Method and apparatus for manufacturing cylinder blocks

A method of manufacturing cylinder blocks. A cylinder block includes cylinder liners, the number of which corresponds to the number of cylinders in the engine, and a block body molded integrally with and about the cylinder liners. A liner assembly is formed by aligning cylinders in a single row and connecting the adjacent cylinder liners. A variable section provided between each pair of cylinders enables the distance between the axes of the outer cylindrical surface of each cylinder liner to be varied. The block body is molded by first arranging the liner assembly in a mold. Molten metal is then charged into the mold. When the metal solidifies, the block body is formed encompassing the liner assembly. A reference point on the block body is used to machine the inner cylindrical surfaces and form the cylinder bores.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a method and an apparatus for 
manufacturing engine cylinder blocks, and more particulary, to a method 
and an apparatus for manufacturing a cylinder block that employs a 
cylinder liner having a plurality of bores for a multiple cylinder engine 
and a block body molded about the liner. 
2. Description of the Related Art 
A cylinder block constitutes a multiple cylinder engine. A first type of 
cylinder block is entirely made of cast iron. TO manufacture this type of 
cylinder block, a rough block material is molded with holes that 
correspond to the engine's cylinders. The walls of each hole are machined 
about an axis that is separated by a predetermined distance from a certain 
reference position on the rough block material to define a cylinder bore. 
Japanese Unexamined Patent Publication No. 5-321751 describes a second type 
of cylinder block, which is shown in FIGS. 24 and 25. As shown in the 
drawings, a cylinder block 93 includes a cylinder liner 91 made of cast 
iron and an aluminum block body 92, which encompasses the liner 91. The 
cylinder liner 91 include a plurality of cylinders 96, which have the same 
wall thickness, and connecting sections 97, which are connected to 
adjacent cylinders 96. The axis L1 of the inner cylindrical surface 94 of 
each cylinder 96 coincides with the axis L2 of the outer cylindrical 
surface 95 of the same cylinder 96. Each cylinder 96 has the same 
diameter. 
The cylinder block 9S of the second type manufactured in the same manner as 
the cylinder block of the first type. In other words, the cylinder liner 
91 is first formed as shown in FIG. 24. After arranging the liner 91 in a 
mold, molten metal is charged into the mold. The block body 92 is formed 
about the liner 91 when the metal solidifies as it contracts. This allows 
the rough block material to be produced with the cylinder liner 91 
contained therein. The inner cylindrical surface 94 of each cylinder 96 is 
machined about an axis which is separated by a predetermined distance from 
a certain reference position provided on the block body 92. As shown in 
FIG. 25, this defines the cylinder bores #1 and #2 in the cylinder block 
However, the molten metal generally contracts about 0.6% after being 
charged into the mold during the molding process. In comparison, 
substantially no contraction takes place in the cylinder liner 91. 
Therefore, when machining the cylinder block 93 of the second type by 
using a reference point on the block body 92 in the same manner as the 
first type, each cylinder bore #1, #2 is formed with their axis L3 
separated from the axis of the outer cylindrical surface 95 of the 
associated cylinder 96. This results in each cylinder 96 having a wall 
which thickness differs between sections. The difference in wall thickness 
may result in insufficient strength of the cylinder 96 especially at 
sections where the walls become thin. In FIG. 25, the double-dotted line 
shows the inner cylindrical surface 94 of each cylinder 96 before 
machining and the solid line shows the cylindrical surface 94 after 
machining. The outer cylindrical surface 95 is shown by the dotted line. 
SUMMARY OF THE INVENTION 
Accordingly, it is a primary objective of the present invention to provide 
a method and an apparatus for manufacturing a cylinder block, which 
includes cylinder liners and a block body molded about the liners, that 
enables the axes of the outer and inner cylindrical surfaces of a cylinder 
of each cylinder liner to coincide with each other and thus allows the 
cylinder to have a wall thickness which is uniform. 
To achieve the foregoing and other objects and in accordance with the 
purpose of the present invention, a method for manufacturing a cylinder 
block for an internal combustion engine is provided. The cylinder block 
has a liner assembly and a block body molded around the liner assembly. 
The liner assembly has a plurality of adjacent cylinder liners, wherein 
each cylinder liner has an outer cylindrical surface, an inner cylindrical 
surface and a cylinder bore formed in the inner cylindrical surface. Each 
outer cylindrical surface, inner cylindrical surface and cylinder bore 
have an independent axis. Each cylinder bore axis is set at a 
predetermined position in the cylinder block. The method comprises forming 
the cylinder liners such that the outer cylindrical surface and the inner 
cylindrical surface of the same cylinder liner are coaxial and such that 
each liner includes a variable coupling structure on its outer surface, 
forming the liner assembly by coupling the cylinder liners with each other 
using the variable coupling structure to align the cylinder liners in a 
single row, wherein the step of forming the liner assembly includes mating 
the coupling structure of one liner with that of an adjacent liner to 
allow variation of the distance between the axes of the outer cylindrical 
surfaces of adjacent cylinder liners, positioning the liner assembly in a 
mold such that the axis of the outer cylindrical surface of each liner s 
offset from the predetermined position of the axis of the cylinder bore 
associated therewith, molding the block body around the liner assembly by 
pouring molten metal into a mold and by solidifying the molten metal, 
wherein the axis of the outer cylindrical surface of each liner relocates 
to substantially coincide with the predetermined position of the axis of 
the associated cylinder bore as a consequence of movement of the variable 
coupling structures as the molten metal cools and is solidified, and 
forming each cylinder bore at the predetermined positions by machining 
each inner cylindrical surface, wherein the predetermined position of each 
cylinder bore axis is a predetermined distance from a predetermined 
reference position on the block body.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
A first embodiment according to the present invention will hereafter be 
described with reference to FIGS. 1 to 11. 
FIGS. 9 and 11 show a cylinder block 11 for a four cylinder engine. The 
cylinder block 11 includes a liner assembly 12 having four cylinder bores 
#1, #2, #3, #4, As shown in FIG. 11, a piston 14 provided with piston 
rings 13 is accommodated for reciprocation in each bore #1-#4. The 
distance between adjacent bores #1-#4 at the closest section is five to 
eight millimeters and thus very narrow. A combustion chamber 30, in which 
a mixture of air and fuel is combusted, is defined by the space above the 
piston 14 in each bore #1-#4. The cylindrical surface of each bore #1-#4 
has a high accuracy (roundness) to seal the combustion chamber and prevent 
the leakage of gas produced by the combustion of the air-fuel mixture. 
As shown in FIGS. 2 and 6, the liner assembly 12 is machined to define the 
cylinder bores #1-#4. More specifically, the liner assembly 12 includes 
first, second, third, and fourth cylinder liners 15, 16, 17, 18. 
