Method for assembling a vane-type cam phaser

Abstract

A partial assembly process for a vane-type cam phaser. A pulley/sprocket is loaded onto a first camshaft-shaped fixture with a cam nose extending beyond the length of an actual cam nose such that a phaser rotor containing a locking bolt, when mounted onto the cam nose, is displaced axially from the pulley/sprocket by an amount sufficient to set the axial engagement of the bolt upon final assembly. A stator is loaded onto the pulley/sprocket and is rotated clockwise until it contacts the rotor, thereby removing all rotational and radial lash from the system. One or more axial holes are bored through the pulley/sprocket and stator and a locking pin such as a roll pin is inserted to permanently pin the stator to the pulley/sprocket. Finally, the partially-assembled phaser is removed from the cam-like fixture, the rotor is fully seated against the pulley/sprocket, the locking bolt is withdrawn from the pulley/sprocket, the rotor is rotated to an intermediate position, and the phaser cover is added to the assembly.

1 . A method for partially assembling a vane-type camshaft phaser, comprising the steps of: 
 a) disposing a stator concentrically onto a surface of a pulley/sprocket, said stator having a plurality of inwardly-extending lobes and said pulley/sprocket having a locking bore for receiving a locking bolt;    b) inserting a first seal ring between said stator and said pulley/sprocket;    c) inserting a wear sleeve in said locking bore in said pulley/sprocket;    d) disposing a rotor having a plurality of radial vanes within said stator at a predetermined axial distance away from said pulley/sprocket, said rotor having said locking bolt extending therefrom;    e) rotating said rotor until said locking bolt is engaged into a stator bore;    f) rotating said stator on said pulley-sprocket until at least one of said rotor vanes makes contact with at least one of said stator lobes;    g) rotating said stator and rotor together further until said locking bolt makes contact with a side of said locking bore in said pulley/sprocket;    h) attaching said stator to said pulley/sprocket to rotationally immobilize said stator with respect to said pulley/sprocket;    i) rotating said rotor to another position wherein said locking bolt is disengaged from said locking bore; and    j) displacing said rotor axially by said predetermined distance into contact with said pulley/sprocket.    
   
   
       2 . (canceled)  
   
   
       3 . (canceled)  
   
   
       4 . A method in accordance with  claim 1  wherein said attaching step further comprises the steps of boring first and second mating holes in said pulley/sprocket and said stator, respectively, and inserting a locking pin into said holes.  
   
   
       5 . A method in accordance with  claim 1  wherein said attaching step further comprises the steps of boring a plurality of first and second mating holes in said pulley/sprocket and said stator, respectively, and inserting at least one locking pin into said holes.  
   
   
       6 . A method in accordance with  claim 1  further comprising the step of urging said stator against said pulley/sprocket prior to said attaching step.