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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 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 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
Page 1 and 2: Deutsche Post AG Entgelt bezahlt 72
Page 3 and 4: MORE BRANDS, MORE BUSINESS WORKSHOP
Page 5: 1 AUDI A6 ALLROAD Most noticeable o
Page 9 and 10: Spin-on oil filter series K and R:
Page 11 and 12: THIS IS HOW YOU DO IT All you need
Page 13 and 14: Cabin air filters do a clean job. D
Page 15 and 16: THE DESERT IT IS THE NIGHTMARE OF A

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