The cylinder liners 15, 16, 17, 18 have cylinders 21, 22, 23, Z4, 
respectively. One first projection 25 and two second projections 27 
project outward from each liner 15-18. Each cylinder 21-24 has an outer 
cylindrical surface 20 and an inner cylindrical surface 19. The axis L2 of 
the outer surface 20 coincides with the axis L1 of the associated inner 
surface 19. The first and second projections 25, 27 relocated along the 
outer wall 20 at diametrically opposed positions with respect to the axes 
L1, L2. The first projection 25 projects from the outer surface 20 and 
extends parallel to the axes L1, L2. A surface 25a is defined at the 
distal end of the first projection 25 arched in correspondence with the 
shape of the outer surface 20 Of the adjacent cylinder 22 (or 23). As 
shown in FIG. 3, a finger 26 projects from each side of the arched surface 
25a. Each finger 26 is tapered to be more narrow toward its end and 
extends parallel to the axes L1, L2. The widest part of each projection 25 
is located between the fingers 26. 
The two second projections 27 are separated from each other and project 
outward from the outer surface 20 extending parallel to the axes L1, L2. 
The distance between the two projections 27 is slightly smaller than the 
distance between the tips of the two fingers 26 of projection 25. A 
receptacle 28 is defined between the two projections 27 and the outer 
surface 20. To connect adjacent cylinder liners 15-18 to one another, the 
first projection 25 is press fitted into the receptacle 28 of the adjacent 
liner 15-18. Three spaces 31, 32, 33 are provided between each adjacent 
pair of connected liners 15-18 to alter the distance W (FIG. 2) between 
the axes L2. The space 31 is defined between the arched surface 25a and 
the opposed wall of the receptacle 28. The spaces 32, 33 are defined 
between the distal end of each second projection 27 and the opposed outer 
surface 20 of the adjacent cylinder 21-24. 
The first projection 25 of each cylinder liner 15-18 is engaged with the 
receptacle 28 of the adjacent liner 15-18 to connect the liners 15-18 and 
form the liner assembly 12. 
As shown in FIG. 9, the cylinder block 11 includes an aluminum block body 
34 molded about the liner assembly 12. The block body 34 is provided with 
a water jacket 35 defined about the liner assembly 12 in a manner 
encompassing each cylinder bore #1-#4. Coolant flows through the water 
jacket 35 to cool the block body 34 and the liner assembly 12. 
It is necessary that the cylinder liners 15-18 satisfy the following 
requirements. (1) wear caused by the repetitive reciprocation of the 
associated piston in the liners 15-18 must be suppressed without etching 
or treating the surface of the liners 15-18 to improve wear resistance. 
(2) Seizing of the pistons 14 must be prevented despite their repetitive 
reciprocation. (3) The hardness of the base material of the cylinder 
liners 15-18 must not be lowered by the heat emitted from the molten metal 
during molding of the cylinder block 11. (4) Strength and toughness must 
be sufficient to resist the molding pressure. (5) Production in the same 
manner as cylinder liners made of cast iron must be possible. This enables 
the employment of the same equipment use to produce cast iron cylinder 
liners. 
It is difficult for a single metal material to satisfy each of the above 
requirements (1) to (5). Thus the cylinder liners 15-18 in this embodiment 
are made of a composite material. That is, each cylinder liner 15-18 has a 
double layer structure that includes an inner layer and an outer layer. 
The outer layer is made of an aluminum alloy and bonded with the inner 
layer. 
The method for manufacturing the above cylinder block 11 will now be 
described. The method includes a step (A) to form the cylinder liner, a 
step (B) to form the liner assembly, a step (c) to arrange the liner 
assembly in a mold, a step (D) to form the block body, and a step (r) to 
form the cylinder bores. 
Cylinder Liner Formation Step (A) 
In step (A) , a matrix powder of a composite metal, alumina, and graphite 
are uniformly mixed. Billets having holes are produced from the mixture by 
performing cold isostatic press (CIP). The billets are put inside a 
container made of an aluminum alloy and then heated. The composite billets 
are than filled into a mold having a shape that matches the cylinder 
liners 15-18. The billets are than pressurized and extruded from the mold. 
This causes metallic Bonding between the powders and allows production of 
an elongated product having a double-layer structure. By cutting the 
elongated product into predetermined lengths, cylinder liners having the 
cylinder and the first and second projections are obtained. The axis of 
the outer cylindrical surface coincides with the axis of the inner 
cylindrical surface for each cylinder. Furthermore, the thickness of the 
wall of the cylinder is uniform. 
Liner Assembly Formation Step (B) 
In step (B), the four liners 15-18 obtained in step (A) are connected to 
one another so as to align the cylinders 2l-24 in a single row. More 
specifically, the first projection 25 is press fitted into the receptacle 
28 of the adjacent cylinder 15-18 with a silicone adhesive applied between 
the arched surface 25a of the first projection 25 and the second 
projections 27 of the adjacent cylinder liner 15-18. This connects 
adjacent cylinders 15-18 as shown in FIGS. 2 and 3. When connecting the 
adjacent cylinders 15-18, the distal ends of the two fingers 26 linearly 
contact the associated second projection 27 as the first projection 25 is 
fitted into the receptacle 28. In other words, there is no planar contact 
between the sides of the first projection 25 and the second projections 
27. 
The same procedure is carried out on each cylinder liner 15-18. An adhesive 
layer 29 is defined between the engaged first projection 25 and the 
receptacle 28 of the adjacent cylinder liners 15-18 as shown in FIGS. 3 
and 4. In the liner assembly 12, the cylinder liners 15-17 are relatively 
movable along the aligned direction of the cylinders 21-24, that is, 
toward and away from one another. The movement allows alteration or the 
distance W between the names L2 of the outer surfaces 20 of each pair of 
adjacent cylinders 21-24. 
Liner Assembly Positioning Step (C) 
In step (C) and the following step (D), a mold 36 illustrated in FIGS. 5 
and 6 is employed. The mold 56 include a fixed mold 37, an upper movable 
mold 38, a lower movable mold 39, a lateral movable mold 40, and a holding 
mechanism 41. The fixed mold 37 has a plurality of holes 42 (the number of 
which corresponds to the number of the cylinders in the engine). A molding 
projection 43 is provided on a side surface 44 of the fixed mold 37 
surrounding each hole 42 to form the water jacket 35. 
