Abstract: A method includes coupling a cylinder head to a cylinder block. A valve member is then moved into a valve pocket defined by the cylinder head such that a first stem portion of the valve member engages an actuator. A first portion of the biasing member is then disposed against a second stem portion of the valve member, the second stem portion being opposite the first stem portion. An end plate is then coupled to the cylinder head such that a second portion of the biasing member engages the end plate.

Abstract: Apparatus and method for improving the fuel efficiency of a 10 kW Tactical Quiet Generator (10 kWTQG) diesel generator in the field. The apparatus includes a small turbocharger adapted to operate at very low boost and a low back pressure exhaust system. The turbocharger provides between approximately 0.5 and 3 pounds of boost over the 10 kWTQG normal operating range. No modifications are required to the 10 kWTQG fuel injection and governor system. The design of the low back pressure exhaust takes advantage of the narrow RPM range of the 10 kWTQG, and when combined with the turbocharger, meets or exceeds ambient noise level requirements. The apparatus is field installable by personnel of general skill levels present for operation of the 10 kWTQG.

Abstract: Disclosed is a pipe arrangement (1) comprising a pipe element (2) that is used to connect, in particular fluidically connect, a turbine outlet of one turbocharger (15) to a turbine inlet of another turbocharger (17). The pipe arrangement is characterized in that a first pipe section (8) of the pipe element (2) includes a first fastening device (14) for attaching a first turbocharger (15) as well as a second fastening device (20) for attaching the pipe element (2) to a first support element (21) of an internal combustion engine. Furthermore, a second pipe section (9) includes a third fastening device (16) for attaching a second turbocharger (17) as well as a fourth fastening device (24) for attaching the pipe element (2) to a second support element (25) of an internal combustion engine.

Abstract: A cylinder block assembly (300) for an X-engine includes a first block half (302) having two cylinder banks (453, 454) and valley openings (361, 362) between the two cylinder banks (453, 454); and a second block half (304) fastened to the first block half (302), the second block half (304) having two cylinder banks (451, 452) and valley openings (361, 362) between the two cylinder banks (451, 452). The valley openings (361, 362) in the first and second block halves (302, 304) allow an X-engine crank train assembly (10, 100) to be assembled within the cylinder block assembly (300).

Abstract: An intake manifold module for preventing fuel leakage of a vehicle, may include a runner unit where a runner may be formed, a mount section connected with the runner unit and mounted at an intake port of a cylinder head, and a reinforcing bracket mounted at an edge around an injector installed on the cylinder head in the mount section, wherein the reinforcing bracket may be pre-mounted in a process line prior to an engine assembly line by using a joining member.

Abstract: A cooling jacket casting core for the production of a cylinder head of an internal combustion engine. The cooling jacket casting core has a slot running at least in part substantially in the direction of a crankshaft longitudinal axis and separating the cooling jacket casting core in at least one section. The slot can run at least in part in an impression of the cooling jacket and can have at least one elevation arranged perpendicular to the longitudinal axis of the cooling jacket casting core.

Abstract: A tool may be used to form an engine cylinder bore in a compacted graphite iron workpiece using helical interpolation. The tool may be rotated about a first axis while orbiting about a second axis that is parallel to the first axis. While rotating and orbiting, the tool may be advanced into the workpiece. This helical interpolation may be used to successively engage cutting or honing elements of the tool with the workpiece. The elements may thereby be permitted to cool between each successive engagement, which may reduce wear on the tool. Various operating parameters associated with the process may have certain relationships that may be exploited in certain ways to obtain ideal results. For instance, a helical interpolation process may be used to perform an act of rough cutting on the workpiece and finish honing on the workpiece, without having to perform an intermediary step of semi-finish boring.

Abstract: An internal-combustion engine has a crankcase, with at least one cylinder for accommodating a piston, the inner face of which cylinder is provided with a coating forming a running surface for the piston. The coating has a plurality of pores and the average size of the pores and/or the pore surface proportion varies over the length of the cylinder.

Abstract: A method for manufacturing an engine block, such as for an internal combustion engine, includes a step of removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area. Material is also removed from the top deck of the engine block surrounding at least one fluid passage to create a second removal area. An insert is positioned within a recessed area defined by the first removal area and the second removal area.

