Abstract: A cylinder head assembly includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head. The integrated cylinder head and turbocharger housing includes: (i) a compact low wetted area to provide an uninterrupted flow path pointed directly at a catalyst face to facilitate achieving cold start emissions targets, (ii) a casting core assembly with specific core geometry and steps for assembly to enable core assembly while meeting all cylinder head and integrated turbine housing functional requirements, (iii) an oxygen sensor disposed pre-turbine in an integrated exhaust manifold, and (iv) a fully integrated PCV make-up air system.

Abstract: A cylinder head assembly for an internal combustion engine includes a cast cylinder head, a turbocharger housing including a compressor housing and turbine housing integrally cast with the cylinder head, and a turbocharger cartridge assembly configured to be inserted into the turbocharger housing and including a shaft coupled between a compressor wheel and a turbine wheel. A compressor cover is configured to couple to the compressor housing and define a compressor inlet and at least partially define a compressor diffuser passage. The cartridge assembly includes a housing having a diffuser flange extending outwardly therefrom, the diffuser flange including a front surface and an opposite contoured volute surface. The compressor diffuser passage is at least partially defined by the compressor cover and the diffuser flange front surface. A compressor volute is at least partially defined by the diffuser flange contoured volute surface and a contoured inner surface of the compressor housing.

Abstract: A cylinder head assembly for an internal combustion engine includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head and having an integrally cast wastegate housing. The turbocharger housing is configured to receive a turbocharger cartridge rotatably supporting a shaft coupled between a compressor wheel and a turbine wheel. The integrally cast wastegate housing defines a wastegate chamber configured to receive a wastegate valve, a flow of exhaust gas from the turbine wheel, and a flow of wastegate exhaust gas.

Abstract: A cylinder head assembly includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head. The integrated cylinder head and turbocharger housing includes: (i) a compact low wetted area to provide an uninterrupted flow path pointed directly at a catalyst face to facilitate achieving cold start emissions targets, (ii) a casting core assembly with specific core geometry and steps for assembly to enable core assembly while meeting all cylinder head and integrated turbine housing functional requirements, (iii) an oxygen sensor disposed pre-turbine in an integrated exhaust manifold, and (iv) a fully integrated PCV make-up air system.

Abstract: A cylinder head assembly for an internal combustion engine includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head and having an integrally cast wastegate housing. The turbocharger housing is configured to receive a turbocharger cartridge rotatably supporting a shaft coupled between a compressor wheel and a turbine wheel. The integrally cast wastegate housing defines a wastegate chamber configured to receive a wastegate valve, a flow of exhaust gas from the turbine wheel, and a flow of wastegate exhaust gas.

Abstract: A cylinder head assembly for an internal combustion engine includes a cast cylinder head, a turbocharger housing integrally cast with the cylinder head, and a water jacket cast into the integrally cast turbocharger housing and configured to receive a flow of coolant for cooling the integrally cast turbocharger housing. The assembly can also include a wastegate housing integrally cast with the cylinder head and the turbocharger housing, and a water jacket cast into the integrally cast wastegate housing. The water jacket is configured to receive a flow of coolant for cooling the integrally cast turbocharger housing and the integrally cast wastegate housing.

Abstract: A flywheel having a molded cage formed around a plurality of magnets attached to the flywheel. The cage extends into one or more grooves formed in the flywheel to resist the shrinkage of the cage inside diameter as it cools following an injection molding process. The gap between the cage and magnets and an adjacent stator is precisely controlled and minimized. Shutoff surfaces formed on the flywheel function as a portion of the die for injection molding of the cage.

Abstract: A flywheel having a molded cage formed around a plurality of magnets attached to the flywheel. The cage extends into one or more grooves formed in the flywheel to resist the shrinkage of the cage inside diameter as it cools following an injection molding process. The gap between the cage and magnets and an adjacent stator is precisely controlled and minimized. Shutoff surfaces formed on the flywheel function as a portion of the die for injection molding of the cage.

Abstract: A flywheel (20) having a molded cage (30) formed around a plurality of magnets (34) attached to the flywheel (20). The cage (30) extends into one or more grooves (40,42) formed in the flywheel (20) to resist the shrinkage of the cage 30 inside diameter as it cools following an injection molding process. The gap (44) between the cage (30) and magnets (34) and an adjacent stator (32) is precisely controlled and minimized. Shutoff surfaces (36,38,46) formed on the flywheel (20) function as a portion of the die for injection molding of the cage (30).

Abstract: An improved air inlet cover for use with outboard motors is disclosed. A particular embodiment of the cover is formed by a generally hollow shell having an open side. An air passage is located opposite the open side at an upper portion of the shell. A baffle extends from an upper inner portion of the shell to an elevation below the air passage and is disposed generally opposite the air passage. An exit port is provided at the bottom of the chamber for discharging water collected therein, and a valve is provided within the exit port. When the exit port is submerged the valve is closed and provides a barrier to water entry. Preferably, the cover is located at an upper forward portion of the outboard motor cowl and both the air passage and air inlet are high up on the upper forward portion.