Deutsche Post AG
Unfortunately we did not know the exact engine designation.
“No problem,” said the engine components expert Holger
Roden, “this will still get you the right spare part in 2 minutes.”
As Holger Roden is a man of action, he took us straight
Arnd Franz, General Manager
3 INDUSTRY NEWS
Changes in the workshop
4 MAHLE INSIDE
Power ex works – recent vehicles
with MAHLE products
Audi starts with the world's most
powerful diesel in Le Mans
A visit to the MIMS in Russia
8 NEW ON THE MARKET
Engine components and filters
A F T E R M A R K E T
MAGAZINE FOR TRADE, WORKSHOP AND ENGINE REPAIR
to the website www.mahle-aftermarket.com and very soon
the required assembly was found – using the new online
engine components catalogue. We are impressed and would
be delighted if you feel the same. More about that on page 10.
10 PISTONS & CO.
Online catalogue: the right engine
component per mouse click
12 FILTERS –
THE PURE TRUTH
Tips on changing cabin air filters
AND THE WORLD’S MOST
POWERFUL DIESEL More on page 6
14 ON LOCATION
Saudi Arabia: engine repair
in the desert
New reference material
After a short breathing space in the 90s, the dynamic in the Eastern European
markets that could be observed for some years, has now developed
into sustained growth in vehicle production and vehicle imports as well as
in the vehicle population. In the meantime, many manufacturers anticipate
sustained demand in Eastern Europe and are investing widely in manufacturing
capacities in the region.
MAHLE Aftermarket is dedicated to supplying these markets efficiently with
spare parts from the MAHLE range. This has made us aware of a gradual
shift in the structure of the vehicle population. For example, after the fall
of the Iron Curtain in Russia, American and later German products were
imported swiftly and the dominance of Russian products was weakened. In
the meantime, more and more vehicles from Japanese and Korean manufacturers
can be noticed. In 2005, Hyundai has taken the position of market
leader among foreign manufacturers – with a share of 17 % of the total
passenger car sales in Russia. They are followed by Toyota, Ford and Daewoo.
In August of this year, MAHLE will show its spare part range for the sixth time
in succession at the Autosalon in Moscow. In addition to the comprehensive
range of components for vehicles of Asian manufacturers, the focus will
be on the extensive MAHLE valve range.
Like in the rest of Eastern Europe, MAHLE products are very popular in
Poland. This increasing demand – but also the demand from neighbouring
countries – has now been addressed by MAHLE with the construction of a
distribution centre in Krotoszyn. From this centre, engine components as
well as filters will be available for distribution to customers in Poland, the
Ukraine, Latvia, Lithuania and Estonia. In addition to the many products
manufactured for MAHLE Aftermarket at the site in Krotoszyn, there will be
n e w s 2
an efficient distribution centre available from the second half of this year that
can handle the larger sales volume.
Under our heading “On location”, we report from extraordinary places,
where MAHLE products are used. For the current issue, we have travelled
to Saudi Arabia, where engines for commercial vehicles are made fit again
to face the extreme conditions in the desert. The technical support and further
training of repair personnel is especially important in those regions and
MAHLE makes important contributions in this area.
Back in the home market of MAHLE: changes can be noticed in the workshop
market of EU countries. As an example, we show how German workshops
deal with implementing the block exemption regulation. Individual
workshops get fit for the competition by extending their range of services,
for instance, by boosting their orientation towards service, multi-branding
or by the decision for a supporting workshop system.
We hope you will enjoy reading our new MAHLE Aftermarket news!
WORKSHOPS IN THE FOURTH YEAR OF THE BLOCK EXEMPTION REGULATION – A MID-TERM REVIEW
The block exemption regulation came into force on 1st October 2002. In
this Europe-wide regulation, the distribution and service of motor vehicles
has been defined. At the same time, the car manufacturers have
reorganised their distribution networks. All this has initiated a radical
process of restructuring. What are the implications for garages and workshops
and where can you find new sales opportunities?
Change as opportunity: automobile business
Gruben, Ford dealer, operates an additional
multi-brand workshop in conjunction with a
An essential issue in the
block exemption regulation is
the discontinuing of single
brand outlets: the block
exemption regulation allows
dealers to sell several vehicle
brands in the same showroom.
At the same time, the
contracts between manufacturers
and their dealers have
been renegotiated – with the
outcome that several businesses
have suddenly found
themselves a new status:
from franchised dealer to
independent dealer – with all
the pros and cons.
Like the family business Gruben in Velden, Lower Saxony/Germany, founded
in 1938 – and for almost as long a Ford franchise dealer. In addition to the
car dealership, a petrol station was opened, which made it a multi-brand
business from early on.
The owner Alvin Gruben extended the already existing contacts to his independent
suppliers of motor vehicle components. Alvin Gruben regards this
development as positive: “The multi-brand repair business is by its nature –
due to the older age of vehicles – characterised by trade in service parts.
A good counterpart to costly contract repairs with their large share of comebacks
and time-consuming troubleshooting.” In order to ensure access to
the constant information flow in respect of troubleshooting, parts identification
and pricing, he joined a workshop concept. Examples for such
concepts are Meisterhaft (ATR), Coparts Plus System (Coparts), AutoCrew
(ZF Trading), Garage AD (Autodistribution), Mon Garage (Partners), Precisium
Garage (Starexcel), Proximeca (Agra), Top Garage (GAU France) and others.
