Abstract: Remanufacturing a used cylinder liner includes receiving a used cylinder liner having a fillet relieved of residual compressive stress via service in an engine, and compressing a material substrate of the cylinder liner forming a fatigue sensitive fillet, such that a non-uniform profile of the fillet is reshaped via plastic deformation of the material substrate. Residual compressive stress is restored to the fillet at least in part via the plastic deformation. A mask and used cylinder liner assembly for processing the used cylinder liner during remanufacturing is also disclosed.

Abstract: A compressor housing defines an inlet bore having a first inlet collar disposed therein. The inlet collar is connected to the housing with a first plurality of radially extending posts. The first plurality of posts is removed to detach the inlet collar from the housing, and the inlet collar is removed from the housing. The same or another inlet collar is concentrically located within a liner. The liner can be located at a radial distance around at least a portion of the inlet collar. The inlet collar is connected to the liner by radially inserting a second plurality of posts through the liner and into the inlet collar. An assembly of the liner containing the inlet collar is inserted into the inlet bore of the housing such that the inlet collar forms the inducer bore of the compressor housing.

Abstract: A method is provided for remanufacturing an engine block. The engine block includes a top deck and a passageway that opens at the top deck, and is partially defined in the engine block by a counterbore having a side surface and a base surface. The method includes spraying solid powder metal onto the side surface and the base surface by a gas dynamic cold spray method so as to form a fill member adhered with the side surface and the base surface.

Abstract: A method of determining wear of a worn surface of a machine component includes providing a scanning device at a distance from the worn surface. The method also includes moving at least one of the scanning device and the worn surface relative to the other and generating a set of data points via the scanning device. Each data point of the set of data points is indicative of a depth of a corresponding point on the worn surface relative to a reference plane. The method further includes determining a maximum depth of the worn surface based on the set of data points and comparing the maximum depth to a reference value to determine a next step in a remanufacturing process of the machine component.

Abstract: A method for repair of a cylinder block including a water ferrule having damage in an area proximate to the water ferrule is disclosed. The repair method includes removing material from the area containing and surrounding the damage. The method also includes providing a counter bore sized to surround the removed material. The counter bore is configured to define a seat at the one end of the water ferrule. A sealing member is aligned and introduced into the seat of the counter bore. The method includes aligning a stepped insert coaxially with the sealing member and the seat. The method also includes a step of introducing the insert into the seat of the counter bore to form an interference fit therewith. The method further includes providing a seal formed by a combination of the sealing member and the insert within the seat of the counter bore.

Abstract: A method of determining wear of a worn surface of a machine component includes providing a scanning device at a distance from the worn surface. The method also includes moving at least one of the scanning device and the worn surface relative to the other and generating a set of data points via the scanning device. Each data point of the set of data points is indicative of a depth of a corresponding point on the worn surface relative to a reference plane. The method further includes determining a maximum depth of the worn surface based on the set of data points and comparing the maximum depth to a reference value to determine a next step in a remanufacturing process of the machine component.

Abstract: A method for repair of a cylinder block including a water ferrule having damage in an area proximate to the water ferrule is disclosed. The repair method includes removing material from the area containing and surrounding the damage. The method also includes providing a counter bore sized to surround the removed material. The counter bore is configured to define a seat at the one end of the water ferrule. A sealing member is aligned and introduced into the seat of the counter bore. The method includes aligning a stepped insert coaxially with the sealing member and the seat. The method also includes a step of introducing the insert into the seat of the counter bore to form an interference fit therewith. The method further includes providing a seal formed by a combination of the sealing member and the insert within the seat of the counter bore.

Abstract: A method for repairing a cast component having a damaged area is provided. The method includes scanning an area adjacent to the damaged area to create a scan. The method includes forming a dam with a void. The void has a profile corresponding to the scan. The method includes positioning the dam adjacent to the damaged area. The method includes heating the cast component. The method includes introducing a repair material into the dam. The method also includes cooling the cast component. The method further includes removing an excess material from the cast component.

Abstract: A cylinder head for an internal combustion engine system is disclosed. The cylinder head has at least one fuel injector. Further, the cylinder head has at least one valve reciprocally moveable with at least one valve guide disposed within the cylinder head. The cylinder head includes a portion. The portion defines an injector mount surface. The cylinder head also includes at least one injector bore disposed within the cylinder head. The injector bore is structured and arranged to receive the injector therein. The cylinder head also includes a peening area being defined on the injector mount surface of the cylinder head. The peening area defines a region being laser peened, such that a compressive stress is induced in the peening area. The compressive stress is induced to an effective depth of approximately up to 2 mm from the injector mount surface.

Abstract: Remanufacturing a used cylinder liner includes receiving a used cylinder liner having a fillet relieved of residual compressive stress via service in an engine, and compressing a material substrate of the cylinder liner forming a fatigue sensitive fillet, such that a non-uniform profile of the fillet is reshaped via plastic deformation of the material substrate. Residual compressive stress is restored to the fillet at least in part via the plastic deformation. A mask and used cylinder liner assembly for processing the used cylinder liner during remanufacturing is also disclosed.