Abstract: An internal combustion engine has at least one combustion chamber and an exhaust gas system arranged on an exhaust gas outlet port. The exhaust gas system includes at least one secondary air injection device for injecting secondary air into the exhaust system between the combustion chamber and an exhaust emission control system arranged in the exhaust gas system. During operation of the internal combustion engine, a residual gas content in the combustion chamber can be changed. The secondary air injection site on the exhaust gas system is arranged so far from the combustion chamber that injected secondary air flows back into the exhaust gas outlet port due to back-flowing exhaust gas in the exhaust gas system but does not flow back into the combustion chamber. This makes it possible to comply with SULEV emission limits even for engines having many combustion chambers and/or exhaust gas turbochargers.

Abstract: A corona ignition system for providing a corona discharge (24) includes an igniter (20) having an electrode (26) with an asymmetrical firing tip (28) relative to an electrode center axis (ae). The firing tip (28) includes a first surface area (A1) facing the fuel injector (42) which is greater than a second surface area (A2) facing a cylinder block (32). The first surface area (A1) presents a projection (60) having a sharp edge, and the second surface area (A2) presents a round outward surface (62). Accordingly, a radio frequency electric field emitted from the first surface area (A1) provides a robust corona discharge (24) in a flammable area at an outside edge (30) of the fuel spray. No electric field is emitted from the second surface area (A2), and no power arcing occurs between the second surface area (A2) and the cylinder block (32).

Abstract: A cover member fastening method and fastening structure are provided which can surly fasten and fix an abutting portion needing firm abutment and fixing and suppress a deformation of the cover member while suppressing a transmission of vibration to the cover member by further reducing the contact area with an engine body. In a fastening structure for a head cover (2) fastened to a cylinder head (1) by a fastening member (7) so as to cover the upper face of the cylinder head (1), an abutting portion (27) that abuts the upper face of the cylinder head (1) is formed on the internal face of the head cover (2). The lower face of a head-cover-side fastening boss (26) protrudes beyond the lower face of a head-cover-side attaching flange (22).

Abstract: An internal combustion engine includes a carrier base having a lower portion configured as a crankcase and an upper portion having a number of upwardly directed assembly provisions such as a crankshaft bay and at least one cylinder deck, with the crankshaft bay and cylinder deck being arranged so that the engine may be assembled from a position above the engine, without the necessity of attaching connecting rods or crankshaft main bearing bolts from underneath the engine.

Abstract: A cooling system for an engine is disclosed. The cooling system may have an engine, a pump configured to receive coolant from the engine and generate a flow of coolant, and a heat exchanger configured to receive the coolant flow. The cooling system may also have a plurality of orifice plates located between the pump and the heat exchanger. At least one of the plurality of orifice plates may be adjustable to control the flow of the coolant from the engine to the heat exchanger.

Abstract: An automotive engine cooling pipe apparatus for fluid-conducting installation with an engine block of an engine comprising a front tube having a proximal portion configured for at least partially slidably and sealably engaging a front sealing ring seated within a front opening of the engine block, a rear tube telescopically engaged with the front tube and having a distal portion configured for at least partially slidably seating within a rear opening of the engine block, and a means for securing the relative positions of the telescoping front and rear tubes in a substantially expanded configuration of the apparatus, whereby expansion of the cooling pipe apparatus within the engine block seats the proximal and distal portions of the front and rear tubes within the respective front and rear openings of the engine block and so provides axial tension thereby stabilizing the installation of the cooling pipe apparatus within the engine block.

Abstract: The present invention provides reduced fatigue stress levels in a stressed area of an engine crankcase by lowering the outer edges of the crankshaft bearing cap fracture-split lines without changing the central axis location of the crankshaft in the crankcase. This is accomplished by causing the fracture-split lines of the bearing caps to angle downward from the horizontal plane of the crankshaft axis to a slightly lower position at the outer edges of the bearing caps. This lowers the outer edges of the bearing caps sufficiently to allow larger radii to be formed on the lateral connectors of the crankcase support webs with the adjacent sidewalls of the crankcase. Accordingly, the fatigue stress levels in the crankcase web members are reduced without requiring a significant change in the crankcase dimensions.

Abstract: The invention relates to a compact device for producing a composite mixture made of two or more fluids, and for aerating and energizing the composite and injecting it into a volume, and more specifically a micro-fuel injector mixing water, air, or any other types of fluid before it is injected into a volume such as a combustion chamber of an engine made of stackable mechanical elements, and the method of assembly and mounting thereof.

