A bolt-on replacement intake manifold has an asymmetrical plenum with a first end including an inlet, a closed terminal end, a concave top surface and a convex bottom surface; a flange; and a plurality of runners extending from the bottom surface of the plenum and terminating at the flange. The plenum defines an interior space in flow communication with the runners. The bottom surface of the plenum is wider than the top surface. The plenum initially widens from the inlet to the first runner and then begins to narrow from the first runner toward the last runner adjacent to the closed terminal end. The runners are tapered, curved, and vary in length. The intake manifold causes air to exit each of the plurality of runners at substantially the same angle. The manifold balances airflow across each runner and increases swirl inside the cylinders enhancing fuel economy, power output, and torque.

Methods and systems are provided for regulating airflow through a charge air cooler integrated in an intake assembly. In one example, an engine intake assembly comprises a plenum having an integrated charge air cooler (CAC), a first header seal positioned around a circumference of a first CAC header, and a first rotatably movable seal positioned in a bypass passage of the plenum. The first movable seal interfaces via sliding contact with the first header seal and adjusting a position of the first movable seal may vary the amount of airflow through the bypass passage.

A thermal fuel delivery system includes an insertion assembly and a fuel device. The insertion assembly includes a housing defining a cavity for housing the fuel device. The housing is disposed above and coupled to a pair of frame members via a plurality of connecting members. The frame members extend laterally away from the housing. The insertion assembly further includes an intake manifold coupled to the housing via a tube. A plurality of runner tubes extend laterally away from the intake manifold and pass through the frame members at an inner portion of the frame members and terminate at an outer portion of the frame members.

A method and a system to restrict the flow of accumulated liquid water from the intake manifold into the cylinders of an internal combustion engine by reducing the velocity of contained liquid water as it moves through the containment feature during vehicle maneuvering are disclosed. The body of the intake manifold includes a water containment feature having a water containment reservoir having an open upper portion and water-restricting interior walls. A water passageway is provided in each interior wall. The water passageway may be of any of several shapes, including a V-shape notch extending from the top of the wall. The interior wall is a central interior wall and the containment reservoir further includes an intermediate interior wall between the side walls that intersects the central interior wall. The water passageway is formed in at least one of the interior walls and may be formed in all of the walls.

A method and a system to eliminate the flow of accumulated liquid water from the intake manifold into the cylinders of an internal combustion engine are disclosed. Particularly, the disclosed inventive concept provides a negative draft to the top of a water containment feature in the form of opposed baffles. The baffles increase the minimum angle the water has to reach to overflow out of the intake manifold and into the cylinders. The angle required to overflow is a composition of gravity and the acceleration of the vehicle. If the maximum acceleration (and thus maximum water angle) is less than the designed negative draft overflow protection, there will not be expected overflow. The water containment reservoir includes two opposed side walls, a front wall, a back wall, and a base. Each side wall has an upper end. The baffle extends from the upper end of at least one side wall.

An intake manifold made of synthetic resin includes first, second and third members stacked in sequence and welded to form the intake manifold; a collector extending inside the intake manifold in a direction of a line of cylinders, a part of wall of the collector being formed by the third member; a plurality of branch passages formed substantially by the first and second members and wound around an outer periphery of the collector; and a connector passage leading from the collector to an outer peripheral side of the branch passage. The first, second and third members are respectively provided with first, second and third cylinder portions that are coaxially arranged with each other in a position between adjacent two branch passages. The connector passage is formed by the first, second and third cylinder portions with the connector passage communicating with an inside space of the collector.

A thermal fuel delivery system includes an insertion assembly and a fuel device. The insertion assembly includes a housing defining a cavity for housing the fuel device. The housing is disposed above and coupled to a pair of frame members via a plurality of connecting members. The frame members extend laterally away from the housing. The insertion assembly further includes an intake manifold coupled to the housing via a tube. A plurality of runner tubes extend laterally away from the intake manifold and pass through the frame members at an inner portion of the frame members and terminate at an outer portion of the frame members.

An airbox for an engine is provided. The airbox includes a first cylinder bank including a plurality of first cylinder sections. The airbox also includes a second cylinder bank including a plurality of second cylinder sections. The airbox further includes an isolation assembly provided in association with the first cylinder bank and the second cylinder bank. The isolation assembly is configured to isolate at least one first cylinder section of the plurality of first cylinder sections from another first cylinder section of the plurality of first cylinder sections, at least one second cylinder section of the plurality of second cylinder sections from another second cylinder section of the plurality of second cylinder sections, and the first cylinder bank from the second cylinder bank.

An intake manifold for an internal combustion engine having: at least one runner having a front side and a back side defining a hollow interior space, and a port for receiving air into the hollow interior space, the back side having a plurality of cylinder holes aligning with cylinder head openings of the internal combustion engine and a plurality of bolt holes configured for receiving a plurality of bolts, each bolt having a bolt head and a bolt thread, the front side having a plurality of access holes aligning with the plurality of bolt holes, the access holes being configured to allow a user to access and secure the bolt head using a bolt-securing tool, the access holes being further configured to receive a seal, such that the intake manifold can be secured to the internal combustion engine with no portion of the bolt thread lying within the hollow interior space of the intake manifold thus preventing obstruction of air circulation through the hollow interior space.

A thermal fuel delivery system includes an insertion assembly and a fuel device. The insertion assembly includes a housing defining a cavity for housing the fuel device. The housing is disposed above and coupled to a pair of frame members via a plurality of connecting members. The frame members extend laterally away from the housing. The insertion assembly further includes an intake manifold coupled to the housing via a tube. A plurality of runner tubes extend laterally away from the intake manifold and pass through the frame members at an inner portion of the frame members and terminate at an outer portion of the frame members.