A piston for an internal combustion engine includes a lower portion and an upper portion. An upper joining plane is positioned between the upper and lower extending through the outer circumference of the piston. At least one lower joining plane is positioned between the upper and lower portions. A solder gap is defined in the upper and lower joining planes wherein a solder containing iron is inserted to fixedly join the upper and lower portions together. Methods for producing pistons through connection of the lower portion to the upper portion with solder are also disclosed.

A manufacturing method for an engine includes: preparing, as a preparing step, a cylinder head having a surface on which a ceiling surface of a combustion chamber is formed; forming, as a film formation step, a thermal insulation film on the ceiling surface; measuring, as a measurement step, a volume of the thermal insulation film; and selecting, as a selection step, a rank for an engine valve to be used in combination with the ceiling surface so as to correspond to an amount of difference of a measured volume of the thermal insulation film from a designed value of a volume of the thermal insulation film, the rank being selected from a plurality of ranks set in correspondence with thicknesses of umbrella portions of engine valves.

A manufacturing method for an engine includes: preparing, as a preparing step, a cylinder head having a surface on which a ceiling surface of a combustion chamber is formed; forming, as a film formation step, a thermal insulation film on the ceiling surface; measuring, as a measurement step, a volume of the thermal insulation film; and selecting, as a selection step, a rank for an engine valve to be used in combination with the ceiling surface so as to correspond to an amount of difference of a measured volume of the thermal insulation film from a designed value of a volume of the thermal insulation film, the rank being selected from a plurality of ranks set in correspondence with thicknesses of umbrella portions of engine valves.

Embodiments of the apparatus relate to a template used to assist in the removal of broken bolts from an intake manifold mounting fasteners. The apparatus includes a template having a plurality of apertures. When the template is used with a cylinder head, one or more of the apertures is designated as an insertion aperture and one or more of the apertures is designated as a connection apertures. Insertion apertures align with bolt holes of the cylinder head containing broken bolts, and connection apertures align with empty bolt holes of the cylinder head that may be used to secure the template to the cylinder head. The template is used to guide a drill bit or other tools through the insertion apertures as the drill bit or other tool performs work to remove a broken bolt within the cylinder head.

Embodiments of the apparatus relate to a template used to assist in the removal of broken bolts from an intake manifold mounting fasteners. The apparatus includes a template having a plurality of apertures. When the template is used with a cylinder head, one or more of the apertures is designated as an insertion aperture and one or more of the apertures is designated as a connection apertures. Insertion apertures align with bolt holes of the cylinder head containing broken bolts, and connection apertures align with empty bolt holes of the cylinder head that may be used to secure the template to the cylinder head. The template is used to guide a drill bit or other tools through the insertion apertures as the drill bit or other tool performs work to remove a broken bolt within the cylinder head.

A rotary pump for a fluid metering system is provided. The rotary pump reciprocates, and is reversed by a signal from a limit switch that is deflected by an actuator arm on a rotating sleeve of the pump system. The rotary pump includes a plunger and optional stopper formed from a two-shot molding process, and including seals overmolded onto the head of the plunger and the head of the optional stopper.

A method for remanufacturing or repairing a cylinder head having a bore configured to receive a fuel injector comprises machining a portion of a surface forming the bore to remove imperfections, inserting a repair component into the bore proximate the machined portion of the bore, and spraying material into the bore proximate the machined portion and the repair component, thereby holding the component into place.

A method for remanufacturing or repairing a cylinder head having a bore configured to receive a fuel injector comprises machining a portion of a surface forming the bore to remove imperfections, inserting a repair component into the bore proximate the machined portion of the bore, and spraying material into the bore proximate the machined portion and the repair component, thereby holding the component into place.

A piston for an internal combustion engine includes a lower portion and an upper portion. An upper joining plane is positioned between the upper and lower extending through the outer circumference of the piston. At least one lower joining plane is positioned between the upper and lower portions. A solder gap is defined in the upper and lower joining planes wherein a solder containing iron is inserted to fixedly join the upper and lower portions together. Methods for producing pistons through connection of the lower portion to the upper portion with solder are also disclosed.

A press base may include a piston cavity formed in the press base and a piston cavity sleeve positioned in the piston cavity. The piston cavity sleeve may include a wall having an outer surface and an inner surface opposite the outer surface. The piston cavity sleeve may further include a floor having an upper surface and a lower surface opposite the upper surface. An outer radius may be formed at a juncture of the outer surface of the wall and lower surface of the floor and an inner radius may be formed at a juncture of the inner surface of the wall and upper surface of the floor. The inner radius may exhibit a radius of curvature that is greater than a radius of curvature of the outer radius.