Abstract: The present invention provides a new and improved method of forming a turbine engine component having a plurality of airfoils disposed in an annular array between inner and outer shroud rings. The method includes forming inner and outer shroud ring patterns. The inner and outer shroud ring patterns may advantageously be formed by solid freeform fabrication techniques, such as stereolithography. An assembly fixture may be utilized to position the inner and outer shroud rings and an array of airfoils in a coaxial relationship. When the inner and outer shroud rings are to be assembled, axially inner and outer shroud ring patterns may be interconnected by providing relative rotation between annular sections of the shroud ring patterns. In addition, adhesive may be utilized to interconnect the sections of the shroud ring patterns.

Abstract: An internal combustion engine, which includes a cylinder block, a cylinder head fastened to the cylinder block, an aperture formed in a side of the cylinder head, and a conduit assembly, such as an intake runner assembly or an exhaust conduit assembly. A combustion chamber is formed by the cylinder block and the cylinder head. The intake runner assembly is received within the aperture and configured to communicate air to the combustion chamber. The intake runner assembly includes a first piece and a second piece. The first piece has a first channel that includes a bend. The second piece has a second channel that includes another bend mirroring the bend of the first channel. The first piece is coupled to the second piece such that the first and second channels together form a flow path through the intake runner assembly, and the bends of the first and second channels together form a smooth turn in the flow path.

Abstract: A balance shaft housing is provided that includes a first housing portion, a second housing portion operatively connected to the first housing portion, with the first housing and the second housing configured to cooperatively define first and second balance shaft chambers. A cover member is secured to the second housing portion and cooperates with the first and second housing portions to define an air flow path outside of the chambers for circulating air to the balance shaft chambers. A method of assembling a balance shaft housing is also provided.

Abstract: A spin balanced crank assembly for two-stroke and four-stroke engines, such as those used in snowmobiles and ATVs, is provided. The crank assembly may achieve an overall two-plane balance engine by adding two additional masses to opposing sides of the crank assembly. The additional masses are each unbalanced to a desired amount and angle in order to offset unbalance in the engine and obtain a balanced assembly. The amount of weight to be added or subtracted may be attached to the masses may be determined by the size and engine from which the crank assembly is a part of because the angle of unbalance of the crank assembly is know beforehand. Additionally, methods for spin balancing two-stroke and four-stroke engines are provided, wherein the method comprises balancing the engine without disassembling the crank.

Abstract: A method includes coupling a cylinder head to a cylinder block. A valve member is then moved into a valve pocket defined by the cylinder head such that a first stem portion of the valve member engages an actuator. A first portion of the biasing member is then disposed against a second stem portion of the valve member, the second stem portion being opposite the first stem portion. An end plate is then coupled to the cylinder head such that a second portion of the biasing member engages the end plate.

Abstract: An Exhaust Gas Recirculation (EGR) apparatus for recirculating engine exhaust gas comprising a valve member disposed in an exhaust gas recirculation passage of an engine, the valve member movable between an open position and a closed position to control the flow of the exhaust gas through the exhaust gas recirculation passage, one or more bleeders to enable flow of exhaust gas through the exhaust gas recirculation passage when the valve member is in the closed position.

Abstract: A method of manufacturing a cylinder block for a multi-cylinder engine is disclosed herein. The cylinder block includes a crankcase and cylinder bores disposed therein separated by cylinder walls. The crankcase is adapted to receive a crankshaft and includes crank chambers disposed therein separated by partition walls. Each of the crank chambers of the crankcase corresponds to one of the cylinder bores of the cylinder block. The cylinder bore side of each partition wall has a honing runoff portion thinner in section than the crankshaft side thereof such that a step face results in the partition walls. Further, a runoff groove is formed in the partition walls of the crank chambers, and also a communication hole is formed at least partially within the runoff groove in at least one of the partition walls to enable communication between crank chambers.

Abstract: The present invention relates to a balance shaft unit for mass balancing for an internal combustion engine of a motor vehicle including at least one balance shaft having at least one balance weight and a housing part in which the balance shaft is journaled. A first gear is associated with the balance shaft and meshes with a second gear. An introduction passage is formed in the housing part through which, starting from an assembly opening, at least one of the two gears can be introduced into the interior of the housing part, with the introduction passage extending perpendicular to the longitudinal axis of the balance shaft. The first gear and the second gear are arranged sequentially with respect to the direction of extent of the introduction passage.

