Abstract: A turbocharger assembly is provided which prevents liquid moisture 82 from damaging an air fuel ratio sensor affixed to the exhaust pipe. The turbocharger assembly includes a turbine housing, a turbine wheel, a volute defined in the turbine housing, and an upwardly extending exhaust pipe. The turbine housing may be affixed to a center turbocharger housing member. The turbine housing includes an anterior region and a posterior region having the volute. The turbine wheel may be disposed in the turbine housing. A liquid moisture 82 pathway may be defined in the turbine housing and is configured to provide liquid fluid communication from the anterior region toward the volute.

Abstract: A turbocharger assembly is provided which prevents liquid moisture 82 from damaging an air fuel ratio sensor affixed to the exhaust pipe. The turbocharger assembly includes a turbine housing, a turbine wheel, a volute defined in the turbine housing, and an upwardly extending exhaust pipe. The turbine housing may be affixed to a center turbocharger housing member. The turbine housing includes an anterior region and a posterior region having the volute. The turbine wheel may be disposed in the turbine housing. A liquid moisture 82 pathway may be defined in the turbine housing and is configured to provide liquid fluid communication from the anterior region toward the volute.

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: 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: 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: In one exemplary embodiment of the present invention, a compressor housing for a forced induction system of an internal combustion engine is provided. The compressor housing includes a compressor inlet passage in fluid communication with a compressor volute configured to house a compressor wheel, the compressor inlet passage comprising a wall that is shared with the compressor volute. The compressor also includes a compressor outlet in fluid communication with the compressor volute, the compressor outlet being configured to direct a compressed gas to an intake manifold of the internal combustion engine.

Abstract: In one exemplary embodiment of the present invention, a compressor housing for a forced induction system of an internal combustion engine is provided. The compressor housing includes a compressor inlet passage in fluid communication with a compressor volute configured to house a compressor wheel, the compressor inlet passage comprising a wall that is shared with the compressor volute. The compressor also includes a compressor outlet in fluid communication with the compressor volute, the compressor outlet being configured to direct a compressed gas to an intake manifold of the internal combustion engine.

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: 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: A turbocharger for an internal combustion engine includes a turbine comprising a turbine wheel attached to a turbine shaft, the turbine wheel and shaft rotatably disposed in a turbine housing, the turbine housing comprising a turbine volute conduit, the turbine volute conduit having a turbine volute inlet and an EGR conduit inlet, the EGR conduit inlet radially spaced from the turbine volute inlet along the turbine volute conduit and opening into an EGR conduit that is joined to the turbine volute conduit. The turbine volute inlet is configured for fluid communication of an exhaust gas received from an engine to the turbine wheel, the EGR conduit configured for fluid communication of the exhaust gas to an engine intake conduit. The turbocharger also includes a compressor comprising a compressor wheel attached to the turbine shaft, the compressor wheel and turbine shaft rotatably disposed in compressor housing.