Abstract: An assembly tool for insertion of engine piston/rod assemblies into an engine cylinder includes a frame, a support arm pivotally carried on the frame, an insertion cylinder carried by the support arm and including an extendable insertion rod having an end adapted to engage a piston in position for insertion; a positioner for positioning the support arm in an insertion position with the rod end engaging a piston; and a control for actuating the insertion rod to insert a piston/rod assembly into the cylinder. Various additional features of an exemplary embodiment are also disclosed.

Abstract: A base material of a peripheral wall and a vane rotor is formed by extrusion molding an aluminum alloy and cutting an extrusion molded article to the desired length. Further, the extrusion molded article can be molded with high accuracy by extracting the aluminum alloy after extrusion. Preferably, 6000 system of Al—Mg—Si is used as an aluminum alloy. The cutting process and polishing process are applied to the roughly molded base material to form the peripheral wall and the vane rotor. By varying the length to be cut, the volume of each retard hydraulic chamber and each advance hydraulic chamber are adjusted. When the volume of the hydraulic chambers are adjusted, the torque for relatively rotating and driving the vane rotor with respect to the housing member can be changed even pressure of working oil is the same.

Abstract: A method of assembling a cylinder head assembly (11) for use with a cylinder block of an internal combustion engine. The method involves providing a cylinder head slab (17) defining a pattern of intake (21) and exhaust (23) poppet valves. The head slab is provided with a plurality of bolt holes (37) defining a bolt hole pattern. Next, a plurality A and B of valve activation modules, selected from a group of possible modules (15;101;201;301) is provided, each defining a plurality of bolt holes (63;109) which correspond with at least a major portion of the bolt holes (37) in the bolt hole pattern. The next step is selecting one module (15;101;201;301) and bolting it to the cylinder head slab (17).

Abstract: In an arrangement and method for mounting a camshaft onto a cylinder head of an internal combustion engine by camshaft bearings disposed on the cylinder head of the engine camshaft bearing by support seats which are formed integrally with the cylinder head and bearing caps which are formed integrally with a cylinder head cover mounted onto the cylinder head, at least one of the bearings is an assembly bearing with a separate assembly bearing cap that has a bearing opening of a diameter greater than that of the camshaft so that the camshaft when placed onto the bearing seats is not fully moved into the bearing seat openings but is fully engaged with the bearing seats only when the cylinder head cover is mounted onto the cylinder head whereby the camshaft in the assembly bearing is moved out of contact with the assembly bearing cap.

Abstract: Disclosed is a method and apparatus for quickly and accurately determining the amount of metal to be removed from the lower portion of an engine block when the engine is to be stroked, i.e. have a longer, replacement, connecting rod installed to increase the engine's cylinder displacement.

Abstract: A method for producing a spark plug, the spark plug comprising a center electrode, a metal shell and an alumina ceramic insulator disposed between the center electrode and the metal shell, wherein at least part of the surface of the insulator is covered with a glaze layer, the method comprising the steps of: preparing a plurality of kinds of element glaze powders wherein each kind of the element glaze powders has a different dilatometric softening point and a different linear expansion coefficient compared to other kinds of element glaze powders; coating a surface of the insulator with the plurality of kinds of element glaze powders so as to form a glaze powder layer; and baking the glaze powder layer to the surface of the insulator so as to form the glaze layer by heating the glaze powder layer.

Abstract: A throttle device in the intake section of an internal combustion engine; the throttle device including a housing part, which contains a flow cross section for an air flow. In the housing part, bearing points are provided for a throttle valve device, which can be actuated by means of an actuating drive. The actuating drive can be inserted into a receiving housing, which has first and second guide surfaces that permit the installation of the actuating drive. Fastening means are provided on the circumference surface of the receiving housing and can accommodate a closing and contacting element, which contacts electrical contacts of the actuating drive.

Abstract: There is provided a method for suspending roller tappets in an internal combustion engine without removal of the cylinder head and gasket. The rocker arm assembly is removed. Each push rod is then removed and replaced with tappet suspension tool to engage a corresponding roller tappet. A suspension tool guide bar is then installed to connect to the tappet suspension tools. The roller tappets are then simultaneously moved to a raised position away from the camshaft forming a clearance between the roller tappets and camshaft bearings. The roller tappets are then secured in the raised position by a securing block. The camshaft can then be removed from the engine block. Alternatively, the rear half of the front cover can be removed by first removing the idler gears, followed by removal of the camshaft, and last removing the rear half of the front cover from the engine case.

Abstract: An apparatus and method of forming a differential assembly is provided that includes the steps of providing a ring gear, which is preferably produced by a precision forging process. The differential case is cast about a portion of the ring gear to secure the ring gear to the differential case and form the differential assembly. Preferably, the ring gear includes projections that are embedded in the differential case during the casting process to enhance the connection between the ring gear and the differential case. In this manner, the ring gear may be constructed from a forged steel and the differential case may be constructed from ductile iron while eliminating the fasteners of the prior art.