The automobile business Gruben has found its right mix of car sales, petrol
station, spare part business and the combination of independent and branded
However, also the automotive industry offers new perspectives for workshops.
Some European vehicle manufacturers have launched their own
brands of service parts such as Motorcraft (Ford), Motrio (Renault) or
Eurorepar (Citroën) – and offer these to former authorised dealers as well
as to previously independent motor vehicle businesses. Workshops can
benefit from the activities of Asian importers by accepting their active
offers and open up an additional source of income with another brand.
Whether integrated into a workshop system or tied to a car manufacturer
(or both) – in order to succeed in the changing repair and maintenance
market, the workshops need the help of the part suppliers. This includes
vehicle identification, the appropriate diagnosis software and work description
inclusive of time figures, information regarding the availability and use
of maintenance and repair plans as well as active instant help during repairs
via hotlines for instance.
On the other hand, it is important to be even more customer oriented, to be
open to additional sales opportunities
– and to be oriented towards demand
and service at the same time.
The reluctance of motorists to carry
out regular servicing can be
addressed with targeted appeals
and information – for example, by
explaining that a filter change that
has been postponed for too long can
result in unpleasant and expensive
consequential damage to the engine.
And that it is always more economical
to use original equipment quality –
as this ultimately saves more than it
costs, thanks to higher reliability and
longer service life.
Changes in the workshop – from
branded operation to service provider
with multi-brand expertise.
n e w s 3
© ams / MPI
In focus: VW Eos
OPEN FOR THE SUMMER
VW EOS: 3 IN 1
At the touch of a button, the new Eos converts from a coupé into a cabriolet. It takes only 25 seconds for the 5-part roof structure to automatically fully
retract – via a switch conveniently located in the centre console. The CSC roof system, specially developed for the latest VW, combines features of a coupé
roof, sliding sunroof and cabrio roof. The driver can freely choose between coupé with closed or open glass sunroof and cabriolet with closed or fully
retracted side windows. Furthermore, it is equipped with a unique integrated glass sunroof with continuously adjustable sunblind as standard.
THE TOP FROM THE SPECIALIST
The Eos is produced in the Portuguese VW plant in Palmela. The special roof structure weighs 90 kg and is produced locally by Webasto – in a production
site that was specifically set up for this purpose. The roofs are then delivered to the VW production site and fitted to the vehicles. To ensure precise fit, a new
flexible mounting system with a total of eight fine adjustable pivot points has been developed.
SPOILED FOR CHOICE
The VW Eos is available with a choice of five different engines: the petrol versions with 1.6 litre FSI engine and 85 kW (115 hp) or 2.0 litre FSI engines with
either 110 kW (150 hp) or 147 kW (200 hp). Exciting dynamic power is provided by the 3.2 litre VR6 with impressive 184 kW (250 hp including dual clutch
transmission DSG). In addition, a 2.0 litre TDI with 103 kW (140 hp) is available.
No matter which engine you choose – MAHLE components are used in all of them. To be more precise: MAHLE pistons, piston rings, piston pins, connecting
rods, valves, valve guides and valve seat inserts as well as air filters.
MAHLE ENGINE COMPONENTS AND MAHLE FILTERS ARE USED IN VEHICLES AND ENGINES OF THE FOLLOWING BRANDS:
Alfa Romeo, Audi, BMW, Case New Holland, Caterpillar, Citroën, Cummins, Daewoo, DAF, Deutz, Ducati, Ferrari, Fiat, Ford, General Motors, Harley Davidson, Hatz, Honda,
Hyundai, Isuzu, Iveco, Jaguar, John Deere, Komatsu, Lancia, Land Rover, Mack, Magna Steyr, MAN, Maserati, Mazda, Mercedes-Benz, Mitsubishi, Moto Guzzi, MWM,
Nissan, Perkins, Peugeot, Porsche, Renault, RVI, Saab, Scania, Seat, Škoda, Smart, Steyr Daimler Puch, Stihl, Suzuki, Toyota, Volkswagen, Volvo, Zettelmeyer.
n e w s 4
E X W O R K S
1 AUDI A6 ALLROAD
Most noticeable on the new Allroad – the typical characteristics of an all-terrain
vehicle: under-run guard made from stainless steel, modified single-frame
radiator grille, larger mirrors, side bars and newly designed bumpers – like the
wheel arches painted in a contrasting colour as standard. The A6 Allroad
Quattro is available with a choice of two petrol and two diesel engines with
6 and 8 cylinders – all with direct fuel injection. A power range from 132 kW
(180 hp) to 257 kW (250 hp) is covered. Gears can be changed either
manually with 6 speeds or via Tiptronic. The standard equipment includes
the four-wheel drive Quattro as well as MAHLE pistons, connecting rods,
valves, air filters, oil mist separators, oil filter modules and – for the US
market – carbon canisters.
2 VW POLO GTI
The Polo series was launched 30 years ago. The most powerful version of its
kind is now coming onto the market: the Polo GTI with 110 kW (150 hp). The
1.8 litre 4-cylinder engine accelerates the car from 0 to 100 km/h in 8.2 seconds
thanks to its torque of 220 Nm. Top speed: 216 km/h. Despite this performance,
the average fuel consumption is only 7.8 litre per 100 km. The fast
runner from Wolfsburg is fitted with the current GTI radiator grille and air intake
with hexagonal grille. The four disc brakes are visible through the 16-inch
alloy wheels. The sports suspension has been lowered by 15 mm compared
with the standard Polo. MAHLE is on board with pistons, piston rings,
connecting rods and – for the US market – carbon canisters.