The upper movable mold 38 is arranged above the molding projection 43 while 
the lower movable mold 39 is provided below the same projection 43. The 
movable molds 38, 39 slide reciprocally in a vertical direction along the 
side surface 44. This allows the movable molds 38, 39 to approach or move 
away from the molding projection 43. The lateral movable mold 40 is 
supported in a manner enabling reciprocal movement in the horizontal 
direction. This allows the movable mold 40 to approach or move away from 
the fixed mold 37. 
The holding mechanism 41 holds the liner assembly 12 arranged in the mold 
36. The mechanism 41 includes a plurality of insertion pins 45 (the number 
of which corresponds to the number of the cylinders in the engine) and 
connecting sections 46, which connect the basal section of each pair of 
adjacent pins 45. The pins 45 and the connecting sections 46 are formed 
integrally. Each pin 45 is cylindrical and has a diameter that is slightly 
smaller than the diameter of the inner cylindrical surface 19 of the 
associated cylinder 21-24. Each pin 45 is inserted in each hole 42 and is 
fixed to the fixed mold 37. 
To position the liner assembly 12 in the mold 36, the three movable molds 
38-40 are moved away from the projections 43 to open the mold 36 as shown 
in FIG. 5. The liner assembly 12 is inserted into the space 43a defined 
between the corresponding projection 43 and pin 45. This causes the liner 
assembly 12 to be fitted on the pins 45. 
The linear contraction of the molten metal in the following step (D) is 
smaller than the widths W1, W2, W3 of the respective spaces 31, 32, 33, 
which are shown in FIG. 3. That is, as shown in FIG. 9, if he distance 
between the axes L3 of the adjacent cylinder bores #1-#4 (the bore pitch) 
i represented by A1, the distance W between the axes L2 of the outer 
cylindrical surface 20 when the liner assembly 12 is attached to the pins 
45 may be represented by A1+.alpha.. The cylinder liners 15-18 may be 
moved toward each other to shorten the distance W. 
Block Body Formation Step (D) 
In step (D), the liner assembly 12 is insert molded in aluminum. More 
specifically, as shown in FIG. 7, the movable molds 38-40 are moved toward 
the projections 43. This closes the mold 36 and defines a cavity 47 
between the fixed mold 37, the movable molds 38-40, and the liner assembly 
12. The block body 34 is formed in the cavity 47. Molten metal is charged 
into the cavity 47 through a passage 48 defined in the lateral movable 
mold 40. 
The molten metal charged in the cavity 47 contracts 0.6% as it solidifies 
and produces stress that is applied to the cylinder liners 15-18 The 
stress causes the cylinder liners 15-18 to follow the contraction of the 
metal and move in a direction narrowing the distance W (FIG. 2) between 
the axes L2 of each pair of adjacent liners 15-18. The narrowing direction 
is a direction that the axis L2 of each liner 15-18 moves in as if moves 
toward the axis L3 of each cylinder bore #1-#4. The bores are formed in 
the following step (S). When the molten metal is solidified, a rough block 
material 49 is produced with the liner assembly 12 insert molded in a 
metal material (aluminum), and the water jacket 35 is defined about the 
assembly 12. In the block material 49, the axes L2 of the outer 
cylindrical surfaces 20 of the cylinders 21-24 coincide with the axes L3 
of the associated cylinder bores #1-#4. 
As shown in FIG. 8, the movable molds 38-40 are then moved away from the 
molding projections 43. The block material 49 is than pushed out of the 
mold 36 by pushing pins (not shown). 
Cylinder Bore Formation step (E) 
In step (E), the inner cylindrical surface 19 of each cylinder 21-24 is 
machined about a point that is separated by a predetermined distance from 
a reference position on the block body 34. As mentioned above, the axes 
L1, L2 of the outer and inner surfaces 19, 20 of each cylinder 21-24 are 
displaced by the contraction of the molten metal during solidification. As 
shown in FIGS. 9 and 10, this enables each cylinder bore #1-#4 to have a 
predetermined radius with its axis L3 coinciding with the axis L2 of the 
inner surface 20 when machined. After machining, the wall thickness of 
each cylinder 21-24 is uniform. This allows the produced cylinder block 11 
to have a structure that does not include sections that are weaker than 
other sections. Thus, the cylinder block 11 differs from the cylinder 
blocks of the prior art. 
AS shown in FIG. 11, in an engine 51, a cylinder head 53 is installed on 
the cylinder block 11 by way of a gasket An oil pan (not shown) is 
arranged under the cylinder block The pistons 14 are accommodated in the 
associated cylinder bores #1-#4. When the engine 51 is started, the 
air-fuel mixture in the combustion chambers 30 is ignited and combusted. 
This vertically reciprocates the pistons 14 in the associated cylinder 
bores #1-#4. 
In this embodiment, each cylinder liner 15-18 is 53 constituted by the 
respective cylinder 21-24, the first projection 25, and the second 
projections 27. Accordingly, adjacent cylinder liners 15-18 may be 
connected to each other simply by engaging the first projection 25 with 
the receptacle 28. In addition, the structure produces the spaces 31-33, 
which serve as a variable section. 
All of the cylinder liners 15-18 have identical shapes. This allows common 
parts to be used at different locations and reduces the number of 
different parts. 
When engaging each first projection 25 with the associated receptacle 28, 
the fingers 26 of the projection 25 contact the associated second 
projections 27 linearly. Thus, the small contact area between the first 
projection Z5 and the receptacle 28 reduces friction therebetween. As a 
result, this facilitates the relative movement of the cylinder liners 
15-18o Accordingly, the cylinder liners 15-18 may move relative to one 
another when the molten metal solidifies and contracts. 
Since the distance A1 between the axes L3 of each pair of adjacent cylinder 
bores #1-#4 becomes smaller, the entire length of the cylinder block 11 
(the length of the block 11 in the aligned direction of the cylinders 
21-24) is shortened. This shortens the length of the engine 51 and allows 
a reduction in the weigh of the engine 51. Furthermore, this lessens the 
restrictions on mounting the engine on the vehicle caused by the size of 
the engine 51. 
There are a few problems caused when insert molding a block body about a 
plurality of adjacent cylinder liners without the projections, As the 
molten metal solidifies, stress is applied to the metal material causing 
it to move from between each pair of adjacent cylinders (i.e., movement in 
the direction indicated by arrows Yd in FIG. 9). This may cause cracks in 
the metal material at positions where the space between the cylinders 
becomes most narrow. As he space between the cylinders becomes more 
narrow, the metal material is more apt to crack. 
However, in this embodiment, the projections 25, 27 are provided at the 
location where the space between adjacent cylinders is most narrow. The 
projections 25, 27 are rigid and the adjacent cylinders liners 15-18 are 
securely connected to one another by the projections 25, 27. Therefore, 
cracks are not formed in the metal material regardless of the application 
of stress in the direction indicated by arrows Yd during solidification. 