Abstract: A method for mounting a load sensing proportion valve assembly of an automobile includes the steps of securing the crank member of the assembly to a side of a rotating shaft, which rotatably attaches the crank member to the proportioning valve of the assembly, using a first connecting member having a first rotating direction. Thereafter, a rod, which is connected to the rear axle housing of the automobile, is connected to the crank member through a slit formed in the crank member using a second connecting member having a second rotating direction. Finally, the first connecting member is removed so as to allow the crank member to be rotated.

Abstract: A method for manufacturing a cylinder block provides an abrasion-resistant layer in a cylinder bore by build-up welding. The method applies build-up welding to preformed recesses along an inner surface of the cylinder bore. After build-up welding, final finishing provides a finished bore surface. The method creates an abrasion-resistant surface in areas prone to piston abrasion and manages welding strain to minimize cylinder block distortion.

Abstract: The invention relates to a method for machining a common rail for a common rail fuel injection system of an internal combustion engine, having a base body, which is equipped with a plurality of connection openings. The invention also relates to a common rail and to a connection stub for application of the method. In the method, the base body is deformed in the region of the connection openings. In the region of each of the connection openings, one through bore is provided, which has two segments of different-sized internal diameters. The connection stub of the invention is characterized in that the outside diameter of the connection stub, on its end toward the common rail, is substantially equivalent to the internal diameter of the segment of the through bore in the common rail having the larger diameter.

Abstract: A transfer control system for enabling technicians to insert a piston assembly into a cylinder of an engine block. The transfer control system ensures that only one technician at a single time is capable of controlling the insertion of the piston assembly into the cylinder of the engine block. The transfer control system has a proximity sensor and a first control system in communication with the proximity sensor. A second control system is in communication with the first control system.

Abstract: A method of manufacturing an implement, including providing a first group of engine types and a second group of transmission types at a common, first manufacturing facility, selecting a desired module configuration, selecting a desired engine from the first group, a desired transmission from the second group, connecting the selected engine and transmission together in the desired module configuration to provide a base of the implement, transporting the base to a second facility, providing a working device at the second facility, and connecting the working device to the base of the implement at the second facility.

Abstract: A camshaft used in an internal combustion engine which has reduced weight and added wear resistance at a lobe of the camshaft. The camshaft is provided to add increased wear resistance and reduced weight to the internal combustion engine for increased efficiency of the internal combustion engine. The camshaft includes wear resistant material at the surface of the lobe of the camshaft. The wear resistant material is distributed on the outer surface of the lobe and incorporated into the base material.

Abstract: A control system and method of use for aligning a piston assembly with a cylinder of an engine block. The control system enables the piston assembly to be properly aligned with the cylinder prior to inserting the piston assembly into the cylinder. The control system includes an apparatus which compares positional information associated with the piston assembly and an apparatus which instructs movement of the piston assembly with respect to the cylinder in response to the positional information.

Abstract: A method of fabricating an annular liner for a combustion chamber of a gas turbine engine. The combustion chamber has a dome including a fuel nozzle for delivering fuel to the combustion chamber. A metal piece is formed into an annular section constituting at least a portion of the liner and having at least one seam extending generally axially with respect to an axial centerline of the liner. An upstream end of the liner is machined to have a registration feature for connecting the liner to the combustion chamber dome in at least one predetermined orientation with respect to the dome. Further, the method includes ensuring the registration feature and the seam are located relative to each other on the liner so the seam is at a preselected position with respect to the combustion chamber dome when the liner is connected to the combustion chamber dome in the predetermined orientation.

Abstract: Fuel injectors, for hydraulically actuated fuel systems with complex seals so high pressure oil can be confined, are assembled in an engine head with a tool that fits with part of the injector. Tool posts have ends that fit in holes of a bracket. The posts are configured to provide clearance from part of the injector above the bracket. The tool drives the injector in place when a surface of the tool is stuck. After using the tool to drive an injector in place, fasteners to secure the injector to the head are inserted through the bracket holes.

Abstract: An integrated fuel rail portion and mounting bracket assembly is provided. The assembly includes an elongated support portion and at least one mounting bracket integrally connected to the elongated support portion. A method of forming the assembly is also provided.

Abstract: A sectional intake manifold includes a flanged first intake manifold section having and a flanged second intake manifold section. Bolts extend through unthreaded bores in the first intake manifold section flange into threaded bores in the second intake manifold section flange to secure the first intake manifold section to the second intake manifold section. A seal is provided between the first section mating flange and the second section mating flange. A method is also provided for converting a conventional intake manifold to a sectional intake manifold according to the present invention.

