Abstract: A turbocharger having a turbine housing with an integral EGR conduit is disclosed. The turbine includes a turbine wheel attached to a turbine shaft and rotatably disposed in a turbine housing having a turbine volute conduit having a turbine inlet passage fluidly coupled to a turbine volute conduit having a turbine volute passage and a turbine volute inlet and an EGR conduit having an EGR passage, the EGR passage having an EGR conduit inlet, the EGR conduit inlet disposed on the turbine inlet conduit. The turbine inlet conduit is configured for fluid communication of a first portion of an exhaust gas flow received from an engine to the turbine wheel. The EGR conduit is configured for fluid communication of a second portion of the exhaust gas flow to an engine intake manifold.

Abstract: An engine assembly includes a cylinder block having at least one cylinder. The engine assembly includes at least one cylinder head coupled to the cylinder block, and at least one intake port coupled to the cylinder head, at least one exhaust port coupled to the cylinder head, and at least one fuel injector coupled to the cylinder head. The engine assembly includes a head cooling extension protruding from the cylinder head. The head cooling extension includes at least one extension wall and defines an extension cooling passageway at least partially enclosed by the at least one extension wall. The extension cooling passageway is at least partly disposed between the exhaust port and the fuel injector in order to create a thermal barrier between the fuel injector and the exhaust port when the coolant flows through the extension cooling passageway.

Abstract: A core structure for a cast crankshaft is provided which eliminates the need to machine and install plugs in one or more of the main bearing lightening holes. This is achieved by configuring the core structure to take out all but a thin wall of material in the center of the main bearing journals.

Abstract: An engine assembly includes a cylinder block having at least one cylinder. The engine assembly includes at least one cylinder head coupled to the cylinder block, and at least one intake port coupled to the cylinder head, at least one exhaust port coupled to the cylinder head, and at least one fuel injector coupled to the cylinder head. The engine assembly includes a head cooling extension protruding from the cylinder head. The head cooling extension includes at least one extension wall and defines an extension cooling passageway at least partially enclosed by the at least one extension wall. The extension cooling passageway is at least partly disposed between the exhaust port and the fuel injector in order to create a thermal barrier between the fuel injector and the exhaust port when the coolant flows through the extension cooling passageway.

Abstract: A core structure for a cast crankshaft is provided which eliminates the need to machine and install plugs in one or more of the main bearing lightening holes. This is achieved by configuring the core structure to take out all but a thin wall of material in the center of the main bearing journals.

Abstract: A crankshaft includes a pin bearing journal, and a counterweight. The pin bearing journal defines a hollow pin core. The hollow pin core includes a first pin core section and a second pin core section, and an enlarged central section disposed between the first pin core section and the second pin core section. The first and second pin core sections each define a cross section having a first and second cross sectional area respectively, and the enlarged central section defines a third cross section defining a third cross sectional area, with the third cross sectional area larger than the first and second cross sectional areas. An isolation window extends through the counterweight. The crankshaft is cast from a high shrink steel alloy having a shrinkage factor equal to or greater than 1%. The enlarged central section and the isolation window improve the castability of the high shrink steel alloy.

Abstract: An internal combustion engine includes a balance shaft assembly having a housing mounted to the cylinder block wherein the housing supports a pair of balance shafts rotatably driven by the crankshaft. The pair of balance shafts rotate in opposite directions and each include a hollow tubular body with an internal eccentric mass. A first of the pair of balance shafts is drivingly connected to a drive sprocket at a first end and can include a first drive gear at a second end that is meshingly engaged with a first driven gear at an end of a second of the pair of balance shafts. A first oil pump is provided at the first end of the pair of balance shaft, and a second oil pump is provided at a second end of the pair of balance shafts. The gears of the oil pumps transfer torque between the pair of balance shafts.

Abstract: In one exemplary embodiment of the present invention, a housing assembly for a forced induction system of an internal combustion engine is provided. The housing includes a turbine housing that further includes a turbine inlet passage in fluid communication with a turbine volute configured to house a turbine wheel. The housing assembly also includes a turbine outlet passage integrated in the turbine housing, the turbine outlet passage in fluid communication with the turbine volute, the turbine outlet passage configured to direct the exhaust gas flow to a catalytic converter coupled to the turbine outlet passage. Further, the housing assembly includes a compressor housing integrated with a compressor inlet passage in fluid communication with a compressor volute configured to house a compressor wheel coupled to the turbine wheel, the compressor inlet passage including a wall that is shared with the compressor volute.

Abstract: In one exemplary embodiment of the invention, a turbine housing for a forced induction system of an internal combustion engine is provided, the turbine housing including a turbine inlet passage in fluid communication with a turbine volute configured to house a turbine wheel, the turbine inlet passage configured to direct an exhaust gas flow from an exhaust manifold to the turbine wheel. The housing also includes a turbine outlet passage in fluid communication with the turbine volute, the turbine outlet passage configured to direct the exhaust gas flow to a catalytic converter coupled to the turbine outlet passage, wherein the turbine outlet passage comprises a cone shaped passage.