The insertion pins 45 may securely be engaged with the corresponding 
cylinder liners 15-18 of the liner assembly 12. As shown in FIGS. 5 and 6, 
the distance between the axes Lx of each pair of adjacent pins 45 varies 
as the temperature changes. Thermal expansion increases as the temperature 
of the mold 36 rises resulting in an increase in the distance between the 
axes Lx. The time elapsed after the molten metal is charged into the mold 
36 effects the temperature of the mold 36. The temperature becomes highest 
immediately after the molten metal is charged and becomes lower as time 
elapses. Accordingly, the distance between each pair of adjacent axes Lx 
varies from when the molten metal is charged into the mold 36 in the 
previous molding cycle to when the liner assembly 12 is positioned in the 
present molding cycle. In such case, the axis of each pin and the axis of 
the corresponding cylinder liner become misaligned if the cylinder liners 
are securely fixed to one another to form the liner assembly. This may 
obstruct the engagement between the liner and the corresponding pins 45. 
However, in this embodiment, the spaces 31-33 provided between each pair of 
adjacent cylinder liners 15-18 allow the liners 15-18 to move in a 
direction that varies the distance W between the axes L2 of the adjacent 
liners 15-18. The position of the cylinder liners 15-18 may be varied to 
coincide the axis L2 of each liner 15-18 with the axis Lx of the 
corresponding pin 45 despite changes in the distance between adjacent axes 
Lx. The alignment of the corresponding axes Lx enables the liner assembly 
12 to be engaged with the pins 45. 
The cost of forming the cylinder liners 15-18 and the liner assembly 12 is 
reduced by the structure of this embodiment. That is, the first and second 
projections 25, 27 serve to connect the adjacent liners 15-18 while also 
serving to define a variable section (spaces 31-33). In comparison with a 
structure providing separate parts that only have a single purpose, the 
structure of this embodiment provides parts that have multiple functions 
and thus saves material costs. 
If a liner assembly is not provided with the variable section, its overall 
length is fixed. In this case, molten metal may enter the space defined 
between the section connecting adjacent liners. To prevent this problem, 
it is required that the connecting section of each liner have a fine 
surface. Thus, it is necessary to machine the connecting section to 
provide a fine surface finish. However, in this embodiment, the connecting 
section of each cylinder 21-24 is provided with the spaces 31-33. The 
connecting sections of the cylinder 21-24 need not be accurately machined 
to produce these spaces 31-33. Thus, machining to obtain a fine surface 
finish for the connecting sections is not required. 
Furthermore, the projections 25, 27 are formed through extrusion in the 
molding step (A) of the cylinder liners 15-18. Thus, no machining of the 
projections 25, 27 is required. 
As described above, the structure of this embodiment saves material costs. 
In addition, machining to improve the surface roughness of the assembly 
and to form the projections 25, 27 is not necessary, This contributes to 
reducing manufacturing costs. 
If the molten metal enters each space 31-33, the metal may restrict the 
movement of the cylinder Liners. However, in this embodiment, the adhesive 
layer 29 seals each space 31-33 and prevents molten metal from entering 
therein. This enables smooth relative movement of the cylinder liners 
15-18. The adhesive layer 29 remains flexible until the molten metal 
solidifies. Thus, the adhesive layer 29 does not hinder the relative 
movement of the cylinder liners 15-18. 
When the cylinder block is made of aluminum, it is required that the 
pistons and the piston rings slide smoothly with respect to the associated 
cylinder bores. To enable smooth sliding, the walls of the cylinder bore 
may be nickel-plated or provided with a layer of metal matrix composite 
(MMC). The cylinder bore walls may also be etched with a high silicon 
alumina alloy (A390). In such cases, the manufacturing methods such as low 
pressure casting or low speed medium pressure casting are employed to 
ensure the quality of the walls of the cylinder bores. However, these 
manufacturing methods increase the thickness of the molded product and 
thus increase the weight of the cylinder block. Furthermore, these methods 
l n then the time required during the casting cycle. 
To cope with this problem, the cylinder liners 15-18 have a double layer 
structure consisting of the inner and outer layers to secure the strength 
and toughness that is equal to that of cylinder liners made of cast iron. 
This allow the liner assembly 12 to be insert molded during the die 
casting process. In addition, this minimizes investments in equipment that 
are required to manufacture the cylinder block 11 of the present 
invention. Furthermore, since the die casting method may be employed, the 
average thickness of the cylinder block 11 may be minimized. This reduces 
the weight of the block 11 and shorten the time required for the casting 
cycle. 
A second embodiment according to the present invention will hereafter be 
described with reference to FIGS. 12-19. 
In this embodiment, the method through which the variable section in the 
liner assembly is formed differs from the first embodiment. Additionally, 
a plurality of serrations are provided on the outer cylindrical surfaces 
20 of the cylinder 21-24 and a coolant passage is provided between the 
sections connecting the adjacent cylinder liners 15-18. These differing 
parts will be described below. Parts that are identical to those in The 
first embodiment will be denoted with the same numeral. 
As shown in FIGS. 13 and 18, the cylinder liners 15-18 are not identical to 
one another. The first cylinder liner 15, located at one end of the liner 
assembly 12 and the fourth cylinder liner (not shown), located at the 
other end of the same assembly 12, have identical shapes. The second 
cylinder liner 16 and the third cylinder liner 17, located between the 
first cylinder liner 15 and the fourth cylinder liner, have identical 
shapes. The fourth liner is rotated 180 degrees with respect to the first 
liner 15. The third liner 17 is rotated 180 degrees with respect to the 
second liner 16. In this manner, the liner assembly 12 is constituted by 
two types of cylinder liners. 
The first liner 15 and the fourth liner each have a cylinder 21 having a 
outer and inner cylindrical surfaces 20, 19, a cylinder 21, and a 
connecting section 55 to connect the cylinder 21 with the adjacent 
cylinder 21. The axis L2 of the outer cylindrical surface 20 coincides 
with the axis L1 of the associated inner cylindrical surface 19. The 
connecting section 55 projects radially outward from each cylinder 21 and 
has a flat abutting surface 54 defined at its distal end. The second and 
third liners 16, 17 each have a respective cylinder 22, 23 and connecting 
sections 57, 59. The cylinders 22, 23 each have outer and inner 
cylindrical surfaces 20, 19. The connecting sections 57, 59 connect the 
cylinders 22, 23 to the adjacent cylinders 21, 24, respectively. The axis 
L2 of the outer cylindrical surface 20 coincides with the axis L1 of the 
associated inner cylindrical surface 19. The connecting sections 57, 59 
project radially outward from the cylinders 57, 59 in opposite directions. 
