A shaft assembly may include two or more Poka-Yoke bearing caps, each Poka-Yoke bearing cap having a pair of reference bores offset from a central axis of the bearing cap by differing offset distances, and each bearing cap defining a semi-circular recess that is positioned so as to align in use a central axis of the semi-cylindrical recess in the bearing cap with an axis of rotation of a shaft rotatably supported by the bearing cap. The differing offsets of the reference bores prevent the bearing cap from being assembled in a reversed orientation. To ensure that each bearing cap can only be fitted in one position, a center spacing between the first and second reference bores of each bearing cap is different to the center spacing used for other bearing caps used to support a single shaft.

A first die segment for forming an internal combustion engine block has cylindrical projections, and die core pieces disposed about the cylindrical projections. A second die segment has die core stubs positioned so as to extend between adjacent die core pieces when the segments are brought together. An engine block formed by the die segments has cylindrical bores formed by the cylindrical projections extending from the deck of the block and voids formed by the die core pieces also extending from the deck and disposed about the cylindrical bores. Pockets formed by the die core stubs extend into sides of the engine block between adjacent voids. The engine block is worked below the level of the deck to undercut each of the pockets, removing material between them and the voids to result in an interconnected water jacket extending about the cylindrical bores, while leaving the deck closed.

A cylinder block of an engine is provided. The cylinder block includes a cast body defining one or more cylindrical bores. The cylinder block also includes a crankshaft bearing wall formed within the cast body. The crankshaft bearing wall is configured to be removably coupled with a bearing cap to define an opening for rotatably supporting a crankshaft of the engine. The cylinder block further includes a chamfered shoulder portion casted on the crankshaft bearing wall.

An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.

Methods of joining components to form vehicle assemblies, such as engine assemblies, are provided. The methods include arranging a first component having a first channel defined therein in a mold, arranging a second component having a second channel defined therein in the mold, and aligning the first and second channel to define a pin-receiving channel. At least one polymeric composite pin is inserted into the pin-receiving channel thereby joining the first and second components, wherein an adhesive is disposed adjacent to at least a portion of the polymeric composite pin.

A cylinder block includes a support wall part that rotatably supports a crank shaft. The support wall part has a fitting recess part to which a bearing cap can be fitted. In each of the left and right corner parts where a bottom surface and a fitting surface of the fitting recess part intersect, a notch groove is formed that extends in the array direction of cylinder bores and has a substantially arc-shaped cross section when cut by the virtual plane along the extension direction thereof. As a result, stress having a greater value as the location becomes closer to the center part in the extension direction of the notch groove can be substantially uniform in the extension direction of said notch groove, and it is possible to effectively mitigate the stress concentration.

A first angle portion where part of a bearing cap side wall portion is cut out and a second angle portion where part of a bearing cap bottom surface portion is cut out are formed in a region (an angle region of a bearing cap) including a part where respective extension portions of the bearing cap side wall portion and the bearing cap bottom surface portion intersect each other, and a gap is provided between the crankcase side wall portion of a journal wall and the first angle portion and between a crankcase bottom surface portion and the second angle portion.

Engine block assemblies and methods for making the same are provided. Methods include casting an engine block around one or more extruded aluminum cylindrical cylinder liners, wherein each cylinder liner includes a cylindrical inner surface and an outer surface, and the outer surface of each of the cylinder liners is contiguous with the engine block and defines a cylinder bore, subsequently surface-preparing the inner surface of each of the cylinder liners, subsequently applying a ferrous liner to an inner side of each of the cylinder liners via thermal spraying, and subsequently machining an inner surface of the ferrous liner. Each of the aluminum cylinder liners are extruded, and can comprise a low silicon content aluminum alloy. The engine block can comprise a high silicon content aluminum alloy. Each of the one or more ferrous liners comprises a thickness of less than about 175 microns.

A heat insulating structure of an internal combustion engine (engine 1) includes a cylinder-head-side heat insulating cover (30) and a cylinder-block-side heat insulating cover (40). Each of the first side walls (32) of the cylinder-head-side heat insulating cover (30) is disposed outwardly of, and is spaced apart from, a corresponding one of the second side walls (43) of the cylinder-block-side heat insulating cover (40) in the width direction of the vehicle. The lower edge of each of the first side walls (32) is positioned below the upper edge of the corresponding one of the second side walls (43) to overlap with the corresponding one of the second side walls (43) when viewed from the side of the vehicle.

A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable salt core is located in each relief, the salt core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the salt core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable salt cores is also disclosed. The expendable salt cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.