Abstract: An intake assembly includes an intake manifold comprising several interfitting sections attached to each other to define a plurality of air passages, and an EGR conduit within the intake manifold including openings in communication with each of the plurality of air passages. The EGR conduit is in communication with a source of exhaust gases and provides for the proximate and decentralized injection of exhaust gases into the intake manifold assembly. The intake manifold assembly also includes a passage that is in communication with a positive crankcase ventilation system (PCV) and a purge gas system. Gases from the PCV system and the gas purge system mix in the passage and then are communicated to the each of the air passages through individual opening passages.

Abstract: An active noise attenuation system includes a speaker housing for a speaker assembly that attenuates noise generated by an air induction system for a vehicle engine. The speaker housing is a generic housing formed from plastic that can be utilized with many different vehicle types. An air cleaner housing is positioned between the speaker housing and the engine for filtering out contaminants from the air before the air is drawn into the engine. Brackets are joined to the air cleaner and speaker housings for mounting the housings to a vehicle structure.

Abstract: An air cleaner, intake manifold, and valve cover are integrated together for attachment to a vehicle engine. The air cleaner is positioned directly between the intake manifold and valve cover to provide a compact induction module. The induction module is mounted to the engine as a single unit. A throttle body is also incorporated into the intake manifold. A tube interconnects the air cleaner and the throttle body. An air filter is installed within the air cleaner to remove contaminants from air prior to entry into the tube.

Abstract: A modular air induction assembly comprises an air induction body, an air filter operatively attached to the air induction body, and a speaker operatively attached to the air induction body. The modular air induction assembly is then installed into the air induction system of a vehicle during production. The air induction body may also comprise a first portion and a second portion that permits service of the assembly following initial vehicle installation.

Abstract: A method and apparatus is provided for the attachment of a throttle shaft to a throttle body. A throttle shaft, a spring, and a cap retainer, are temporarily assembled as a throttle shaft subassembly. A set of locking members extend from the cap retainer to engage a set of locking surfaces adjacent the throttle shaft to retain the spring in tension. The cap retainer fits onto a boss extending from the throttle body and is lockable thereto by a set of fingers which are received into engagement recesses located on the boss. As the shaft subassembly is guided into the throttle body, the cap retainer is rotated by the engagement surfaces and the locking members are disengaged from the locking surfaces to at least partially unload the spring to mount the shaft.

Abstract: An active noise attenuation system (10) comprises a speaker (26) in communication with a flow body (78). The speaker (26) emits an output for attenuating noise from the flow body (78). A control unit (31) communicates with the speaker (26) and controls the output. A housing (14) has one volume (18) acting as a liquid storage chamber and another volume (22) acting as a speaker chamber.

Abstract: The air induction system comprises an air induction body with a mouth and a speaker forming an interface with the mouth. A fender portion of a vehicle at least partially covers the interface, protecting the interface from environmental conditions. A control unit controls with the speaker to thereby generate a noise attenuating sound.

Abstract: A fuel module carrier assembly mounted between an intake manifold and an internal combustion engine includes an electrical lead, coil assemblies, fuel modules, fuel module seals, a molded carrier and runner seals. The fuel module carrier assembly retains and protects the electric fuel module components.

Abstract: An intake manifold (10) includes a fuel rail cavity (30) which receives a metallic fuel rail (14) enclosed by a molded fuel rail cavity cover (32). The fuel rail (14) communicates with each of a plurality of engine cylinders (16) through a fuel module (18). An injector cup (28) fits upon each module cylinder to provide an interface between the fuel module and the fuel rail. Another intake manifold (10) includes a fuel rail (14) which directly interfaces with each fuel module (18) through a bellows (38) attached directly thereto.

Abstract: An intake manifold (10) includes an integral fuel rail (14) at least partially surrounded by a volume (22). The volume (22), being adjacent the fuel rail (14), minimizes the permeation of fuel out of the fuel rail (14). The volume (22) is also utilizable as a sealed storage space to contain an air induction component (26) to more effectively utilize the packaging space of the intake manifold (10).