Abstract: To provide a high-pressure fuel injection pipe preventing like a generation crack of a pocket portion during formation of a connection head portion, and being robust against fatigue, wherein the connection head portion is configured such that cylindrical face has contours in a section along the axial direction of the pipe from an end portion of a fillet portion of an annular flange portion toward the seat face formed such that an opening angle ? to an axis of the pipe in the section in the axial direction of the pipe satisfies 0°<??20° and a ratio of the length h of the cylindrical face in the axial direction of the pipe and the length H from a terminal of the connection head portion to an end portion of the cylindrical face on the side of the fillet portion satisfies 0.33?h/H?0.85.

Abstract: This disclosure provides a fuel line assembly for use with an internal combustion engine, an internal combustion engine including such as fuel line assembly, and a method for providing leak containment and detection in a fuel system, each of which include a double-walled fuel line including a high pressure fuel line component. The double-walled fuel line includes a high pressure fuel line, a jacket surrounding the high pressure fuel line, and a low pressure passage between the high pressure fuel line and the jacket. A fuel line nut includes a main body that houses a portion of the high pressure fuel line, and a first end portion supporting an enlarged end portion of the high pressure fuel line protruding from the first end portion. A second end portion of the fuel line nut sealingly connects to the jacket to extend the low pressure passage into an area between the main body and the housed high pressure fuel line.

Abstract: A partition member used in a cylinder block of an internal combustion engine is disclosed. The partition member is arranged in a groove-like cooling passage through which a cooling heat medium flows. The partition member includes a separating wall and a flexible lip member. The separating wall divides the cooling passage into an inner passage and an outer passage. The inner passage is located close to the cylinder bores, and the outer passage is located outside of the inner passage. The lip member extends from the separating wall toward the opening of the cooling passage in such a manner that, when the partition member is arranged in the cooling passage, the lip member contacts one of the inner surfaces of the cylinder block forming the cooling passage. When the partition member is arranged in the cooling passage, the distal edge portion of the flexible lip member contacts the inner surface due to force produced through flexible shape restoration of the lip member.

Abstract: A regenerator (100) for a thermal cycle engine with external combustion, according to the invention comprises a network of fibers wherein a majority of the fibers at least partially encircles the axis of the regenerator. The fibers were part of a fiber web, which is coiled and sintered thereby obtaining the regenerator.

Abstract: An intake-side space around intake ports and an exhaust-side lower space around exhaust ports are provided in a main cooling jacket portion. These spaces are connected to each other. In a sub cooling jacket portion, an exhaust-side upper space is provided at a level above the exhaust-side lower space. The main cooling jacket portion and the sub cooling jacket portion are connected to each other via a cylindrical-hole connecting passage extending vertically and separate from each other vertically via a wall portion in another area than the connecting passage. Accordingly, a cooling device of an engine which can restrain the exhaust gas from being cooled too much improperly is provided.

Abstract: The invention relates to a dual material device that includes an insert (12), a part (14) made of a material other than that of) the insert, the insert and the part being assembled by moulding one around the other, the interface between the insert and the part defining at least one junction plane (40), and a bore (26, 28) for receiving a pin, formed in said device and extending through the junction plane, wherein the bore includes an inlet chamfer (36) for guiding the pin up to a pin engagement section (38), characterised in that the inlet chamfer (36) extends beyond the junction plane (40).

Abstract: A variable valve timing device for an internal combustion engine includes: a variable valve timing mechanism that changes a valve timing; and a phase limiting mechanism that locks a rotational phase between a housing rotor and a vane rotor at an intermediate phase. The phase limiting mechanism engages a first limiting pin with a first engaging groove and engages a second limiting pin with a second engaging groove to lock the housing rotor to the vane rotor. A retard-side side surface of an engaging hole is configured so as to be able to adjust a clearance between the second limiting pin and the retard-side side surface when the first limiting pin is engaged with a first advance end portion.