3 MERCEDES SPRINTER
When you talk about the new Sprinter, you should really talk about 1,000
Sprinters: taking the different wheelbases, lengths, heights, weights, body and
engine as well as transmission configurations into consideration, it is possible
to make up about 1,000 different versions. The petrol version is equipped with
a 100 litre fuel tank as standard; for the more economical diesel versions, a
75 litre tank is sufficient. The 2.2 litre 4-cylinder diesel is available in four
power ratings between 88 hp and 150 hp. The top engine is the V6 diesel
with impressive 184 hp and 400 Nm. Even more powerful is the only petrol
engine in the range, a 6-cylinder engine with 3.5 litre displacement and
258 hp. Used in all Sprinter versions are MAHLE oil and fuel filters, oil mist separators,
valves, valve guides and valve seat inserts as well as cylinder liners.
4 FORD S-MAX
The 4.77 m long and 1.66 m high Ford S-Max offers space for up to seven
passengers. The S-Max is equipped with the new “Ford Flat System” (FFS), a
concept that allows easy flattening of the seats without removal. It is available
with a choice of two petrol engines and two diesel engines. The top of the
engine range is the 2.5 litre 5-cylinder petrol engine with 162 kW (220 hp),
also used in the Focus ST. Next down the line are a 2.0 litre 4-cylinder petrol
engine with 145 hp and a 2.0 litre 4-cylinder turbo diesel with power ratings
of 130 and 140 hp. Our contribution to the new Ford: pistons, piston pins,
connecting rods, cylinder liners, camshafts and oil filters made by MAHLE.
5 PEUGEOT 207
Depending on the version, the 207 comes with different front sections. The
Classic version has a gently curved bumper fascia with edge protection in the
same colour as the car body. In contrast, the Sport version has a front section
with a stronger shaped lower profile. Circular fog lights with chrome surrounds
are integrated right and left of the air intake. Initially, a choice of one diesel
engine (with particulate filter) and two petrol engines is available. Also on board
are MAHLE oil and fuel filters, pistons, piston rings and pins, cylinder liners,
camshafts and – for the US market – carbon canisters.
6 AUDI Q7
In its standard version, the Q7 is a 5-seater – on request, two additional seats
can be ordered for the third row of seats. The two rows at the back can be
folded flat. This provides a luggage space of 2,035 litres when required. At the
launch of the series, a choice of two engines is available. First, there is a new
4.2 litre V8 with petrol direct injection (FSI) and 350 hp. The second version is
a 3.0 litre TDI with 6 cylinders and 233 hp. In both engines MAHLE oil filter
modules, oil mist separators, air filters, valve seat inserts, pistons and connecting
rods are used.
n e w s 5
© ams / MPI
A DIESEL IN
WHEN THE STARTING SIGNAL IS GIVEN IN LE MANS ON 17 JUNE 2006, A NEW CHAPTER IN THE HIS-
TORY OF THE TRADITIONAL 24-HOUR LONG-DISTANCE RACE WILL BE OPENED. FOR THE FIRST TIME,
A DIESEL WILL JOIN THE RACE – AND IS EVEN REGARDED AS A HOT FAVOURITE FOR THE TITLE.
AUDI HAS CREATED A NEW DIMENSION OF DIESEL ENGINES
Not only an innovation for Le Mans: the completely new developed V12 TDI
engine with 5.5 litre and bi-turbo charging delivers more than 650 hp. It is
especially quiet and low in fuel consumption – the latter is an advantage
that should not be underrated in a long-distance race.
Ulrich Baretzky, head of engine technology at Audi Sport, calls the engine
“the diesel with the highest specific power in the world” and the project “the
greatest challenge so far that Audi Sport has faced during its long history.”
The engine of the R10 is made completely from aluminium – this is also a
first for a diesel engine. The tremendous torque of more than 1,100 Nm
makes extreme demands on the power transmission
of the R10 - the forces are that huge, that the test
phase has already been rather costly: Audi Sport
had to modify the engine test beds and had to fit
special heavy-duty transmissions.
MAXIMUM PERFORMANCE IN ANY RANGE
The fuel-mixture formation in the new Audi is
managed by a modern Common Rail system. The
injection pressure is far above 1,600 bar. And the
ignition pressure reaches values that have never
before been implemented in any Audi engine. The
optimum torque range lies between 3,000 and 5,000
rpm – an exceptional low level for a racing engine.
The driver can make use of the engine power almost
from idling speed. A further special feature of this diesel technology:
significantly fewer gear changes are required from the driver in the R10
compared to the previous model R8.
A NEW LOOK
In addition to the engine innovations of the Sport prototype, new standards
have also been set in respect of the chassis: most noticeable here are the
combination of monocoque and body. While the predecessor R8 had a
classic chassis with plastic fairing, the R10 can manage without additional
fairing: most of the carbon fiber parts are directly exposed to the airflow.
This saves weight – especially important, as the large size of the V12 TDI of
the R10 with its 5.5 litre makes it longer and heavier than the engine of the
R8. This explains also the significantly longer wheelbase of the R10.
