembly may be rotationally supported by the first camshaft housing assembly and arranged between the first portion and second portion.

Abstract: A cylinder head including a dam defining a reservoir surrounding the periphery of the fuel pump tappet/roller follower mounting hole is provided. The cylinder head includes a tappet/roller follower mounted in the tappet/roller follower mounting hole and in communication with a cam and a fuel pump. The fuel pump is located on the high side of the head and oil drainage occurs in a direction away from the mounting hole. The dam and reservoir are configured to retain lubricant in the mounting hole and the sliding interface between the mounting hole and the tappet/roller follower. The dam and reservoir are configured to retain a minimum level of oil in the mounting hole when the head is in vehicle position. A method is provided for retaining lubrication in the tappet/roller follower hole by forming a dam defining a reservoir in the head and passively providing lubricant to the tappet/roller follower hole.

Abstract: A central direct injection (DI) cylinder head is configured with an intake valvetrain and an exhaust valvetrain separated by an uncovered central DI valley. The uncovered central DI valley limits oil flow from the high side chamber to the low side chamber and PCV transfer. Oil drainage and additional PCV transfer between the intake and exhaust chambers is provided by drain/vent passages integrally cast into the casting of the cylinder head. The drain/vent passages may be of varying configuration, and may be located between an injector port of a first cylinder set and a spark plug port of an adjacent cylinder set, or at either or both ends of the cylinder head. A method is provided to form a casting of the cylinder head as described herein, including casting of a plurality of drain/vent passages between the first chamber and the second chamber of the cylinder head.

Abstract: An engine assembly may include an engine structure, a first camshaft housing assembly and a first camshaft assembly. The first camshaft housing assembly may be supported by the engine structure and have a first portion providing a first plurality of bearing support surfaces on a first side and a second portion coupled to the first portion and providing a second plurality of bearing support surfaces on a second side opposite the first side. The first camshaft assembly may be rotationally supported by the first camshaft housing assembly and arranged between the first portion and second portion.

Abstract: A cylinder head including a dam defining a reservoir surrounding the periphery of the fuel pump tappet/roller follower mounting hole is provided. The cylinder head includes a tappet/roller follower mounted in the tappet/roller follower mounting hole and in communication with a cam and a fuel pump. The fuel pump is located on the high side of the head and oil drainage occurs in a direction away from the mounting hole. The dam and reservoir are configured to retain lubricant in the mounting hole and the sliding interface between the mounting hole and the tappet/roller follower. The dam and reservoir are configured to retain a minimum level of oil in the mounting hole when the head is in vehicle position. A method is provided for retaining lubrication in the tappet/roller follower hole by forming a dam defining a reservoir in the head and passively providing lubricant to the tappet/roller follower hole.

Abstract: A cylinder head for an internal combustion engine comprises a cooling water jacket having a high volume lower portion and a low volume upper portion. A plurality of coolant risers in the high volume lower portion are configured to receive high pressure coolant from coolant openings in a cylinder block. Coolant risers extending between the high volume lower portion and low volume upper portion define restrictions regulate coolant flow from the high volume lower portion to the low volume upper portion at a predetermined volume and flow.

Abstract: A central direct injection (DI) cylinder head is configured with an intake valvetrain and an exhaust valvetrain separated by an uncovered central DI valley. The uncovered central DI valley limits oil flow from the high side chamber to the low side chamber and PCV transfer. Oil drainage and additional PCV transfer between the intake and exhaust chambers is provided by drain/vent passages integrally cast into the casting of the cylinder head. The drain/vent passages may be of varying configuration, and may be located between an injector port of a first cylinder set and a spark plug port of an adjacent cylinder set, or at either or both ends of the cylinder head. A method is provided to form a casting of the cylinder head as described herein, including casting of a plurality of drain/vent passages between the first chamber and the second chamber of the cylinder head.

Abstract: An engine includes cams for actuating intake and exhaust valves controlling transport of air and combustion products to and from a combustion chamber of the engine. The cams have valve opening and closing curves capable of being timed so that the intake valve opening curve partially overlaps the exhaust valve closing curve, allowing retention of some combustion products in the combustion chamber with an incoming air charge. At least one of the cams has variable timing to vary the valve overlap for controlling the amount of exhaust gas retention or recirculation (EGR). The overlapping portions of the cam opening and closing curves are extended to provide a relatively linear variation in valve overlap area over the range of cam variable timing. Thus, variation of exhaust gas retention in the combustion chamber becomes a relatively constant function of the duration of valve overlap in each engine cycle and control of the amount of EGR is improved.

Abstract: An engine includes cams for actuating intake and exhaust valves controlling transport of air and combustion products to and from a combustion chamber of the engine. The cams have valve opening and closing curves capable of being timed so that the intake valve opening curve partially overlaps the exhaust valve closing curve, allowing retention of some combustion products in the combustion chamber with an incoming air charge. At least one of the cams has variable timing to vary the valve overlap for controlling the amount of exhaust gas retention or recirculation (EGR). The overlapping portions of the cam opening and closing curves are extended to provide a relatively linear variation in valve overlap area over the range of cam variable timing. Thus, variation of exhaust gas retention in the combustion chamber becomes a relatively constant function of the duration of valve overlap in each engine cycle and control of the amount of EGR is improved.