Abstract: Steel fuel rails are provided with the mechanical components of a plurality of fuel injector valve bodies. The electronics for operating those valves are molded into an injector pack. The valve bodies are inserted into the passages associated with the injector pack such that the electronics are part of a single molded plastic portion. A corrugated seal is sealed to an outer portion of the passage on the injector pack. Thus, the present invention eliminates the number of connections for supplying fuel that needed to be sealed in the prior art. Further, the number of required assembly steps is reduced over the prior art.

Abstract: An air cleaner, intake manifold, and valve cover are integrated together for attachment to a vehicle engine. The air cleaner is positioned directly between the intake manifold and valve cover to provide a compact induction module. The induction module is mounted to the engine as a single unit. A throttle body is also incorporated into the intake manifold. A tube interconnects the air cleaner and the throttle body. An air filter is installed within the air cleaner to remove contaminants from air prior to entry into the tube.

Abstract: Steel fuel rails are provided with the mechanical components of a plurality of fuel injector valve bodies. The electronics for operating those valves are molded into an injector pack. The valve bodies are inserted into the passages associated with the injector pack such that the electronics are part of a single molded plastic portion. A corrugated seal is sealed to an outer portion of the passage on the injector pack. Thus, the present invention eliminates the number of connections for supplying fuel that needed to be sealed in the prior art. Further, the number of required assembly steps is reduced over the prior art.

Abstract: An intake manifold (10) includes a fuel rail cavity (30) which receives a metallic fuel rail (14) enclosed by a molded fuel rail cavity cover (32). The fuel rail (14) communicates with each of a plurality of engine cylinders (16) through a fuel module (18). An injector cup (28) fits upon each module cylinder to provide an interface between the fuel module and the fuel rail. Another intake manifold (10) includes a fuel rail (14) which directly interfaces with each fuel module (18) through a bellows (38) attached directly thereto.

Abstract: An intake manifold (10) includes an integral fuel rail (14) at least partially surrounded by a volume (22). The volume (22), being adjacent the fuel rail (14), minimizes the permeation of fuel out of the fuel rail (14). The volume (22) is also utilizable as a sealed storage space to contain an air induction component (24) to more effectively utilize the packaging space of the intake manifold (10).

Abstract: A fuel module carrier assembly mounted between an intake manifold and an internal combustion engine includes an electrical lead, coil assemblies, fuel modules, fuel module seals, a molded carrier and runner seals. The fuel module carrier assembly retains and protects the electrical fuel module components. The electrical lead is molded or assembled into the carrier such that the intake manifold is separate from any metallic or wire components which heretofore were molded directly therein. In one carrier assembly, the fuel modules are inserted into the carrier from the lower or engine. Another carrier assembly receives fuel modules which are plugged into fuel module openings. Another carrier assembly includes an electrical lead having a plurality of connectors each of which receives a fuel module assembly having a fuel module and a mating module connector.

Abstract: Laser welding is used to attach an air induction component to a hose member. The air induction component includes a wall with an opening that cooperates with the hose member. The hose member includes a flange that directly engages the wall of the induction component on a surface surrounding the opening. One of the hose or induction component is made from a laser transparent material and the other of the hose or induction component is formed from a laser absorbing material. Contour through transmission welding is used to generate a laser beam that passes through the transparent material, heats the absorbing material, which in turn heats the transparent material and forms a laser weld.

Abstract: An air induction system with active noise control includes a self-cleaning air filter that is integrated within an air intake housing. The self-cleaning air filter filters out contaminants such as dust and dirt particulates from air flowing through the intake housing. The self-cleaning filter is powered and controlled by the same electronic unit that is used to power the active noise control system.

Abstract: An active noise control system (26) includes an error microphone (28), a speaker (29) and an active resonator (30) which communicate with an ANC controller (32). The active resonator is a Helmholtz resonator which is coupled to an air introduction body (19). The resonance frequency of the active resonator is varied in response to the ANC controller (32) which provides logic which responds to sensor signals to eliminate low frequency noise such that the ANC system speaker (29) will effectively control and/or spectral shape the remaining noise.

Abstract: A method and apparatus is provided for snap-fit attachment of a throttle shaft to a throttle body. A pair of resilient cantilevered tangs is formed on a distal end of the throttle shaft. Bearings are installed within a bore formed in the throttle body to rotatably support the shaft. The shaft is inserted through an opening in the bearings to compress the tangs and the tangs are resiliently returned to an extended position to prevent withdrawal of the shaft from the throttle body.