Abstract: An internal combustion engine may be coupled to a two-step engine boosting system to provide desired boost to the engine to meet torque demand. The two-step engine boosting system may first provide boost to the engine by nitrous oxide injection into the engine, followed by switching to providing boost from a frame rail air boosting system to generate the desired boost. Air from an air pump coupled to a transmission of the engine may flow air to the frame rail air boosting system for storage and for subsequent use in providing boost to the engine.

Abstract: Methods and systems are provided for regulating airflow through a charge air cooler integrated in an intake assembly. In one example, an engine intake assembly comprises a plenum having an integrated charge air cooler (CAC), a first header seal positioned around a circumference of a first CAC header, and a first rotatably movable seal positioned in a bypass passage of the plenum. The first movable seal interfaces via sliding contact with the first header seal and adjusting a position of the first movable seal may vary the amount of airflow through the bypass passage.

Abstract: A cam carrier assembly includes a body made of a material lighter than aluminum. The body has a first side operably coupled with a cylinder head and a second side having bearing surfaces with bearing inserts. The bearing inserts support the camshaft. A series of apertures extend between the first and second sides of the body. Lobes of the camshaft operably couple with the valves of the cylinder head through the series of apertures extending between the first and second sides of the body.

Abstract: Systems for defining an internally threaded bore in a composite material component include one or more thread forming tools each defining a thread forming portion and a locating fixture configured to hold the one or more thread forming tools in a predetermined configuration defining a pattern of internally threaded bores to be provided in the composite material component. The thread forming portions include a plurality of thread forming surfaces each defining a pitch, a crest fillet radius, and a root fillet radius, and define internally threaded bores having an interior helical thread defining a plurality of full crest radii and a plurality of full root radii. A component forming fixture is provided for abutting the locating fixture whereby the one or more thread forming tools are held in an interior of the forming fixture. Methods for forming composite material components having internally threaded bores using the described systems are described.

Abstract: A system and method for cleaning deposits, such as carbon build-up, from an air induction path of a motor vehicle engine. A reservoir mounted onboard the vehicle is in fluid communication with the induction path and contains a cleaning solution. A control module activates a valve to meters a flow of the solution into an air intake plenum in response to a signal indicating a parameter related to operation of the engine. The solvent may be delivered in a quantity calculated to collect at sump of the intake plenum and be drawn into the engine when intake air flow exceeds a threshold rate. The engine-related parameter may be distance travelled by the vehicle.

Abstract: Methods and systems are provided for selectively re-cooling intake air downstream of a charge air cooler. In one example, a system may include a cylinder head defining a plurality of cylinders, the cylinder head including a plurality of inlet ports each fluidically coupled to a respective cylinder, a refrigerant supply, and a refrigerant passage surrounding each inlet port and fluidically coupled to the refrigerant supply, the refrigerant passage shaped to correspond to an outer profile of each inlet port.

Abstract: An engine has a cylinder block with first and second cylinders separated by a bore bridge, and a block cooling jacket having a slot in the bore bridge and intersecting a block deck face. The engine has one of a cylinder head and a head gasket with a surface configured to mate with the block deck face, the surface having a tab sized to be received by the slot to form a cooling passage therebetween. An engine has a cylinder block with a block deck face defining a first cylinder and a second cylinder separated by an interbore region. The block is independent of a cylinder liner. The block forms a cooling jacket with a fluid passage surrounding the first and second cylinders and an open channel extending across the interbore region and intersecting the block deck face.

Abstract: An engine has a cylinder block with first and second cylinders separated by a bore bridge. The block has a cooling jacket with a cooling channel intersecting a block deck face and circumferentially surrounding the first and second cylinders such that the engine block has an open deck configuration. The engine has a cylinder head with a surface configured to mate with the deck face of the block. The surface of the head has a sleeve protruding therefrom. The sleeve is sized to be received by the channel to circumferentially surround the first and second cylinders to structurally support the cylinders.