The connecting sections 57, 59 have respective flat abutting surface 56, 
58 defined at their distal end. A plurality of serrations 61 extend 
parallel to the axes L1, L2 on the outer cylindrical surface 20 of each 
cylinder 21-24. 
In this embodiment, an adhesive is used to connect the four cylinder liners 
15-18 to one another and define the variable section. More specifically, 
an adhesive layer 62 is provided between the opposed abutting surfaces 54, 
56 of each pair of adjacent connecting sections 55, 57. An adhesive layer 
62 is also provided between the opposed abutting surfaces 58 of the 
connecting sections 59, 59 projecting from the second and third liners 16, 
17, respectively. As shown in FIG. 12, the adhesive layer 62 is formed by 
applying the adhesive around the abutting surfaces 54, 96, 58 in a 
substantially rectangular frame-like manner. The lower section 62a of the 
adhesive layer 62 has a greater area than other sections of the same layer 
62a. Each adhesive layer 62 enables relative movement of the cylinder 
liners 15-18 in a direction narrowing the distance W between the axes L2 
of the adjacent liners 15-18 when the molten metal contracts as it 
solidifies. 
It is necessary that the adhesive layer 62 satisfy the following 
requirements. The layer 62 must connect the abutting surfaces 54, 56, 58 
of the respective connecting sections 55, 57, 59 to connect adjacent 
liners 15-18 with each other. The layer 62 must have flexibility during 
the process in which the molten metal solidifies and contracts. The layer 
62 must resist the instantaneous high temperature and high pressure during 
molding to prevent the molten metal from entering the space between the 
connecting sections 55, 57, 59. To satisfy these requirements, the 
employment of a silicone adhesive is desirable in this embodiment, 
As shown in FIGS. 15, 16, 17, and 19, coolant passages 64, 65 are provided 
so that the coolant 63 in the water jacket 35 is drawn into the area 
between each pair of adjacent cylinder bores #1, #2, #3, #4. Each coolant 
passage 64 includes a plurality (four) of rectangular closed spaces 66, 
which are laterally elongated, and pairs of holes 67, each extending 
vertically through the sides of each set of closed spaces 66. The closed 
spaces 66 are provided at the upper portion of the a adjacent connecting 
sections 55, 57. Each hole 67 connects the closed spaces 66 to the water 
jacket 35. The coolant passage 65 includes a plurality (four) of 
rectangular closed spaces 68, which are laterally elongated, and pairs of 
holes 69, each extending vertically through the sides of the closed spaces 
68. The closed spaces 68 are provided at the upper portion of the adjacent 
connecting sections 59. Each hole 69 connects the closed spaces 68 to the 
water jacket 35. 
A plurality (four) of grooves 71 extend between the sides of the abutting 
surface 56 at the upper portion of the second cylinder liner 16 to define 
the closed spaces 66. As shown in FIGS. 13 and 14, each groove 71 has a 
depth D and extends in a direction perpendicular to the axes L1, L2. The 
abutting surface of the third cylinder liner 17 is provided with identical 
grooves (not shown). The abutting surfaces 54 of the first and fourth 
cylinder liners 15, 18 are not provided with such grooves. The closed 
spaces 66 having a predetermined width are defined between the grooves 71 
and the opposed abutting surface 54 when connecting the first and second 
cylinder liners 15, t6 or the fourth and third cylinder liners 18, 17 with 
the adhesive layers 62. 
A plurality (four) of grooves 72 extend between the sides of the abutting 
surfaces 56, 58 at the upper portion of the second and third cylinder 
liner 16, 17. Each groove 72 has a depth D/2 which is half the depth D of 
the grooves 71 and extends in a direction perpendicular to the axes L1. 
L2. The closed spaces 68 having a predetermined width are defined between 
the opposed grooves 72 when connecting the second and third cylinder 
liners 16, 17 to each other. 
The structure of this embodiment minimizes machining of the cylinder liners 
15-18 that is required to define the closed spaces 66, 68 and enables, the 
closed spaces 66, 68 to be defined halfway between the adjacent cylinder 
bores #1-#4. By providing the closed spaces 66, 58 at the halfway point 
between the adjacent cylinder bores #1-#4 , the distance between the 
coolant passages 64, 65 and the bores #1-#4 is equalized. This allows 
uniform cooling of the adjacent bores #1-4. 
Since the temperature at the upper portion of each abutting surface 54, 56, 
58 becomes highest when the engine is running, the grooves 71, 72 are 
provided only at the upper section of each abutting surface 54, 56, 58. 
Without the coolant passages 64, 65, the cooling effect of the coolant 
flowing through the water jacket 35 may be insufficient. In other words, 
heat is produced during operation of the engine 51 when the air-fuel 
mixture is ignited and combusted in each combustion chamber 30. Since each 
combustion chamber 30 is defined at the section above the piston 14, the 
upper portion of each cylinder liner 15-18 is heated by the heat of the 
chamber 30. The effects of the combustion heat become smaller at positions 
lower than the combustion chambers 30. Thus, the lower portions of the 
cylinder liners 15-18 may be sufficiently cooled by the coolant flowing 
through the water jacket 35. Accordingly, the coolant passages 64, 65 need 
not be provided between the lower portions of the adjacent bores #1-#4. 
The steps of the method to manufacture the cylinder block 11 in this 
embodiment will now be described. The method includes the steps (A)-(E) of 
the first embodiment and a Step (F) in which the holes 67, 69 are formed. 
Cylinder Liner Formation Step (A) 
In step (A), ballets are produced through the CIP method in the same manner 
as the first embodiment. The billets are then pressurized and extruded to 
produce an elongated product having a double-layer structure. By cutting 
the elongated product into predetermined lengths, cylinder liners having a 
cylinder and a single connecting section are obtained. Cylinder liners 
having a cylinder id two connecting sections are also obtained by cutting 
the elongated product in the same manner. The axis of the outer 
cylindrical surface coincides with the axis of the inner cylindrical 
surface for each cylinder. Furthermore, the thickness of the wall of the 
cylinder is uniform. 