Abstract: A compressor housing defines an inlet bore having a first inlet collar disposed therein. The inlet collar is connected to the housing with a first plurality of radially extending posts. The first plurality of posts is removed to detach the inlet collar from the housing, and the inlet collar is removed from the housing. The same or another inlet collar is concentrically located within a liner. The liner can be located at a radial distance around at least a portion of the inlet collar. The inlet collar is connected to the liner by radially inserting a second plurality of posts through the liner and into the inlet collar. An assembly of the liner containing the inlet collar is inserted into the inlet bore of the housing such that the inlet collar forms the inducer bore of the compressor housing.

Abstract: A compressor housing defines an inlet bore having a first inlet collar disposed therein. The inlet collar is connected to the housing with a first plurality of radially extending posts. The first plurality of posts is removed to detach the inlet collar from the housing, and the inlet collar is removed from the housing. The same or another inlet collar is concentrically located within a liner. The liner can be located at a radial distance around at least a portion of the inlet collar. The inlet collar is connected to the liner by radially inserting a second plurality of posts through the liner and into the inlet collar. An assembly of the liner containing the inlet collar is inserted into the inlet bore of the housing such that the inlet collar forms the inducer bore of the compressor housing.

Abstract: A tool for removing a piston ring from a piston is provided. The tool includes a handle portion, an elongate portion, and a working portion. The elongate portion defines a longitudinal axis. The working portion includes a first section and a second section coupled to the first section at a pivot region. The first section is coupled to the elongate portion and is inclined at a first angle relative to the longitudinal axis. A retaining member protrudes from the first section. The second section includes a leading edge. A thickness of the second section decreases continuously from the pivot region to the leading edge and a width of the second section increases continuously from the pivot region to the leading edge. The working portion includes a ramp member extending from an upper surface of the second section. The ramp member includes an engaging surface to engage a piston ring.

Abstract: A method for manufacturing an engine block includes removing material from the top deck of the engine block surrounding a first opening to create a first recessed area, placing a first seal within the first recessed area, positioning a first insert within the first recessed area and against the first seal. The method may also include removing material from the top deck of the engine block surrounding a second opening to create a second recessed area that at least partially overlaps the first recessed area, placing a second seal in the second recessed area and positioning a second insert within the second recessed area and against the second seal.

Abstract: A self-centering seal for a counterbore with an inner passageway and a counterbore diameter defining a recessed area is described. The self-centering seal includes an annular shape including an aperture defined by an inner diameter matched to the diameter of the inner passageway, a circular outer edge having an outer diameter less than the counterbore diameter, a sealing surface at least partially disposed between the inner diameter and the circular outer edge, and a plurality of centering tabs projecting form the outer edge. The self-centering seal may, for example, be used in engine manufacture in conjunction with counterbores and inserts around fluid passages.

Abstract: A method for manufacturing an engine block includes removing material from the top deck of the engine block surrounding a first opening to create a first recessed area, placing a first seal within the first recessed area, positioning a first insert within the first recessed area and against the first seal. The method may also include removing material from the top deck of the engine block surrounding a second opening to create a second recessed area that at least partially overlaps the first recessed area, placing a second seal in the second recessed area and positioning a second insert within the second recessed area and against the second seal.

Abstract: A process for remanufacturing a cylinder head that includes a worn or damaged rocker arm stand adapted to receive a rocker shaft to which at least one rocker arm is mounted, the steps including machining a channel in a surface of the worn or damaged rocker arm stand, securing an insert into the channel, and machining the insert to form a remanufactured inner facing surface. The remanufactured cylinder head includes at least one rocker arm stand that has a machined channel with a remanufactured insert secured therein, the rocker shaft being disposed adjacent the inner facing surface, not the rocker arm stand.

Abstract: A process for remanufacturing a cylinder head that includes a worn or damaged rocker arm stand adapted to receive a rocker shaft to which at least one rocker arm is mounted, the steps including machining a channel in a surface of the worn or damaged rocker arm stand, securing an insert into the channel, and machining the insert to form a remanufactured inner facing surface. The remanufactured cylinder head includes at least one rocker arm stand that has a machined channel with a remanufactured insert secured therein, the rocker shaft being disposed adjacent the inner facing surface, not the rocker arm stand.

Abstract: The present disclosure, in one form, provides a process for remanufacturing a flanged cylinder liner, comprising the steps of machining a top portion of the cylinder liner to remove the cylinder liner flange, thereby creating a flange seat portion, preparing the top portion of the cylinder liner to receive a replacement cylindrical flanged sleeve collar, aligning the center axis of the cylinder liner with the center axis of the cylindrical flanged sleeve collar, placing the sleeve collar into contact with the cylinder liner such that the cylindrical flanged sleeve collar abuts with the flange seat portion and affixing the cylindrical flanged sleeve collar onto the liner.

Abstract: An insert for use in a remanufactured cylinder head rocker arm stand, the insert comprising an inner facing surface having a radius within a range of 35 to 45 mm and a length within a range of 70 to 103 mm, and an outer facing surface adapted for disposal against a channel in the rocker arm stand, the rocker arm shaft being disposed adjacent the inner facing surface in use, but not adjacent the rocker arm stand.