[PDF] MAHLE news 3/05 Helvetica - Mahle.com

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[PDF] MAHLE news 3/05 Helvetica - Mahle.com

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ALLEMAGNE

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

OVERVIEW

2 EDITORIAL

Arnd Franz, General Manager

MAHLE Aftermarket

3 INDUSTRY NEWS

Changes in the workshop

4 MAHLE INSIDE

Power ex works – recent vehicles

with MAHLE products

6 MOTORSPORT

Audi starts with the world's most

powerful diesel in Le Mans

7 EVENTS

A visit to the MIMS in Russia

8 NEW ON THE MARKET

Engine components and filters

news

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

2/2006

LE MANS

AND THE WORLD’S MOST

POWERFUL DIESEL More on page 6

14 ON LOCATION

Saudi Arabia: engine repair

in the desert

16 MARKET

New reference material

for experts

www.mahle-aftermarket.com


EDITORIAL

Arnd Franz,

General Manager

MAHLE Aftermarket.

Dear readers

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

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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!

Arnd Franz


MORE BRANDS,

MORE BUSINESS

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

petrol station.

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

workshop.

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.

INDUSTRY NEWS

AFTERMARKET

n e w s 3


© ams / MPI

MAHLE INSIDE

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.

MAHLE INSIDE

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.

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n e w s 4

Power

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

1 2

3 4

5

6

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.

MAHLE INSIDE

AFTERMARKET

n e w s 5

© ams / MPI


MOTORSPORT

A DIESEL IN

LE MANS

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,

AFTERMARKET

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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

MAHLE.

THE MIMS

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

distribution network.

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

international visitors.

MAHLE AFTERMARKET:

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

range.

AFTERMARKET

n e w s 7

EVENTS


NEW ON THE MARKET

PORTER

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.

FULL THROTTLE

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).

AFTERMARKET

n e w s 8

WET LINERS

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.

WELL EQUIPPED

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.

RACING RINGS

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.

RUSTPROOF

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).

ECO? LOGICAL!

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.

RENAULTS LITTLE

HELPERS

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

WELL LUBRICATED

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

element.

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.

AFTERMARKET

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

the CD-ROM.

AFTERMARKET

n e w s 10

Picture 1: You can access the online engine components catalogue via the home page

www.mahle-aftermarket.com.


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

browser window.

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

CATALOGUE

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

“Terms of use”, you can find the imprint and the terms of use of the online

catalogue.

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

identified engines.

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

component first.

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: aftermarket@mahle.com.

PISTONS & CO.

AFTERMARKET

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”.

CHANGING

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.

AFTERMARKET

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

the middle.

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.

PERFECT FIT

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

time.

IT IS VITAL TO FIT THE CABIN AIR FILTER CAREFULLY –

HERE THE MOST IMPORTANT STAGES, SHOWN BY THE EXAMPLE OF A LA 242.

BLADE

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.

BYPASS

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

housing.

AFTERMARKET

n e w s 13


ON LOCATION

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.

AFTERMARKET

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.


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

equipment quality.

ON LOCATION

AFTERMARKET

n e w s 15


MARKET

IMPRINT

Expertise fresh

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

Pragstraße 26–46

70376 Stuttgart – Germany

www.mahle-aftermarket.com

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.

AFTERMARKET

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

promotion package.

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