TECHNOLOGY TRANSFER TO THE ROAD
Audi is actively involved in the development of sport prototypes. This leads to
new technologies, innovations and new design principles. On the one hand,
n e w s 6
this is done in order to continue with the tradition of Audi victories in the
24-hours of Le Mans. However, on the other hand – and this is presumably
the decisive reason – it also makes it possible that the series production can
benefit from motor sport innovations. In contrast to extremely high-revving
Formula 1 engines, the direct technology transfer from Le Mans motor sport
to series products is possible. This is because the rules demand that the
engine speeds are kept in a similar range as in production vehicles. For more
than 25 years, the motor sports successes of Audi have been associated with
innovations that later became established in production cars.
Examples are the Quattro drive system (in 1980 the revolution in rally sport
– and later on the racing circuit) and the TFSI technology
(first used in 2001 at the 24-hours of Le
Mans). The Audi R8, with 61 victories the most successful
Le Mans prototype of all times, is still the
world's only racing car that combines turbo charging
with direct fuel injection (TFSI).
Incidentally, TFSI and Quattro drive are now used in
the Audi's sports series engines as a matter of
course. And this is similar with TDI technology: every
second Audi is delivered with a TDI engine today.
With the diesel commitment in Le Mans, Audi will extend
its lead in the TDI sector further (and its status
as supplier of the sportiest diesels).
SPECIAL CHALLENGES: PISTON DEVELOPMENT AND PLATING
OF THE CYLINDER WORKING SURFACE
Ignition pressures up to 200 bar and specific power values of more than
70 kW/l are not exceptional for modern diesel engines anymore. In order
to withstand these stresses, optimised, high-temperature resistant alloys
and designs as well as effective cooling is required at the sides of pistons.
For this purpose, MAHLE has developed forged pistons with cooled ring
carriers for the first time. In a special manufacturing process, ring carriers
and cooling channels are combined into one system. This provides the
pistons with significantly improved heat dissipation properties, especially
at the first ring groove and the combustion cavity and allows continuous
operation at such extreme pressures and temperatures. MAHLE has already
produced 5 million of these forged pistons with cooled ring carriers for use
in production engines. Also the NIKASIL ® coating of cylinder working
surfaces, developed by MAHLE, has already demonstrated its advantages
in respect of wear resistance and reduction of friction in the R8 TFSI and
now also in the R10 TDI.
AT THE PULSE
OF THE MARKET
THE RUSSIAN MARKET IS MOVING. THE COUNTRY WITH 145 MILLION INHABITANTS AND A SURFACE
AREA OF 17 MILLION KM 2 HAS BEEN SUBJECT TO RAPID BUT SUCCESSFUL CHANGE FOR 15 YEARS:
ECONOMIC GROWTH IS INCREASING STEADILY. THE MAIN REASON FOR THIS IS THE EXPORT OF RAW
MATERIALS. A SIGNIFICANT INCREASE IN THE ECONOMIC POWER OF RUSSIA IS THE POSITIVE OUTCOME.
THE POTENTIAL FOR THE AFTERMARKET
So Russia is a particularly important growth market – with great potential
for the automotive component market. This is because the 32 million vehicles
that are currently used in Russia require spare parts all the time. Currently,
the roads are mainly filled with locally produced cars such as Lada. MAHLE
supplies complete pistons (pistons with rings, pins and circlips), piston
rings and oil filters for these cars. At the same time, the number of European
cars on Russian roads is increasing continuously. These cars are mainly
delivered with original filters and engine components made by MAHLE –
supported by the availability of such components in the aftermarket.
The same applies to the Asian vehicles that are becoming more and more
popular in Russia. The spare parts requirement is also here assured by
Due to the dynamic Russian automobile market, automotive trade fairs and
exhibitions are becoming more and more important. One of the most important
events is the Moscow International Motor Show (MIMS). The largest
motor vehicle trade fair of Eastern Europe takes place from August 30 to
September 3, 2006, already for the 10th time – this year for the first time on
the new exhibition site “Crocus City”. The MIMS is regarded as the major
trade fair of the sector in Russia and the CIS.
With its focus on spare parts and accessory, the MIMS is – in addition to the
German Automechanika and the French Equip Auto – a central international
place to go for the aftermarket. In addition to the customary technical
discussions with established customers, it offers an ideal platform for MAHLE
Aftermarket to make new contacts and to improve the efficiency of its
The MIMS has increased in size over the years. In the mean time, more than
1,000 exhibitors show their newest developments and trends regarding all
aspects of the automobile. In the past year, the trade fair attracted 150,000
FROM THE INDIVIDUAL TRADER TO THE DEALER NETWORK
The activities of MAHLE Aftermarket in Russia started with the targeted
acquisition of dealers. These were comprehensively informed about the
products with the help of technical presentations – and could be won over
to MAHLE this way. In a short time, a countrywide distribution network
was developed from these positive individual contacts and this is being
expanded all the time. Today, this dealer network runs from north to south
from St. Petersburg via Moscow, Rostov on the Don River, Saratov, Krasnodar
to Pyatigorsk – and from west to east from Moscow to Kirov, Ekaterinburg,
Novosibirsk up to Barnaul in the Altai Mountains.
The Russian market is of great strategic importance to MAHLE Aftermarket.