Liner Assembly Formation Step (B) 
In step (B), two of each type of the cylinder liners obtained in step (A) 
are connected to one another so as align the cylinder 21-24in a single 
row. More specifically, a silicone adhesive is applied around at least one 
of the opposed connecting sections 55, 57 (or 59, 59) of the abutting 
surface 54, 56 (or 58, 58). For example, as shown in FIG. 12 the adhesive 
is applied about the abutting surface 56, in which the grooves 71 are 
defined, in a rectangular frame-like manner. The area of the applied 
adhesive is larger at the bottom section of each abutting surface 55, 57, 
59 than other sections of the same surface 55, 57, 59. Each pair of 
adjacent connecting sections 55, 57 (or 59, 59) are then adhered to each 
other by the adhesive. This connects adjacent cylinders 15-18 and defines 
the liner assembly 12. In the assembly 12, a space corresponding to the 
thickness of the applied adhesive is defined between each of the connected 
butting surfaces 54, 56 (or 59, 59). This enables relative movement of the 
cylinder liners 15-18 along the aligned direction of their cylinders. The 
movement alters the distance W between each pair of adjacent axes L2. 
As shown in FIG. 18, the closed spaces 66, 68 are defined in the connecting 
sections of the adjacent cylinder liners 15-18 by connecting the opposed 
abutting surfaces 56 (or 58, 58). That is, the closed surfaces 66 are 
defined between the abutting surface 54 and the grooves 71 of the 
associated first and second cylinder liners 15, 16. In the same manner, 
the closed spaces 66 are defined between the fourth and third cylinder 
liners 18, 17. The closed spaces 68 are defined between the pair of 
opposed groove 72, 72 of the second and third cylinder liners 16, 17. Each 
of the closed spaces 66, 68 has the same volume and is located halfway 
between each pair of adjacent cylinder bores #1-#4. 
Liner Assembly Positioning Step (C) 
In step (C), the three movable molds 38-40 are separated from the molding 
projections 43 in the same manner as the first embodiment. The liner 
assembly 12 is inserted into the space 43a defined between the 
corresponding projection 43 and pin 46. This fits the liner assembly 12 on 
the pins 45 and positions the assembly 12 in the mold 36 (refer to FIG. 
5). In this state, the distance between the opposed abutting surfaces 54, 
56 (or 58, 58) of the adjacent connecting section 55, 57 (or 59, 59) is 
greater than the linear contraction of the molten metal in the following 
step (D). In this state, the cylinder liners 15-18 may be moved toward 
each other to narrow the distance W. 
Block Body Formation Step (D) 
In step (D), the movable molds 38-40 , are moved toward the projections 43 
to define the cavity 47 between the fixed mold 37, the movable molds 
38-40, and the liner assembly 12 in the same manner as in the first 
embodiment. The block body 34 is formed in the cavity 47. Molten metal is 
charged into he cavity 47 through the passage 48 defined in the lateral 
movable mold 40 (refer to FIG. 7). 
The molten metal charged in the cavity 47 contracts 0.6% as it solidifies 
and produces stress that is applied to the cylinder liners 15-18. The 
rectangular frame-like adhesive layer 62 is formed along the periphery of 
the abutting surface 54, 56, 58 to prevent molten metal from entering the 
space between the connecting sections 55, 57 or the connecting sections 
58, 58. The adhesive layer 62 is made of a silicone resin and is thus 
flexible. The stress causes the cylinder liners 15-18 to follow the 
contraction and move relatively in a direction narrowing the distance W 
between the axes L2 of each pair of adjacent liners 15-18. The adhesive 
layer 62 is deformed by the relative movement of the cylinder liners 
15-18. 
When the molten metal is solidified, a rough block material 49 is obtained 
with the liner assembly 12 insert molded in aluminum and the water jacket 
35 defined about the assembly 12. In the block material 49, the axle L2 of 
the outer cylindrical surface 20 of each cylinder 21-24 coincides with the 
axis L3 of the associated cylinder bore #1-#4. 
As shown in FIG. 8, the movable molds 38-40 are than moved away from the 
molding projections 43. The block material 49 is than pushed out of the 
mold 36 by pushing pins (not shown). 
In the block material 49, the inner cylindrical surface 19 of each cylinder 
21-24 of the liner assembly 12 is exposed. The other parts of the liner 
assembly 12 are encompassed by the aluminum casting (block body 34). The 
plurality (four) of closed spaces 66, 68 are defined between each pair of 
adjacent connecting sections 58, 57 and 59, 59. In this state, the closed 
spaces 66, 68 are not yet connected with the water jacket 35. 
Cylinder Bore Formation Step (E) 
In step (E), the inner cylindrical surface 19 of each cylinder 21-24 is 
machined about a point that is separated by a predetermined distance from 
a reference position On the block body 34. As mentioned above, the axes 
L1, L2 of the outer and inner surfaces 19, 20 of each cylinder 21-24 are 
displaced by the contraction of molten metal during solidification. As 
shown in FIG. 19, this enables each cylinder bore #1-#4 to have a 
predetermined radius and an axis L3 that coincides with the axis L2 of the 
inner surface 20 when machined. Therefore, the wall thickness of each 
cylinder 21-24 becomes uniform after machining. As in the first 
embodiment, this allows the produced cylinder block 11 to have a structure 
that does not include weaker sections. 
Hole Formation Step (F) 
In step (F), the sides of the abutted portion of the connecting sections 
55, 57 (or 59, 59) are perforated by drills, or the like, to define the 
holes 67, 69. The holes 67, 69 connect the ends of each closed space 66, 
68 with the water jacket 35. The closed spaces 66, 68 and the holes 67, 69 
constitute coolant passages 64, 65, respectively, between the bores #1-4. 
In the engine 51, which employs the cylinder block 11 of the second 
embodiment, a portion of the coolant 63 flowing through the water jacket 
35 flows through the coolant passages 64, 65 as shown by the arrows in 
FIG. 15. Heat transfer is performed between the heated cylinder liners 
15-18 and the coolant 63 to cool the liners 5-18. In this embodiment, the 
distance between each bore #1-#4 and the associated coolant passage 64, 65 
is equal. Therefore, the coolant 63 flowing through the passages 64, 65 
cools the adjacent cylinder liners 15-18 in a uniform manner. 
When the liner assembly 12 is arranged in the mold 36, the lower part of 
the adhesive layer 62, which is closest to a molten metal port 48a, 
receives the high pressure of the molten metal during molding. However, in 
this embodiment, the lower section 62a of the adhesive layer 62 has a 
greater area than other sections of the same layer 62. Thus, the adhesive 
layer 62 securely prevent molten metal from entering the space between the 
connecting sections 55, 57 or 59, 59 despite the high pressure acting 
against the layer 62. 
The molten metal, which is highly pressurized and has a high temperature, 
contacts the adhesive layer 62 during molding. However, since a silicone 
adhesive is used as the adhesive, the adhesive layer 62 sufficiently 
resists the heat of the molten metal. 