Abstract: A cam carrier assembly includes a cylinder head having valves and a camshaft having lobes. A cam carrier has a first side coupled with the cylinder head engaging around the valves and a second side with bearing surfaces supporting the camshaft. A series of apertures extend between the first and second sides for the lobes to interface with the valves. The cam carrier is made of carbon fiber composite insulating the camshaft from the cylinder head and providing substantial weight reduction to an upper section of an associated engine.

Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.

Abstract: Methods and systems are presented for powering a generator via a flexible driveshaft coupled to a vehicle power take off unit. In one example, a flexible driveshaft with a non-rotatable outer sheath and inner, rotatable mandrel may be coupled to a generator complementary connector to power the generator with torque from a power take off unit.

Abstract: Methods and systems are provided for injecting air from a compressed air source into an intake port of a Miller Cycle engine. In one example, a method may comprise positioning an intake valve, coupled to a cylinder of a four-cycle internal combustion engine, in an open position during a portion of an intake stroke through a portion of a compression stroke of a piston reciprocating within said cylinder. The method may additionally comprise supplying air to said intake valve from a first source, and injecting air against said intake valve from a second source while said intake valve is open during said compression stroke.

Abstract: Methods and systems are presented for powering a generator via a flexible driveshaft coupled to a vehicle power take off unit. In one example, a flexible driveshaft with a non-rotatable outer sheath and inner, rotatable mandrel may be coupled to a generator complementary connector to power the generator with torque from a power take off unit.

Abstract: An engine cylinder head comprising an internal metal structure formed from a metal material and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: Methods and systems are provided for introducing a charge motion to a cylinder via a bladder in an intake manifold runner. In one example, a system may include positioning a bladder in an intake port proximate to a cylinder.

Abstract: A system and methods for routing condensate collected in a heat exchanger reservoir to either a combustion chamber of an engine or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, the method includes accumulating a portion of compressed air in an accumulator, and when an engine output is below a predetermined amount, coupling a part of the accumulated air with the condensate through a passage into the combustion chamber. Thereby, the methods described may be used to distribute condensate formed in the heat exchanger even at low engine loads.

Abstract: Methods and systems are provided for regulating airflow through a charge air cooler integrated in an intake assembly. In one example, an engine intake assembly comprises a plenum having an integrated charge air cooler (CAC), a first header seal positioned around a circumference of a first CAC header, and a first rotatably movable seal positioned in a bypass passage of the plenum. The first movable seal interfaces via sliding contact with the first header seal and adjusting a position of the first movable seal may vary the amount of airflow through the bypass passage.

Abstract: A cam carrier assembly includes a cylinder head having valves and a camshaft having lobes. A cam carrier has a first side coupled with the cylinder head engaging around the valves and a second side with bearing surfaces supporting the camshaft. A series of apertures extend between the first and second sides for the lobes to interface with the valves. The cam carrier is made of carbon fiber composite insulating the camshaft from the cylinder head and providing substantial weight reduction to an upper section of an associated engine.

Abstract: A valve cover module includes a unitary cover and carrier made of a carbon fiber composite. The unitary cover and carrier has a lower side with a peripheral edge for attaching to a cylinder head. The lower side of the unitary cover and carrier also has a series of cavities interconnected with aligned apertures defining bearing surfaces. A plurality of cam lobes is disposed in the series of cavities. Also, the valve cover module includes a camshaft rotatable on the bearing surfaces and extending through the aligned apertures to couple with the cam lobes.

Abstract: A system and methods for routing condensate collected in a heat exchanger reservoir to either an air intake system or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, condensate is routed to a first position along the engine air intake system in a first mode of operation, and a second position upstream of the catalyst along the engine exhaust in a second mode of operation, and a third position downstream of the catalyst along the engine exhaust in a third mode of operation. When substantially no contaminates are detected, the condensate may be routed into the engine exhaust upstream of the catalyst in order to cool the catalyst.