Abstract: A camshaft phaser includes a housing with a harmonic gear drive unit disposed therein. The harmonic gear drive unit includes a circular spline and a dynamic spline, a flexspline disposed radially within the circular spline and the dynamic spline, a wave generator disposed radially within the flexspline, and a rotational actuator connectable to the wave generator. One of the circular spline and the dynamic spline is fixed to the housing. A hub is rotatably disposed radially within the housing and attachable to the camshaft and fixed to the other of the circular spline and the dynamic spline. An anti-rotation means is provided for temporarily fixing the circular spline to the dynamic spline in order to prevent relative rotation therebetween when the hub is being attached to the camshaft. The anti-rotation means prevents damage to the harmonic gear drive unit while the camshaft phaser is being installed onto the camshaft.

Abstract: A method and apparatus for engine piston installation in which robots are used for the entire engine piston installation process. A first robot equipped with a stuffing gripper and force control picks up a piston with a connection rod, detects the piston ring presence, squeeze the rings, find the engine cylinder bore, and stuffs the piston into the cylinder bore. A second robot can be used to load and unload the engine block, hold the block and position it to the location, and indexes the crankshaft into the proper orientation for each cylinder bore. A set of tools either fixed on a stationary station or on a third robot is used to guide the piston connecting rod, transport and place on the connecting rod cap, and fasten the cap onto the connecting rod. The piston connecting rod guiding process may be omitted in piston stuffing for some types of engines.

Abstract: An exhaust gas re-induction apparatus and system. The exhaust gas re-induction apparatus is coupled to an exhaust system or catalytic converter of an engine. The exhaust gas re-induction apparatus includes an oxygen sensor substitute apparatus having an exhaust gas diffusion chamber disposed therein, and an exhaust gas interface housing to receive the oxygen sensor substitute apparatus. A recirculation conduit connects the exhaust gas re-induction apparatus to an air inlet of an engine. The oxygen sensor substitute apparatus includes a coupling section to attach the oxygen sensor substitute apparatus in place of an oxygen sensor apparatus. The oxygen sensor substitute apparatus also includes an exhaust gas dispersion section having a plurality of orifices for dispersing exhaust gas. The exhaust gas re-induction apparatus and the recirculation conduit have always-open passages in which the exhaust gas is recirculated to the engine at different rates depending essentially on the operating speed of the engine.

Abstract: A piston assembly includes an annular body defining a groove, with a ring disposed within the groove. The piston assembly includes a centering device disposed within the groove between an inner face of the ring and a root of the groove. The centering device centers the ring concentrically within the groove when the ring is in an uncompressed condition, prior to installation into a bore of an engine block, to prevent the inner face of the ring from moving radially outward beyond an outer edge of the groove when the ring is in the uncompressed condition.

Abstract: An engine assembly comprising a cylinder head, turbocharger in fluid communication with the cylinder head and exhaust conduit in fluid communication with the turbocharger and method of making the assembly using a single human assembler includes: mounting the turbine to the cylinder head; using a first assembly aid to form a slidable joint between the exhaust conduit and head; using a second assembly aid to form a movable joint between the turbine and exhaust conduit and align the turbine outlet flange and exhaust conduit inlet flange; using a third assembly aid to pilotingly engage the flanges; disposing a clamp about the turbine outlet flange and the exhaust conduit inlet flange; tightening the second assembly aid sufficiently to form an immovable joint; tightening the clamp to form a sealed joint between the flanges; and tightening the first assembly aid to form a fixed joint.

Abstract: A method for a cylinder bore having a sliding surface which slides with respect to a counter member includes forming the sliding surface on a molded block by a boring processing with respect to the molded block, crushing cavities at the sliding surface and in the vicinity thereof by plastic working after the boring processing, smoothing the sliding surface, and forming a coating having seizure resistance on the sliding surface after the plastic working.

Abstract: An intake body, systems, and method for reducing acoustic resonance in pressure tap passages include determining and/or setting the length of the drilling tap passages to a value such that the natural frequency of each pressure tap passage is outside of or does not substantially overlap with operational frequency content of an air stream in the intake body. The intake body, systems and method reduce the possibility of exciting the natural acoustic frequencies of the pressure tap passages, and can lead to improved signal-to-noise ratio when detecting EGR flow using a delta-P measurement system.

Abstract: A system and method are disclosed for fabricating and running an engine in two modes. The first mode is an efficiency mode having a high compression ratio and efficiency for low to medium loads. The second mode is a power mode having high power density for higher loads. The system may use a lean mixture in the efficiency mode, which mixture is made richer for more power in the power mode. The system may also use ignition timing to allow the efficiency mode and the high power mode to be at the same mixture.

