Abstract: An intake manifold is provided that comprises a plurality of intake manifold runners 12, and each intake manifold runner comprises at least one elongated rib 15 and at least one elongated blister 14. The elongated rib 15 and the at least one elongated blister 14 operate together to control structural failure of the intake manifold in an impact event. Specifically, the elongated rib acts to receive and concentrate load while the at least one elongated blister provides an area of intentional failure, thus restricting the failure to a focused area on the intake manifold.

Abstract: In an intake manifold that has charge-motion-control valves (CMCVs), a gap exists between the flapper valves and the wall of the intake runners. Although the gap is maintained as small as practical, it cannot be eliminated because manufacturing tolerances and temperature variations to which the intake manifold is subjected must be accommodated to prevent binding of the flapper valves. Some flow makes an end run through the gap leading to undesirable fluid mechanics. Disclosed herein is a seal that is positioned to rest gently upon the flapper valve near the gap such that the gap is substantially sealed off while applying a modest force on the CMCV so that the actuation torque is minimally impacted. The seal has a press-in-place portion inserted into a pocket formed in the manifold to hold it in place and a lip portion that extends out from the press-in-place portion to obstruct the gap.

Abstract: A coupling system for attaching a first part to a second part using a locator and expansion shear pin is disclosed. The first part has a first flange and may be a formed part, such as an intake manifold. The second part has a second flange and may be a component, such as a throttle body, for attachment to the first part. The component includes a fastener-passing bore having an inner diameter. The locator and expansion shear pin extends perpendicularly from the first flange. The pin includes an expansion wall extending beyond the surface of the flange. A fastener-receiving bore is formed concentrically in the pin relative to the wall. The wall is expandable from a first diameter to a second diameter. The first diameter is less than the inner diameter of the fastener-passing bore. The second diameter is at least equal to the inner diameter of the fastener-passing bore.

Abstract: The present invention in one or more embodiments provides a positioning bracket or a retention bracket to position an actuating arm connected to and at least partially external of an intake manifold, where the positioning bracket includes a body portion to receive there-through a fastener, and an ear portion extending from the body portion and defining an ear aperture to receive there-though a pin of the actuating arm.

Abstract: A method and apparatus for providing constant fresh air ventilation to the engine crankcase is disclosed. The apparatus is adapted for use with an internal combustion engine having a crankcase, an intake manifold and an air input attached to the manifold. The system includes an integrated vacuum actuator connected to the intake manifold, an actuator duct positioned between the vacuum actuator and the air input, an air-from-oil separator associated with the crankcase, a separator duct and separator control valve positioned between the separator and the intake manifold, and a bypass duct and bypass control valve between the separator duct and the actuator duct. The air input comprises an initial intake pipe and an intermediate intake pipe with the intermediate intake pipe being positioned between the initial intake pipe and the intake manifold. A fresh air control pipe and regulator assembly is attached to the intermediate intake pipe.

Abstract: An internal combustion engine having manifold ports and positive crankcase ventilation (PCV) passages integrated into the cam cover is disclosed. The engine system comprises a cam cover having an internal, gas-passing passage, a PCV valve associated with the passage, an oil separator associated with the PCV valve, and an intake manifold having a port, the port being associated with the PCV valve. An oil separator is fitted between the gas-passing passage and the PCV valve. The oil separator is mounted on the cam cover. A manifold chamber is also provided and the PCV oil separator is associated with the manifold chamber.

Abstract: A high pressure charge air feed arrangement for an internal combustion engine is provided. The arrangement includes an intake having a high pressure output, a rocker cover having an intake runner defining a high pressure charge flow path, and a gas and oil separator having a flow accelerator with input and output sides. The high pressure output of the intake is attached to one end of the path and the accelerator is attached to the other end. The path is connected between the input and output sides of the accelerator. The separator includes upper and lower plenums divided by a wall having an oil and gas diffuser. The input side is connected to the lower plenum and the output side is connected to a crankcase oil return line. The flow accelerator may be any type of fluid accelerator, including but not limited to a venturi pump and a jet pump.

Abstract: A locking sealing arrangement for providing a fluid tight seal between a cap or a spigot and an adjacent structure is set forth. The locking sealing cap includes a peripheral sealing member such as an o-ring to form the fluid tight seal. The locking sealing cap engages the inner surface of the adjacent support structure by a cam-lock arrangement. A locking tab extends from the surface of the support structure. A tab-receiving slot is formed in the locking sealing cap. Once the locking tab is aligned in the tab-receiving slot, rotational movement of the locking sealing cap causes engagement of the locking sealing cap with the support structure. One embodiment of the locking sealing cap includes an internal torque feature for receiving a tool to allow engagement. In another embodiment of the locking sealing cap an external, multi-sided tool engagement surface is provided.

Abstract: An engine intake manifold is provided. The engine intake manifold includes a manifold chamber configured to receive positive crankcase ventilation (PCV) gas from a PCV conduit outlet, the manifold chamber including a condensate-containment tray with a plurality of baffles to form a plurality of separate cavities below the PCV conduit outlet.