Abstract: To provide an oil seal removing method that may dispense with a step for forming a hole to an iron core in the oil seal by using a drill and may be applied, as desired, even in a narrow space, and to provide a seal removal tool that is superior in versatility to a taper screw type tool screwed into an inner diameter portion of the oil seal, an L-shaped jaw (2) formed with arcuate portions (2a and 2a′) at its tip end portion, and a retainer plate (1) with holes (3) at its body portion is prepared. The L-shaped jaw (2) is pressingly inserted into a contact interface between an oil seal body (6) and a crankshaft (5). Next, the retainer plate is tilted through 90 degrees to engage the jaw (2) with an end face of the iron core (10). Next, a tip (tip end) (4′) of a driver (4) is inserted into the hole (3), and a grip of a lever is drawn as indicated by an arrow (9) while abutting the tip (tip end) (4′) against an end face (5c) of a pulley shaft.

Abstract: A generally disc-shaped flywheel which is an integral one-piece forged structure formed by forging of a carbon steel blank and consisting of an inner portion having a friction surface and an outer ring gear portion disposed radially outwardly of the inner portion. The flywheel is formed by forging the carbon steel blank to obtain an intermediate product consisting of the inner portion and the outer ring gear portion, hardening the friction surface of the inner portion of the intermediate product, and shot peening the hardened friction surface to form a multiplicity of recesses in the hardened friction surface.

Abstract: A method of manufacturing a cylinder for an internal combustion engine, which is manufactured by a process wherein a raw cylinder body having an insert core left remained therein is obtained using an insert core comprising a cylindrical body having almost the same outer diameter as the diameter of bore of the cylinder, and a scavenging port-forming portion projecting radially outward from the cylindrical body and having almost the same cross-sectional configuration as that of the scavenging port, the cylinder bore of the raw cylinder body thus obtained is then subjected to a boring to remove the cylindrical portion of the insert core, and the scavenging port-forming portion of the insert core which is left remained in the raw cylinder body is removed by making use of a press.

Abstract: A method is provided for manufacturing common rails, such as a high-pressure fluid manifold or a block rail that may be use in an accumulator fluid injection system. The method includes providing a main tubular rail with a flow passage extending in an axial direction. A bottomed lower hole is formed generally transverse to the axial flow passage. A pressing force is applied to the bottomed lower hole to generate a residual compressive stress in a circumferential part of the end portion of the bottom hole. The bottom lower hole then is made to communicate with the flow passage in the main rail. Defects that may have been caused by the application of the pressing force then are cut off. The removal of the defects improves an internal pressure fatigue strength, achieves high durability and ensures freedom from leakage.

Abstract: A heater head assembly for a multi-cylinder heat engine the stirling engine, such as a multi-cylinder Stirling engine, having a plurality of regenerators and cylinders. Each regenerator has a regenerator manifold and each cylinder has a cylinder manifold. First identical cast heater tubes connect the regenerator manifold to first heater tube openings in a heater head manifold. Second identical cast heater tubes connect second heater tube openings in the heater head manifold to the cylinder manifold. The first and second heater tubes are parallel with respect to each other and form a pair of partial concentric staggered arrays. The heater tubes are rotationally asymmetric, having fin sections with less surface area upstream than downstream and thicknesses which decrease radially away from the central passageways of said heater tubes.

Abstract: A horizontal-mount bracket system for holding sensor position with respect to a horizontal-mount bracket, wherein facial interaction between the bracket and the sensor body provides automatic setting of the air gap which setting is preserved such that if the sensor is ever reinstalled, the air gap is precisely reset to its original value. A multi-component bracket has first and second bracket components which lay juxtaposed, one atop the other. The first bracket component has a first sensor opening and the second bracket component has a second sensor opening wherein initially the first and second sensor openings are mutually communicating and aligned just sufficiently so that the sensor body is free to vertically move therein. The sensor body is placed into a sensor port of an engine block so that the tip of the sensor body rests upon a surface of a reluctor.

Abstract: Fuel injectors, for hydraulically actuated fuel systems with complex seals so high pressure oil can be confined, are assembled in an engine head with a tool that fits with part of the injector. Tool posts have ends that fit in holes of a bracket. The posts are configured to provide clearance from part of the injector above the bracket. The tool drives the injector in place when a surface of the tool is stuck. After using the tool to drive an injector in place, fasteners to secure the injector to the head are inserted through the bracket holes.

Abstract: The object of the invention is a process for producing an acoustically resistive layer, particularly for the nacelles of aircraft jet engines, characterized in that it comprises the following steps:

Abstract: This invention relates to a method for the manufacture of a gas-turbine combustion chamber which consists of individual wall sections produced by casting. To make up the combustion chamber, the wall sections are joined by laser welding. Preferably, the individual wall sections are segments of the annular or circular combustion chamber, with the casting material of the wall sections being a high-temperature nickel-base casting alloy.