The activities in this area will therefore be further extended – in order
to create the best conditions for an even better supply of the market,
reaching down to regional levels and a further expansion of the product
n e w s 7
NEW ON THE MARKET
The Oil spin-on filter OC 482 in construction
equipment and agricultural machines as
well as in HGVs from Case, Cummins, ERF,
Foden, Seddon-Atkinson and Timberjack
ensures that dirt particles are kept out of the
oil circuit and the oil quality is maintained.
Oil spin-on filter for HGVs and construction equipment from
Case, Cummins, ERF, Foden, Seddon-Atkinson and Timberjack.
Part no. 76830905 (MAHLE) or 76830913 (Knecht).
Pistons for Z 16 YNG, R4 (101 hp).
Part no. 012 23.
The engine identification Z 16 YNG stands for a 1.6 litre
dual fuel petrol / gas engine from Opel, which powers the
Zafira. The pistons for the 4-valve engine with 101 hp
output are available in standard dimensions as well as in
79.250 mm and 79.500 mm.
Air filter element for Citroën, Ford and Peugeot.
Part no. 76663348 (MAHLE)
or 76663355 (Knecht).
n e w s 8
The Peugeot 106, 206,
306 and 307 are powered
by the same modern
Euro 4 petrol engine – the
TU 3 JP L 4. Its 75 hp are
delivered by an assembly
with 75.000 mm pistons
and wet liners.
Pistons for TU 3 JP L 4, R4 (75 hp).
Part no. 040 02.
A very special air filter is used in the Citroën C1, C2 and C3, the Ford Fiesta and Fusion
as well as in the Peugeot 107, 206 and 307: a special version of the LX 1569 with sealing
loop as well as foam layer for pre-cleaning and noise insulation.
The hot road version of the classic Porsche 911,
the Turbo, generates 70 hp per cylinder – or 117 hp
per litre displacement. A small but refined ring set
is used in this engine: the taper-face ring is 1.2 mm
thin, the taper-faced Napier ring 1.75 mm and the
coil-supported oil control ring 2.0 mm.
Ring set for M 96, 70, B6 (420 hp).
Part no. 504 39 N0.
The coolant filter WFC 1 filters the water in the coolant
circuit with the aid of additives – and therefore protects
from corrosion. It is used as original equipment in the
HGVs and construction equipment from Case, ERF,
Foden, Liebherr and Seddon-Atkinson.
Coolant filter for HGVs and construction
equipment from Case, ERF, Foden,
Liebherr and Seddon-Atkinson.
Part no. 76831218 (MAHLE)
or 76831226 (Knecht).
Spin-on oil filter
series K and R:
Part no. 76887210 (MAHLE)
or 76887202 (Knecht).
Air filter element for BMW
motorbikes of the K series:
Part no. 76816268 (MAHLE)
or 76816250 (Knecht).
TESTED ON THE RACING CIRCUIT
Spin-on filters for the BMW K 1200 R, the world's most powerful naked bike, and its
sister the series version K 1200 S: the air filter LX 966 – used twice in the series version
– and the oil filter OC 306, a spin-on filter with integrated anti-drain and bypass
valve that is also used for motorbikes of the R series.
Oil filter cartridge
for the diesel engines
of Citroën, Ford,
Peugeot and Volvo.
Part no. 76832406 (MAHLE)
or 76832398 (Knecht).
The oil filter cartridge OX 339/2 D Eco convinces with its environmental
friendliness – with fleece end plate and internal support frame made
from plastic. It is original equipment for the 2.0 litre diesel engine of the
Citroën C4 und C5, the Ford Focus, the Peugeot 307 and 407 as well
as the Volvo S40 and V50.
The 1.4 und 1.6 litre petrol
engines K 4 J and K 4 M
from Renault have 16 little
helpers that manage the
fuel/exhaust exchange in
the engine. These inlet
and exhaust valves are
used as standard in the
Clio, Mégane and Laguna
of the 1997-2001 models.
Inlet and exhaust valve for Renault
K 4 J/M (107–116 hp).
Part no. 021 VE 30920
and 021 VA 30921.
NEW ON THE MARKET
In the diesel and petrol versions of the Audi A6, starting from
model 5/04, the two filters LX 1006/1 D and LX 1006/2 D
are used. The two air filter elements differ only in pleat depth. A
useful fitting aid: to assure the correct fit of the o-ring, it has to be
lubricated with Palatinol – a small tube is supplied with the filter
Air filter element for Audi A6.
Diesel versions: part no. 76886774 (MAHLE) or 76886766 (Knecht).
Petrol versions: part no. 76886758 (MAHLE) or 76886741 (Knecht).
THE A TEAM
Diesel power in the Mercedes-Benz A Class: engines with
1.7 litre displacement and – depending on the version –
between 60 and 95 hp. The MAHLE ring-carrier pistons with
cooling channels are now available for professional repairs.
Special features: latest geometric design of the combustion
cavity and a comprehensive ring package consisting of
molybdenum and chromium rings.
Pistons for Mercedes-Benz
OM 668 DE17 A/LA, R4 (60–95 hp).
Part no. 003 15.
n e w s 9
PISTONS & CO.