Abstract: In one or more embodiments, a bracket assembly for an intake manifold having a shaft is provided to include a bracket to be positioned at least partially external to the intake manifold and defining a shaft aperture to partially receive the shaft, and an elastic retainer to be positioned at least partially between the shaft and a wall of the shaft aperture. The elastic retainer may be positioned to contact the shaft or may be positioned to contact an external surface of the intake manifold.

Abstract: An intake manifold is adapted for use with an engine in a front wheel drive vehicle and a rear wheel drive vehicle, for example, with both a transversely mounted and longitudinally mounted engine. The intake manifold is modular and includes a plenum body defining a first port and a second port. A series of runners are adapted to connect to the plenum body. A throttle body connector is adapted to connect to the first port and the second port based on the engine positioning in the vehicle. An end plate is adapted to connect to the first port and the second port.

Abstract: An oil separator in a positive crankcase ventilation (PCV) system is described herein. The oil separator includes an oil separation conduit in fluidic communication with an intake conduit and an oil reservoir and an entry conduit including an entry conduit orifice arranged at an angle of between 80 and 100 degrees with regard to the oil separation conduit, the entry conduit orifice opening into the separation conduit at a point between the separation conduit outlet and the separation conduit inlet.

Abstract: A vehicle incorporates a turbocharged internal combustion engine and a crankcase ventilation system. That crankcase ventilation system includes a first vent line connecting a cam cover at a first spigot to an air inlet duct at a second spigot. In addition the system includes a second vent line connected between the crankcase and the intake manifold of the engine. A one-way valve is provided in the second vent line. A restriction is integrated into either the first spigot, the second spigot or a quick connect that connects the first vent line to the first or second spigot.

Abstract: An engine intake manifold is provided. The engine intake manifold includes a manifold chamber configured to receive positive crankcase ventilation (PCV) gas from a PCV conduit outlet, the manifold chamber including a condensate-containment tray with a plurality of baffles to form a plurality of separate cavities below the PCV conduit outlet.

Abstract: An internal combustion engine having manifold ports and positive crankcase ventilation (PCV) passages integrated into the cam cover is disclosed. The engine system comprises a cam cover having an internal, gas-passing passage, a PCV valve associated with the passage, an oil separator associated with the PCV valve, and an intake manifold having a port, the port associated with the PCV valve. An oil separator is fitted between the passage and the PCV valve. The oil separator is mounted on the cam cover. A manifold chamber is also provided and the PCV oil separator is associated with the manifold chamber.

Abstract: An oil separator in a positive crankcase ventilation (PCV) system is described herein. The oil separator includes an oil separation conduit in fluidic communication with an intake conduit and an oil reservoir and an entry conduit including an entry conduit orifice arranged at an angle of between 80 and 100 degrees with regard to the oil separation conduit, the entry conduit orifice opening into the separation conduit at a point between the separation conduit outlet and the separation conduit inlet.

Abstract: A method of securing a composite plastic part to an engine with a bolt or a bolt and washer. The bolt has a head including teeth that are adapted to engage either the part or the washer. The bolt is tightened to cause the teeth to compress the surface of the part to resist rotation that may become loosened as a result of vibration of the engine. The part may be an intake manifold, a cam cover or an oil pan. Locking features, such as teeth, may be provided on the clamping surface of the bolt and on both surfaces of the washer. Alternatively, a knurled or serrated surface may be provided instead of the teeth.

Abstract: A locking sealing arrangement for providing a fluid tight seal between a cap or a spigot and an adjacent structure is set forth. The locking sealing cap includes a peripheral sealing member such as an o-ring to form the fluid tight seal. The locking sealing cap engages the inner surface of the adjacent support structure by a cam-lock arrangement. A locking tab extends from the surface of the support structure. A tab-receiving slot is formed in the locking sealing cap. Once the locking tab is aligned in the tab-receiving slot, rotational movement of the locking sealing cap causes engagement of the locking sealing cap with the support structure. One embodiment of the locking sealing cap includes an internal torque feature for receiving a tool to allow engagement. In another embodiment of the locking sealing cap an external, multi-sided tool engagement surface is provided.

Abstract: A positive crankcase ventilation (PCV) system is provided herein. The PCV system includes an engine assembly, the engine assembly including an engine block, a cylinder head, a valve cover, and an intake manifold and a PCV passage providing fluidic communication between a crankcase of the engine assembly and a cylinder intake port of the engine assembly without hoses or conduits external to the engine assembly.

Abstract: A sealing arrangement for a post for an intake manifold having a first portion and a second portion held together is set forth. Each of the portions extends from a shell half that, when the two shells are attached to one another, form the intake manifold. Each of the portions includes a face. A groove is formed on at least one of the portions. A seal is fitted in the groove. A fastener hole is formed in the portions. In one portion the fastener hole passes through the portion and in the other a thread is formed by a thread forming fastener. The seal may be positioned in a groove formed on a post face, in a groove formed adjacent the opening of the fastener-receiving hole in the post, or in a groove formed on an interior wall of the post adjacent a cap fitted over the head of the thread forming fastener.