The adhesive layer 62, which has a predetermined width and flexibility, 
enables relative movement of the adjacent cylinder liners 15-18 and allows 
the distance W between their axes L2 to be varied. Thus, the position of 
the cylinder liners 15-18 may be varied to coincide the axis L2 of each 
liner 15-18 with the axis Lx of the corresponding pin 45 despite changes 
in the distance between adjacent axes Lx. Accordingly the liner assembly 
12 may securely be engaged with the pins 45 during its positioning step. 
If adjacent cylinder liners are fixed to each other in the same manner as 
the prior art, stress produced by the contraction of the molten metal 
during solidification may compress and deform the cylinders in their 
aligned direction. To cope with such deformation, it is necessary to 
increase the thickness of the cylinder walls at certain sections when the 
liners are formed in step (A). 
In comparison, the deformation of the adhesive layer 62 absorbs the stress 
produced by the contraction of the molten metal during solidification in 
the second embodiment. This suppresses deformation of the cylinders 21-24. 
Accordingly, it is not necessary to increase the thickness of the walls of 
the cylinders 21-24. 
The flexibility of the adhesive layers 62 between the adjacent connecting 
sections 55, 57 and the connecting sections 59, 59 enables the layer 62 to 
be securely adhered to the abutting surfaces 54, 56, 58. Hence, the 
adhesive layer 62 deforms in correspondence with the abutting surfaces 54, 
56, 58 even when the surfaces 54, 56, 58 are not flat. Accordingly, the 
abutting surfaces 54, 56, 58 need not be machined smoothly to prevent 
space from being defined between the cylinder liners 15-18. 
The first and fourth cylinder liners 15, 18 are identical to each other 
while the second and third cylinder liners 16, 17 are identical to each 
other. Thus, common parts may be employed to form the liner assembly 12. 
This reduces the required types of parts. In other words, the four 
cylinder liners 15-18 may be obtained by producing two types of cylinder 
liners in the cylinder liner formation step (A). 
The abutting surface 54 of the connecting section 55 for the first and 
fourth cylinder liners 15, 18 are not provided with grooves. This reduces 
manufacturing steps and saves machining costs that are related to the 
formation of the closed spaces 66. 
The block body 34 and the cylinder liners 15-18 are made of different 
materials. The difference in the linear expansion coefficient of each 
material results in the heat the engine 51 producing slight spaces at the 
section joining the block body 34 to the cylinder liners 15-18. This may 
degrade the strength holding the cylinder liners 15-18 in the block body 
34. 
To cope with this, serrations 61 are provided on the outer cylindrical 
surface of each cylinder 21-24. The serrations 61 enable the cylinder 
21-24 to be securely adhered to the block body 34. Hence, the cylinder 
liners 15-18 are firmly held regardless of the volume expansion of the 
block body 34 caused by the engine heat. 
The closed spaces 66, 68 are defined by the grooves 71, 72. The rigidity of 
the cylinder in each cylinder liner is improved by this structure in 
comparison to when the closed spaces are defined by a single recess. 
A third embodiment according to the present invention will hereafter be 
described with reference to FIGS. 20-23. 
This embodiment differs from the first and second embodiments in that the 
length of the connecting sections 59 with respect to the aligned direction 
of the cylinders 21-24 is constant and that the wall thickness of each 
cylinder 21-24 is not uniform. Parts that are identical to those used in 
the second embodiment are denoted with the same numerals. 
As shown in FIG. 20, the cylinder liners 15-18, which constitute the liner 
assembly 12, have connecting section s 57, 59 formed integrally with their 
outer cylindrical surface 20. The axis L2 of each outer cylindrical 
surface 20 is offset from the axis L1 of the associated inner cylindrical 
surface 19 in a direction toward the middle of the liner assembly 12. In 
other words, the wall thickness of each cylinder 21-24 varies. The walls 
of each cylinder 21-24 become thicker on the side facing the center of the 
liner assembly 12. 
More specifically, the axis L2 of the outer cylindrical surface 20 of the 
cylinder 21 included in the first cylinder liner 15 coincides with the 
axis L3 of the cylinder bore #1. The axis L2 of the outer cylindrical 
surface 20 of the cylinder 22 included in the second cylinder liner 16 
coincides with the axis L3 of the cylinder bore #2. 
The abutting section between the second and third cylinder liners 16, 17 
serve as a reference position 73. The distance between the reference 
position 73 and the axis L3 of the cylinder bore #1 (or #4) is represented 
by B. The distance between the reference position 73 and the axis L3 of 
the cylinder bore #2 (or #3) is represented by C. The alteration rate of 
the distance W between adjacent axes L2 when the molten metal Contracts as 
it solidifies is represented by .beta.. The axis L1 of the inner 
cylindrical surface 19 in the first cylinder liner 15 (or the fourth 
cylinder liner 8) is separated from the reference position 73 by a 
distance expressed by B.multidot.(1+.beta./100). The axis L1 of the inner 
cylindrical surface 19 in the second cylinder liner 16 (or the third 
cylinder liner 17) is separated from the reference position 73 by a 
distance expressed by C.multidot.(1+.beta./100). In other words, the 
contraction of the molten metal is taken into consideration when 
offsetting the axis L1 away from the associated axis L3. The offset 
position corresponds to the axis Lx of the associated insertion pin 45 in 
the mold 36. 
In this embodiment, the following structure is employed to connect adjacent 
cylinder liners 15-18. As shown in FIG. 22, a groove 74 is defined on each 
side of either one of the abutting surfaces 54, 56 (or 58, 58). Each 
groove 74 extends parallel to the axis L1. A projection 75 corresponding 
to each groove 74 and extending parallel o the axis L1 is provided on the 
other abutting surface. The projections 75 engage the associated groove 
74. The engaged grooves 74 and projections 75 correspond to the position 
where the holes 67, 69 are formed in step (F). 
The grooves 74 and the associated projections 75 are engaged in a manner 
such that they allow molten metal to enter spaces 76, 77 that are defined 
therebetween. It is required that each space 96, 77 have a width of 0.2 mm 
or more to allow molten metal to be drawn therein. There is a possibility 
that a sufficient amount of molten metal (in this case, aluminum) will not 
enter the spaces 76, 77 if their width is more narrow than 0.2 mm. 
Each step of the method to manufacture the cylinder block 11 of this 
embodiment will now be described. In the same manner as the second 
embodiment, the method consists of steps (A)-(F). 
Cylinder Liner Formation Step (A) 
In the same manner as the first embodiment, in step (A), billets are 
produced through the CIP method. The billets are then extruded to produce 
an elongated product having double-layer structure. By cutting the 
elongated product into predetermined lengths, cylinder liner s having a 
cylinder and a single connecting section are obtained. Cylinder liners 
having a cylinder and two connecting sections are also obtained by cutting 
the elongated product in the same manner. The axis of the outer 
cylindrical surface is offset from the axis of the inner cylindrical 
surface in each cylinder. Thus, the wall of each cylinder becomes thicker 
on the side facing the center of the group of cylinders. 