MORE THAN 2,200 PAGES
IN 2 MINUTES
AS AN ENGINE REPAIRER YOU HAVE TWO CHOICES IF YOU WANT TO TRACE REQUIRED PARTS: YOU CAN EITHER
LEAF THROUGH FOUR THICK VOLUMES OF THE MAHLE ENGINE COMPONENTS CATALOGUES – OR YOU CAN
FIND YOUR PARTS FAST AND COMFORTABLY USING THE NEW MAHLE ONLINE ENGINE COMPONENTS CATALOGUE.
When looking for the right spare part it can be said: You can't know
everything, but you have to know where to find it. In this case, at
www.mahle-aftermarket.com. There you can find all the data from the
MAHLE catalogues pistons/cylinders/assemblies, piston ring sets, bearings
and valves – user-friendly arranged and supplemented with a wealth of
helpful and interesting information.
The advantages of the online catalogue: it is updated daily and is therefore
more up-to-date than any printed catalogue or any CD-ROM. In addition,
the reference work on the web allows the direct comparison between
different engine details. Incidentally, in the online catalogue you find
the same symbols that are already familiar from the printed forms and
n e w s 10
Picture 1: You can access the online engine components catalogue via the home page
THIS IS HOW YOU DO IT
All you need is a computer with Internet access. First, go to the home page
“www.mahle-aftermarket.com” (picture 1). Then select “MAHLE Europe” at
the right and afterwards the desired language in the navigation bar. On this
page (picture 2), you find the button “Engine components catalogue” at
the right. Click this button – and the electronic catalogue opens in a new
Picture 2: One click on the button “Engine components catalogue”– and the electronic
catalogue is opened in a new browser window.
WELCOME TO THE MAHLE ONLINE ENGINE COMPONENTS
Now you can choose: either you search for the “Engine” that you are currently
repairing. Alternatively, you can search for the “Vehicle” to which the engine is
fitted. Or you search under “Product” for a particular engine component – your
decision is made by simply clicking on the corresponding button.
In addition, we offer the section “Service documents” on this page, which you
would find otherwise in the introduction of the corresponding printed catalogue.
This includes the glossary, explanation of symbols and technical terms
as well as functional descriptions of the relevant products. In the section
WHEN THE ENGINE DESIGNATION IS INCOMPLETE
Let us assume you know the designation of the engine – however, only in fragments.
A good opportunity to test the capability of the search function: under
the section “Engine”/“Parameter”, enter the information you know (in our
example the fragments “542”, “LA” and “956”) in the field “Designation” and
click on “Start search”. The result: two engines are listed in the online catalogue
that fulfil the search criterion (picture 3).
Picture 3: Search result after entering a fragmented engine designation.
In order to refine the search, click on the detail icon of the two engines
(picture 4). Now you can compare different technical details (such as displacement,
power, number of valves, etc.) – and find the correct engine this
Picture 4: After clicking the detail icon, you can compare the technical data of the
way. After clicking the icon “show products” , all MAHLE Original engine
components used in that particular engine are displayed (picture 5). If you click
now on the detail icon that is shown at the right of each engine component
– in our example (picture 6) an assembly – all available product information
is displayed. Now you should be able to order your part without problems.
Picture 5: When clicking the icon “engine components”, all MAHLE Original engine
components used in the engine are displayed.
Picture 6: Select the desired component using the relevant icon and you get all
available product information.
TIP: THE MORE YOU KNOW ABOUT THE ENGINE THE FASTER
YOU WILL SUCCEED
As shown in picture 3, you have a choice of eight search boxes. The more you
can enter, the more definite is the result – with seven entries, the probability to
find the correct part is 90 – 95 %.
WHEN YOU ONLY KNOW THE VEHICLE (AND POSSIBLY THE
YEAR OF MANUFACTURE)
If you do not know the engine designation but only the vehicle (possibly the
year of manufacture) to which the engine is fitted, you can search left under
“Vehicle”. From the correct vehicle, you can find the corresponding engine –
and then the required product.
AND IF YOU KNOW HARDLY ANYTHING ABOUT THE ENGINE
OR THE VEHICLE: THE FULL TEXT SEARCH
In addition to searching for parameters, you can also use a full text search
facility for engines and vehicles. This compares your entered information with
all stored data and can sometimes find the proverbial needle in a haystack.
WHEN YOU KNOW THE OE NUMBER
In this case you can use the field “Article number” (picture 7) in the section
“Product” – and the corresponding part is displayed immediately. If the
article number is incomplete, it is best if you can define the type of engine
Picture 7: Do you know the complete OE-number? Then enter the number into the box
“Article number”– and the corresponding MAHLE Original engine component is displayed.
DO YOU NOW FEEL LIKE TRYING THE ONLINE CATALOGUE FOR
YOUR NEXT SEARCH?
Just go to your computer, type “www.mahle-aftermarket.com” and off you go!
If you still have any questions, suggestions or requests regarding our online
catalogue, we look forward to receiving your e-mail: firstname.lastname@example.org.
PISTONS & CO.
n e w s 11
FILTERS – THE PURE TRUTH
To allow easy access to
the fitting instructions, the
packaging comes with a
handy perforated “zip”.
CABIN AIR FILTERS
ALL UNDER CONTROL
THE MAJORITY OF NEWLY DELIVERED VEHICLES IN EUROPE ARE EQUIPPED WITH CABIN AIR FILTERS.