Abstract: A method of forming a cylinder head includes casting the cylinder head to include an integral cast-in exhaust manifold. The integral cast-in exhaust manifold defines an intermediate exhaust gas passage in fluid communication with exhaust ports and an exhaust gas outlet passage in fluid communication with the intermediate exhaust gas passage. The cast cylinder head includes a coolant cavity to receive a cooling fluid. The coolant cavity includes first and second portions extending around an outer circumference of the exhaust gas outlet passage separated from one another by a first cast-in wall. The method further includes machining the first cast-in wall to provide fluid communication between the first and second portions of the coolant cavity. Machining the first cast-in wall forms a first coolant passage created by the first and second portions of the coolant cavity and the machined passage around the outer circumference of the exhaust gas outlet passage.

Abstract: An engine assembly may include an engine block, a cylinder head coupled to the engine block, and first and second intake valves supported by the cylinder head. The engine block may define a first set of cylinder bores arranged longitudinally in series and including a first cylinder bore and a second cylinder bore adjacent the first cylinder bore. The cylinder head may define a cavity forming an intake manifold region, a first intake runner extending laterally inward from the intake manifold region toward the first cylinder bore and a second intake runner extending laterally inward from the intake manifold region toward the second cylinder bore. The first intake valve may selectively provide communication between the first intake runner and the first cylinder bore. The second intake valve may selectively provide communication between the second intake runner and the second cylinder bore.

Abstract: A turbocharger having a turbine housing with an integral EGR conduit is disclosed. The turbine includes a turbine wheel attached to a turbine shaft and rotatably disposed in a turbine housing having a turbine volute conduit having a turbine inlet passage fluidly coupled to a turbine volute conduit having a turbine volute passage and a turbine volute inlet and an EGR conduit having an EGR passage, the EGR passage having an EGR conduit inlet, the EGR conduit inlet disposed on the turbine inlet conduit. The turbine inlet conduit is configured for fluid communication of a first portion of an exhaust gas flow received from an engine to the turbine wheel. The EGR conduit is configured for fluid communication of a second portion of the exhaust gas flow to an engine intake manifold.

Abstract: An engine is provided with features allowing a method of assembly that combines the ease of assembly of a net-assembled system with the positional accuracy of an index-assembled system in order to meet critical valve to piston clearance requirements, especially critical in a diesel engine.

Abstract: A piston squirter system for an internal combustion engine includes an oil reservoir, a variable displacement pump, and, for each cylinder, a piston squirter that sprays oil onto a piston for cooling and lubricating. A gallery connects the variable displacement pump to the piston squirters. The variable displacement pump receives oil from the oil reservoir and distributes the oil through the gallery to the piston squirters at a flow rate according to pressure required. The gallery does not require a relief valve and the piston squirters do not require check valves.

Abstract: A method of forming a cylinder head includes casting the cylinder head to include an integral cast-in exhaust manifold. The integral cast-in exhaust manifold defines an intermediate exhaust gas passage in fluid communication with exhaust ports and an exhaust gas outlet passage in fluid communication with the intermediate exhaust gas passage. The cast cylinder head includes a coolant cavity to receive a cooling fluid. The coolant cavity includes first and second portions extending around an outer circumference of the exhaust gas outlet passage separated from one another by a first cast-in wall. The method further includes machining the first cast-in wall to provide fluid communication between the first and second portions of the coolant cavity. Machining the first cast-in wall forms a first coolant passage created by the first and second portions of the coolant cavity and the machined passage around the outer circumference of the exhaust gas outlet passage.

Abstract: A piston squirter system and method for an internal combustion engine is disclosed. The piston squirter system includes an oil reservoir, a variable displacement pump, and, for each cylinder, a piston squirter that sprays oil onto a piston for cooling and lubricating. A gallery connects the variable displacement pump to the piston squirters. The variable displacement pump receives oil from the oil reservoir and distributes the oil through the gallery to the piston squirters at a flow rate according to pressure required. The gallery does not require a relief valve and the piston squirters do not require check valves.

Abstract: An engine is provided with features allowing a method of assembly that combines the ease of assembly of a net-assembled system with the positional accuracy of an index-assembled system in order to meet critical valve to piston clearance requirements, especially critical in a diesel engine.

Abstract: A drive plate assembly includes a plate member adapted for mounting to an engine block. The plate member has first and second gears mounted thereto such that they intermesh. The backlash of the gears is predetermined by mounting to the plate member and unaffected by mounting the plate member to the engine block. A method of assembling a powertrain is also provided.

Abstract: A method for adjusting the timing of an internal combustion engine having a crankshaft and a camshaft to manage the thermal load on the engine. The method includes the step of altering the timing of the camshaft with respect to the timing of the crankshaft to reduce thermal load on the engine. Preferably, the step of altering the timing of the camshaft is accomplished with a variable camshaft phaser.

Abstract: A method for adjusting the timing of an internal combustion engine having a crankshaft and a camshaft to manage the thermal load on the engine. The method includes the step of altering the timing of the camshaft with respect to the timing of the crankshaft to reduce thermal load on the engine. Preferably, the step of altering the timing of the camshaft is accomplished with a variable camshaft phaser.