Liner Assembly Formation Step (B) 
In step (B), the cylinder liners 15-18 are connected to one another so as 
to align the cylinders 2-24 in a single row. More specifically, the 
adjacent cylinder liners 15-18 are moved toward each other so as to engage 
the groove 74 with the associated projection 75. The engagement enables 
the abutting surfaces 54, 56 (or 58, 58) to abut against each other. The 
connected cylinder liners 15-18 define a liner assembly 12 having spaces 
66 (or 68) and spaces 76, 77 defined between the connecting sections 55, 
57 (or 59, 59). 
Liner Assembly Positioning step (c) 
In step (C), the movable molds 38-40 are separated from the molding 
projections 43 in the same manner as the first embodiment. The liner 
assembly 12 is inserted into the space 43a defined between the 
corresponding projection 43 and pin 46. This fits the liner assembly 12 on 
the pins 45 and positions the assembly 12 in the mold 36 (refer to FIG. 
5). In this state, the axis 19 of each inner cylindrical surface 19 is 
offset with respect to the axis L3 of the associated cylinder bore #1-#4 
to a position corresponding to the axis Lx of the associated insertion pin 
45. This enables the cylinder liners 15-18 to be fitted on the 
corresponding pin 45. 
Block Body Formation Step (D) 
In step (D), the movable molds 38-40 are moved toward the projections 43 to 
define the cavity 47 between the fixed mold 37, the movable molds 38-40, 
and the liner assembly 12, Molten metal is charged into the cavity 47 
through the passage 48 defined in the lateral movable mold 40 (refer to 
FIG. 7). The width of each space 76, 77 (0.2 mm or greater) is wide enough 
to securely enable the molten metal to flow therein when filling the 
cavity 47 with the metal. 
The molten metal charged in the cavity 47 contracts 0.6% as it solidifies 
and produces stress that is applied to the cylinder liners 15-18. However, 
the length of the liner assembly 12 remains unchanged. 
When the molten metal is solidified, a rough block material 49 is obtained 
with the liner assembly 12 insert molded in aluminum. The block material 
49 includes the spaces 76, 77 that are filled with aluminum and the water 
jacket 35 that is defined about the assembly 12. 
As shown in FIG. 8, the movable molds 38-40 are than moved away from the 
molding projections 43. The block material 49 is than pushed out of the 
mold 36 by pushing pins (no shown). 
In the block material 49, the inner cylindrical surface 19 of each cylinder 
21-24 of the liner assembly 12 is exposed. The other parts of the liner 
assembly 12 is encompassed by the aluminum casting (block body 34). The 
closed spaces 66 (or 68) are defined between each of the adjacent 
connecting sections 55, 57(or 59, 59). In this state, the closed spaces 
66, 68 are not yet connected with the water jacket 35. 
Cylinder Bore Formation Step (E) 
In step (E), the inner cylindrical surface 19 in the cylinder 21 of the 
first cylinder liner 15 is machined about a point that is separated by a 
predetermined distance B from the reference position 73. The inner 
cylindrical surface 19 in the cylinder 22 of the second cylinder liner 16 
is machined about a point that is separated by a predetermined distance C 
from the reference position 73. The axis L2 of the outer cylindrical 
surface 20 of each cylinder 21-24 is offset toward the reference position 
73 with respect to the axis L1 of the associated inner cylindrical surface 
19. In addition, each inner cylindrical surface 19 is machined about the 
axis L3, which is separated from its own axis L1. This allows the wall 
thickness of each machined cylinder 21-24 to be uniform. Thus, as in the 
first embodiment, the produced cylinder block 11 has a structure that does 
not include weaker sections. 
Hole Formation Step (F) 
In the same manner as the second embodiment, as shown in FIGS. 21 and 23, 
in step (F), the sides of the abutted part of the connecting sections 55, 
57 (or the connecting sections 59, 59) are perforated by drills, or the 
like, to define the holes 67, 69. The holes 67, 69 connect the ends of 
each closed space 66, 68 with the water jacket 35. The closed spaces 66, 
68 and the holes 67, 69 constitute a coolant passage 64, 65 between the 
bores #1-#4. 
In this embodiment, the spaces 76, 77 are filled with metal. This prevents 
the coolant 63 from entering each space 76, 77 when flowing through the 
holes 67, 69. Thus, the coolant 63 does not leak out of the bottom of the 
cylinder block 11 through each space 76, 77 into a crankcase 79. 
Although only three embodiments of the present invention have been 
described herein, it should be apparent to those skilled in the art that 
the present invention may be embodied in many other specific forms without 
departing from the spirit or scope of the invention. Particularly, it 
should be understood that the present invention may be embodied as 
described below. 
In the first embodiment, the adhesive layer 29 is provided between each 
pair of adjacent cylinder liners 15-18 when forming the liner assembly 12 
in step (B). However, the adhesive layers 29 may be omitted from the liner 
assembly 12. This may cause the molten metal to enter the spaces 31-33 
when forming the block body 34 in step (D). In such case, the flexibility 
of the molten metal allows each space 31-33 to be narrowed. Thus, the 
relative movement of the cylinder liners 15-18 is not completely blocked 
by the molten metal. 
The serrations 61 employed in the second embodiment may also be provided on 
the outer cylindrical surface 20 of each cylinder 21-24 in the first and 
third embodiments. 
Methods such as die casting, medium pressure casting, low pressure casting, 
gravity casting, suction casting, or the like may be employed to produce 
the block body 34. 
In addition to silicone adhesives, ceramic or alumina adhesives may also be 
used as the material of the adhesive layers 29, 62. 
In addition to aluminum alloy, cast iron or alloyed cast iron may be used 
as the material of the cylinder liners 15-18. In this case, the cylinder 
liners 15-18 are formed through casting. The projections 25, 27, 75 and 
the grooves 71, 72, 74 may be formed roughly when casted and finished 
through machining, 
The manufacturing method of the present invention is not limited to 
cylinder blocks having four cylinders but may be applied to cylinder 
blocks having two cylinders or more. 
In the third embodiment, each pair of adjacent cylinder liners 15-18 may be 
connected to each other by welding together their peripheral sections. 
Each pair of adjacent cylinder liners 15-18 may also be connected to each 
other by engaging keyways provided in the sides of one of the abutting 
surface with corresponding keys provided on the opposed abutting surface. 
Therefore, the present examples and embodiments are to be considered is 
illustrative and not restrictive and the invention is not to be limited to 
the details given herein, but may be modified within the scope of the 
appended claims.