IN GERMANY ALONE, THIS AMOUNTS TO MORE THAN 10,000 NEWLY REGISTERED VEHICLES PER DAY –
AND THE TREND IS CLEARLY RISING. FOR THE WORKSHOP, THIS MEANS THE PROSPECT OF ATTRACTIVE
ADDITIONAL INCOME DUE TO THE GROWING REPLACEMENT DEMAND THAT FOLLOWS – AND THE
KNOW-HOW WHEN CHANGING AND FITTING THE PROFITABLE CLEANING DEVICES.
n e w s 12
Cabin air filters do a clean job. During only one hour driving,
an air volume of up to 100,000 litres is blown into the vehicle
interior. All the more important is regular change of filter
elements. It is important to observe replacement periods
stipulated by the automotive industry. As filter manufacturers,
we recommend changing the cabin air filter after 12,000 to
15,000 km – however, at least once per year or more often in
case of higher dust concentration.
This is because a saturated filter reduces the blower output
and significantly delays clearing of steamed up windows. If the
filter change is postponed for too long, the accumulated dirt of
an old filter, together with moisture can become a breeding
ground for bacteria and mould. These can settle in the ducts
of the ventilation and air conditioning system and lead to
extremely unpleasant odours and harmful emissions into the
vehicle interior. Therefore, we would like to give some advice
here for fast and safe filter replacement.
SEARCHED AND FOUND
First of all: where is the filter? You can find information about
the exact location on the CD-ROM “Filter product range” or
in our online filter catalogue at “www.mahle-aftermarket.com”
– and conveniently, also on the inside of our new packaging
for MAHLE and Knecht cabin air filters. There you can find the
printed fitting instructions – clear and always available, which
saves time and money in the workshop. For easy access, a
tear-open strip is integrated into the packaging.
~ 1 mm
Sandwich construction under the electron microscope: combi-filter
(LAK), consisting of two fleece layers with an active carbon layer in
POINTING THE WAY: THE RIGHT WAY UP
One of the most frequent fitting errors is placing the filter the
wrong way round. The correct fitting orientation is exactly described
in the vehicle specific instructions. In addition, the flow
direction of the filter is indicated with small arrows at the side
part. Also, the correct positioning of recesses and fixing projections
should be observed.
When fitting the filter it is also important that it is placed
exactly into the intended location. Otherwise, a bypass can
develop – this is an opening that allows unfiltered air to reach
the vehicle interior. Incidentally, did you know that a bypass
caused by improper fitting can have the same effect on the
air quality in the vehicle as an open side window?
CUSTOM FIT IN ORIGINAL EQUIPMENT QUALITY
Filters from MAHLE are fitted as original equipment. Also
workshops benefit from such high quality – because our
filters for the Aftermarket are manufactured according to the
same high standards.
A GROWING SOURCE OF INCOME: CABIN AIR
FILTERS WITH ACTIVE CARBON LAYERS
More and more customers recognise the trend from cabin air
filters with simple particulate filters (LA) towards the more
beneficial combi-filters with active carbon layers (LAK). Even
separate active carbon packages are used in some vehicles.
Due to the sandwich construction of the combi-filter (see also
the electron microscope image), two independent functions
have been combined in one filter. Cabin air filters with active
carbon layers retain not only dirt particles such as dust, pollen
and soot but also remove gaseous contaminations such as
harmful exhaust fumes, high ozone concentrations and unpleasant
odours from the air. These gases (mainly hydrocarbons
as well as inorganic and harmful gases such as hydrogen
sulphide, sulphur dioxide and nitrogen oxides) are absorbed by
the active carbon layer.
Cabin air filters with active carbon layers ensure significantly
healthier air in the vehicle interior. This provides considerable
relief to allergic passengers, people that are sensitive to smells
as well as sufferers from respiratory complaints – provided the
filters are of good quality and replaced professionally in good
IT IS VITAL TO FIT THE CABIN AIR FILTER CAREFULLY –
HERE THE MOST IMPORTANT STAGES, SHOWN BY THE EXAMPLE OF A LA 242.
For many cabin air filters, a so-called blade location is used. This
blade slides into the first pleat during fitting to ensure tight sealing.
This filter has been destroyed during fitting: the filter was not fitted
correctly over the blades. This has caused the pleats to bend and
resulted in a large bypass allowing unfiltered air to flow past the filter.
The filter effect is therefore largely cancelled out. The distortion of
the filter can also be seen clearly and has a detrimental effect on the
sealing at the longer side.
FILTERS – THE PURE TRUTH
New: also the packaging for the cabin air filters
has now been designed in line with the complete
filter range – in the typical design of the two
brands MAHLE Filter and Knecht.
The clearly designed fitting instructions –
for fast and safe filter change.
This is how a correctly fitted filter looks: the pleats
are aligned straight; the insert fits exactly into the
n e w s 13
CONDITIONS ARE EXTREME IN SAUDI ARABIA. THE COUNTRY WITH A LARGE SURFACE
AREA OF NEARLY 2 MILLION KM2 REPAIRS IN
AND ABOUT 26 MILLION INHABITANTS CONSIST LARGELY
OF DUSTY, HOT DESERT. THIS DEMANDS HIGH QUALITY ENGINE COMPONENTS. AFTER ALL,
LONG, DUSTY DESERT ROADS
On the one hand, the transport sector in Saudi Arabia is characterised by a
large haulage fleet of more than 5,000 vehicles and a network of workshops.