Abstract: Embodiments of the invention provide a vehicle in which an intake device including a throttle body is connected to a rear-side surface of a cylinder head which constitutes a part of an engine body which is mounted on a vehicle-body frame in a state where an axis of a crankshaft is arranged along the longitudinal direction, wherein a sufficient clearance can be ensured between the intake device and a member which is arranged above the throttle body. A posture of the throttle body 30 is set such that an axis C2 of an intake passage formed in the throttle body 30 extends in the rearward and downward direction.

Abstract: A method of converting a diesel engine to a natural gas engine comprising inserting a spark plug into a diesel fuel injector opening in a cylinder head; installing a throttle body on the diesel engine; installing a throttle body adaptor between a throttle body and an intake manifold of said diesel engine; and modifying a piston, whereby the compression ratio of said piston is decreased during operation of said piston. The method also includes installation of a waste gate and waste gate adaptor and a timing mask.

Abstract: A method of forming a gearbox includes the use of hollow structural steel.

Abstract: A method is provided for producing an engine wall structure that includes an inner wall, to which hot gas is admitted during engine operation, an outer wall, which is colder than the inner wall during engine operation, and at least two webs that connect the inner wall with the outer wall and delimit a cooling duct between the walls. The engine wall structure is produced by wire-electro discharge machining the duct out of a solid sheet forming the entire engine wall structure including the inner wall, the outer wall and the webs.

Abstract: A block casting for an internal combustion engine and method of its manufacture provide reduced engine block size and weight, and/or increased engine displacement, through cylinder-forming walls that decrease in thickness from minimal explosion-resistant thicknesses at their combustion chamber ends to reduced thicknesses at their other ends.

Abstract: A device for delivering a reducing agent, in particular a liquid urea-water solution, includes at least two of the following elements: a storage device (e.g. a tank), a delivery device (e.g. a pump), a deflecting device (e.g. a valve), a detecting device (e.g. a sensor), a separating device (e.g. a filter) and an outlet device (e.g. a nozzle, injector), which are interconnected by a line device. At least one element is pressure-sensitive and the adjacent line device near the pressure-sensitive element forms at least one heat sink. A device having a targeted freezing behavior is thus provided, allowing pressure-sensitive elements to be protected. A method for producing a motor vehicle is also provided.

Abstract: An automotive engine cooling pipe apparatus for fluid-conducting installation with an engine block of an engine comprising a front tube having a proximal portion configured for at least partially slidably and sealably engaging a front sealing ring seated within a front opening of the engine block, a rear tube telescopically received within the front tube and having a distal portion configured for at least partially slidably seating within a rear opening of the engine block, and a means for securing the relative positions of the telescoping front and rear tubes in a substantially expanded configuration of the apparatus, whereby expansion of the cooling pipe apparatus within the engine block seats the proximal and distal portions of the front and rear tubes within the respective front and rear openings of the engine block and so provides axial tension thereby stabilizing the installation of the cooling pipe apparatus within the engine block.

Abstract: A method for securing a balancer shaft module to an engine is provided, the method including the steps of passing a mounting feature into at least two mounting apertures of the balancer shaft module; simultaneously rotating two of the mounting features within the mounting aperture, wherein the simultaneous rotation of the two mounting features laterally moves the balancer shaft module with respect to the engine; and securing the balancer shaft module to the engine.

Abstract: A cell for automated assembly operations, in particular for the assembly of parts of multicylinder internal-combustion engines, has manipulator members that are designed for simultaneous assembly of a plurality of elements on a work piece and that are adjustable for varying the distance between the positions of said elements.

Abstract: A method for manufacturing an engine includes the steps of: casting a side skirt having first and second opposing sidewalls and casting a transverse wall of the cast material connecting the sidewalls. The transverse wall will form a bulkhead and a main bearing cap. A first void and a second void are cast into the transverse wall on opposite lateral sides of a main bearing journal location, each void adjacent to one of the sidewalls. A main bearing journal hole is then machined into the transverse wall. Cast material is removed along a first removal path from the edge of the transverse wall and ending into the first void, and along a second removal path from the edge of the transverse wall and ending into the second void. A tool exerts an opening force within the circular bore to fracture the cast material along the first and second fracture planes to separate the main bearing cap from the bulkhead.