Abstract: A cam phaser includes a rotor, a stator, and a cover. The rotor defines a first hole and a second hole and can rotate relative to the stator between a first intermediate position and a second intermediate position. The cover is mounted on the stator and defines a first lock pin seat and a second lock pin seat. The cam phaser includes a first lock pin and a second lock pin. The first lock pin can move along the first hole and into the first lock pin seat to lock the rotor relative to the stator at the first intermediate position. The second lock pin can move along the second hole and into the second lock pin seat to lock the rotor relative to the stator at the second intermediate position.

Abstract: A control valve includes a valve body, which defines first, second, and third valve passageways. The valve body also defines a supply passageway. The control valve includes a first spool movable relative to the valve body between first and second positions. The control valve includes a second spool movable relative to the valve body between open and closed positions. The supply passageway is in fluid communication with the first valve passageway when the first spool is in the first position. The supply passageway is in fluid communication with the second valve passageway when the first spool is in the second position. The supply passageway is in fluid communication with the third valve passageway when the second spool is in the open position. The second spool precludes fluid flow between the supply passageway and the third valve passageway when the second spool is in the closed position.

Abstract: A control valve includes a valve body, which defines first, second, and third valve passageways. The valve body also defines a supply passageway. The control valve includes a first spool movable relative to the valve body between first and second positions. The control valve includes a second spool movable relative to the valve body between open and closed positions. The supply passageway is in fluid communication with the first valve passageway when the first spool is in the first position. The supply passageway is in fluid communication with the second valve passageway when the first spool is in the second position. The supply passageway is in fluid communication with the third valve passageway when the second spool is in the open position. The second spool precludes fluid flow between the supply passageway and the third valve passageway when the second spool is in the closed position.

Abstract: A cam phaser includes a rotor, a stator, and a cover. The rotor defines a first hole and a second hole and can rotate relative to the stator between a first intermediate position and a second intermediate position. The cover is mounted on the stator and defines a first lock pin seat and a second lock pin seat. The cam phaser includes a first lock pin and a second lock pin. The first lock pin can move along the first hole and into the first lock pin seat to lock the rotor relative to the stator at the first intermediate position. The second lock pin can move along the second hole and into the second lock pin seat to lock the rotor relative to the stator at the second intermediate position.

Abstract: A motion limiter system for a cam phaser includes a retractable motion limiter pin that is selectively extendable from a rotor in a cam phaser to contact a lobe on a stator to provide a positive stop for the rotor prior to engagement of a locking pin. Alternatively, the cam phaser may include two pins that are selectively extendable from opposite openings in a hole in the rotor to engage seats that are slightly offset from one another.

Abstract: A method of setting lash in a cam phaser includes rotating a stator having a lobe in a first direction so that the lobe contacts a motion limiter pin disposed within a first hole in a rotor, causing the compression of a spring until a motion limiter lock pin enters a groove on the motion limiter pin and contacts a wall at one end of the groove. The rotor is then rotated in conjunction with the stator in the first direction until a rotor locking pin that is disposed within a second hole in the rotor engages a lock pin seat on a cover at one end of the seat. The rotor is then held in place while rotating the stator in a second direction so that there is a gap between the wall at one end of the groove and the motion limiter locking pin.

Abstract: A method of setting lash in a cam phaser includes rotating a stator having a lobe in a first direction so that the lobe contacts a motion limiter pin disposed within a first hole in a rotor, causing the compression of a spring until a motion limiter lock pin enters a groove on the motion limiter pin and contacts a wall at one end of the groove. The rotor is then rotated in conjunction with the stator in the first direction until a rotor locking pin that is disposed within a second hole in the rotor engages a lock pin seat on a cover at one end of the seat. The rotor is then held in place while rotating the stator in a second direction so that there is a gap between the wall at one end of the groove and the motion limiter locking pin.

Abstract: A motion limiter system for a cam phaser includes a retractable motion limiter pin that is selectively extendable from a rotor in a cam phaser to contact a lobe on a stator to provide a positive stop for the rotor prior to engagement of a locking pin. Alternatively, the cam phaser may include two pins that are selectively extendable from opposite openings in a hole in the rotor to engage seats that are slightly offset from one another.

Abstract: A partial assembly process for a vane-type cam phaser. A pulley/sprocket is loaded onto a first camshaft-shaped fixture with a cam nose extending beyond the length of an actual cam nose such that a phaser rotor containing a locking bolt, when mounted onto the cam nose, is displaced axially from the pulley/sprocket by an amount sufficient to set the axial engagement of the bolt upon final assembly. A stator is loaded onto the pulley/sprocket and is rotated clockwise until it contacts the rotor, thereby removing all rotational and radial lash from the system. One or more axial holes are bored through the pulley/sprocket and stator and a locking pin such as a roll pin is inserted to permanently pin the stator to the pulley/sprocket.

Abstract: A partial assembly process for a vane-type cam phaser. A pulley/sprocket is loaded onto a first camshaft-shaped fixture with a cam nose extending beyond the length of an actual cam nose such that a phaser rotor containing a locking bolt, when mounted onto the cam nose, is displaced axially from the pulley/sprocket by an amount sufficient to set the axial engagement of the bolt upon final assembly. A stator is loaded onto the pulley/sprocket and is rotated clockwise until it contacts the rotor, thereby removing all rotational and radial lash from the system. One or more axial holes are bored through the pulley/sprocket and stator and a locking pin such as a roll pin is inserted to permanently pin the stator to the pulley/sprocket.