On the other hand, there are many individual businesses that guard their old
lorry with their life – and only a trusted mechanic is allowed near the vehicle.
Most of the heavy lorries originate from Germany or Sweden and have been imported
second-hand. Mercedes actually builds an Actros version in the country.
ELECTRONICS – NO THANK YOU!
Robust engines that can be serviced by “any mechanic” are in demand on
dusty desert roads. Proven mechanical components are preferred over electronic
components. This goes as far that even electronic injection pumps are
replaced by mechanical pumps. “What moves can be comprehended... and
repaired”, explains the skilled motor vehicle mechanic Hisham, who moved
from Amman to Saudi Arabia.
n e w s 14
No surprise then, that the vehicle fleet consists mainly of old Mercedes
lorries of the series LP and SK – real heavy duty vehicles which, if necessary,
can be up and running again with do-it-yourself skills. The standard lorry
engine in Saudi Arabia is a 6-cylinder with low horsepower that is older than
30 years: the OM 355. From today's perspective it has high fuel consumption
– to say nothing of the emission figures. Its great advantage: everything in
the old age engine can be repaired or replaced. And the supply with spare
parts in original equipment quality is assured – thanks to MAHLE. The
motor vehicle parts reach the repairers via importers or wholesalers and
retailers. The majority of the imported engine components are actually used
in commercial vehicles, while car engines are rarely overhauled. Mainly
reconditioned engines from imported and dismantled accident vehicles
are used for cars.
Impressions of the repair market in Saudi Arabia: scorching heat, parched roads and everywhere only sand – robust engines with tried and tested mechanical technology are here
in high demand. It must be possible to get any lorry running again with manual means – in the workshops as well as in the middle of the desert.
IT IS THE NIGHTMARE OF ANY LORRY DRIVER TO BREAK DOWN IN SCORCHING HEAT IN
THE MIDDLE OF THE DESERT.
“POLLEN FILTER? WHAT IS THAT?”
Sadik, a lorry driver who originates from Bangladesh, asked incredulously: “Air
conditioning? Air suspension? You live well! Pollen filter? What is that?” And
then he explains what his favourite vehicle is – and why: “My favourite is a cabbehind-engine
truck as it still has a crumple zone... just in case a camel runs
into the road.”
REPAIRS WITH ALL MEANS
These are considerations hardly imaginable in European terms. This applies
also to the multi-cultural setting in which the defective engines are repaired in
Saudi Arabia. Many of the mechanics, supervisors and engineers are migrant
workers from the Middle East, Asia and Africa. There exists no real common
language. However, working life together proceeds surprisingly well. Often
separated from their families for a long time – the experts return on average
only every 2nd year for 4-8 weeks to their home country – they appear to be
content and proud of their work.
REPAIR INSTEAD OF REPLACEMENT
Expensive machines and tools are unaffordable for many workshops. The
most important thing here is experience, creativity and above all know-how.
Advanced training such as that offered by MAHLE locally is therefore an important
source of information for the mechanics. While the defective components
and systems are mostly completely replaced in Europe, the vehicles and
engines here have to be repaired with much skill – the engines preferably with
MAHLE Original engine components. Is there a better recommendation for
their quality and resilience?
The engine components used here have to withstand a considerable amount of stress and need to be of best quality. Highly esteemed: MAHLE Original products in original
n e w s 15
FROM THE PRESS
“WHAT WE DO FOR OUR DISTRIBUTORS, AND WHAT WE DON’T DO.”
Granted, the subtitle of our new brochure is a little provocative. Anyhow –
or just because of this – it is worth to have a look at the informative
16 pages. Designed for the fast reader, you can get a real overview in just
5 minutes of how trade and workshop can benefit from our products and
services. The focus is on current industry topics such as product quality,
MAHLE Aftermarket news 2/2006
EDITING: MAHLE Aftermarket news
MAHLE Aftermarket GmbH
70376 Stuttgart – Germany
RESPONSIBLE FOR THE CONTENTS: Arnd Franz
EDITORS: Andrea Arnold, Yves Canaple, Paul Grosvenor, Andreas
Kimmerle, Hans-Ulrich Melchert, Peter Riedmayer, Holger Roden
EXTERNAL EDITORS: Julia Edele, Sabine Steinmaier
(Bransch & Partner GmbH, Stuttgart)
DESIGN AND PRODUCTION: Bransch & Partner GmbH, Stuttgart
PHOTOS: Bransch & Partner GmbH, Stuttgart,
MAHLE GmbH, Stuttgart, Simianer & Blühdorn GmbH, Stuttgart
REPRODUCTION: HKS GmbH, Stuttgart
PRINTING AND DISTRIBUTION: R+R Medienpartner, Riederich
All Rights Reserved. Reproduction and publication of any kind, including in electronic media and/or
in parts, only with prior express written consent from MAHLE Aftermarket GmbH. For further
information and authorised copies, please contact your MAHLE sales partner/agent.
n e w s 16
Printed in Germany.RR.05/06
range management, information flow, process optimisation, sales support
as well as image and pricing, always accompanied by specific offers and
measures that will support you in your daily business.
The brochure is available through your MAHLE sales partner/agent.
A little foretaste of our new expert brochure – here about sales promotion.
Speak to your sales partner/agent in order to get your personal sales