MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:32 Uhr Seite 1
What is the purpose of a magazine for the motor vehicle aftermarket?
It has to tempt you. Tempt you to read it. Not a simple
task in times of high-speed Internet connections, animated
picture worlds and fast changing bits of information. In every
editorial meeting, the team of the MAHLE After market
news therefore needs to answer the question: “What can we
tell our readers that will interest them? What do our readers
want to know?” And also, of course: “How can we present
these, hopefully, interesting facts so that readers are tempted
to actually read them, instead of just glancing over them?” In
order to tempt you, our valued readers, we have decided to
inform you about some matters that you can only find out
A F T E R M A R K E T
MAGAZINE FOR TRADE, WORKSHOP AND ENGINE REPAIR
GLOBAL STAR. LOCAL HEROES.
THE MAHLE BRAND FAMILY WITH THE “GLOBAL STAR” MAHLE ORIGINAL AND
THE TRADITIONAL REGIONAL BRANDS KNECHT AND PERFECT CIRCLE.
Arnd Franz, General Manager
The new MAHLE brand strategy
4 MAHLE INSIDE
Power ex works: recent vehicles
with MAHLE products
MAHLE Aftermarket at
international trade fairs
7 INDUSTRY NEWS
“Right to Repair” – an initiative for
the independent repair market
8 NEW ON THE MARKET
Engine components and filters
from us. For instance, how the development in the MAHLE
brand environment is progressing. Or what one of our most
important partners in the Russian market wants to tell you. Or
what types of commercial vehicles are currently leaving the
production sites with MAHLE products fitted. Or what we do
against product counterfeiting in cooperation with customs.
(No, sorry, we have to make a correction here: We do not
have an exclusive on this story – it has already been shown
on German television. However, we do not want to keep it
from our readers in the whole of Europe.) But now, we do not
want to test your patience any longer... and wish you lots of
enjoyment reading our magazine – yes, reading.
10 PISTONS & CO.
The task of bearings: materials,
alloys and slide layers
12 FILTERS –
THE PURE TRUTH
Commercial vehicle air filters:
safety thanks to flame-retardant
More information on page 3!
14 CUSTOMER PORTRAIT
Interview with Konstantin Aslanidis,
General Manager ABS-auto, Russia
15 ON LOCATION
MAHLE active against
counterfeits – in the centre of
the Automechanika Frankfurt
new catalogues, new CDs
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:33 Uhr Seite 2
The MAHLE group has been growing continuously. Along with the group,
the brand portfolio has also become larger: in particular, due to the recent
acquisitions (such as the Dana engine component business), MAHLE has as
well become the owner of those brands.
Such a large variety of brands demands critical evaluation and also correction
from time to time. However, before we started restructuring our brands, we
consulted those who deal with these brands on a day-by-day basis, invest in
them and finally earn their money with them – our customers. For this purpose,
we have asked a renowned, independent institute to prepare a list of questions.
With the help of this questionnaire, we have conducted personal interviews
with a representative choice of our customers from trade, engine repair and
workshops as well as fleet management and haulage operations – from Europe,
the Maghreb countries, the USA, South America, China and the Middle East.
We have asked them about their brand preferences, the familiarity and
importance of our particular brands and their price positioning in the competitive
environment as well as their growth forecast in respect of both the
brands and product lines. In addition, we have asked for every brand the
elementary question: “What would happen if we withdrew this brand from
the market?” Our customers took their time. They addressed our questions in
detail – and have thereby helped us to optimise the MAHLE brand portfolio.
We would like to take this opportunity to thank you for your participation.
n e w s 2
The knowledge gained from all this is now being put into action: We have
restructured the brands in the European aftermarket – and have revised our
market strategies. For the European aftermarket this means: MAHLE Original
is now the Global Star with the full programme in engine components and
filters, accompanied by the filter specialist Knecht and the engine components
brand Perfect Circle with extended range as well as Clevite, the American
specialised brand for US commercial vehicle applications. You can find more
about this on the opposite page – where we also introduce our modernised
brand logos, which we will start using halfway through this year.
The implementation of a brand strategy and the corresponding brand
management are important measures in a constantly changing market.
At MAHLE, we define the notion of brand management a little wider. This
is because the trust of our customers in the brand and the quality of the
products is one of the most important prerequisites for continuous growth
and good sales throughout all trade levels. For us, this means: not only to
offer uncompromising quality in our own products – but also to act against
product counterfeiting. Many automotive component manufacturers are
doing the same. However, at MAHLE we take this a step further: with a
highly visible raid in the middle of the Frankfurt Automechanika, during
which more than 250 counterfeit products were confiscated from more than
50 exhibition stands. We tell you more about this on page 15.
We also meet our responsibilities towards our aftermarket customers with
another initiative – as partner in the “Right to repair” initiative. This campaign,
initiated by renowned associations of the motor vehicle aftermarket,
supports independent workshops and spare part dealers in their request
that products in original equipment quality can be declared as such and
relevant information from such sources can be utilized, also now that the
block exemption regulation has run out – in the interest of a growing motor
vehicle repair market. You find more about this important topic on page 7.
We hope you find reading our magazine interesting and entertaining.
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:33 Uhr Seite 3
Brands exist – in the markets in which they are active. And the company
that owns good brands needs to look after them and adapt them
to the market and also to current trends. This continuous brand management
comprises a number of measures – in particular in a large
group such as MAHLE, in which several strong brands coexist. To keep
the brand structure transparent and the brand variety manageable, our
brand family has been reformulated and restructured. In this context,
we have also harmonised the logos of our brands, i. e. made them
graphically more consistent. We give you here a preview of our new
logos that you will encounter on our packaging and advertising material
very soon – and an overview of the new structure of the MAHLE
brand environment in the aftermarket.
MAHLE ORIGINAL – THE “GLOBAL STAR”
IN THE MAHLE AFTERMARKET BRAND PORTFOLIO
The brand MAHLE stands for engine components
and filters of uncompromising quality
– in original equipment and in the aftermarket.
This brand power is backed-up by a
group with worldwide activities, highly innovative R&D facilities and an efficient
network of international production sites and that supplies the automotive
equipment market with high-quality products: MAHLE. Therefore, it stands to
reason that this brand should also become the main brand in the international
aftermarket – and this under the well-known name MAHLE Original.
MAHLE FILTER BECOMES MAHLE ORIGINAL
Up to now, the engine components of MAHLE have been available under the
brand MAHLE Original … and the filters under the brand MAHLE Filter. But
strictly speaking it could be said that all MAHLE products are “original MAHLE”.
Therefore, we have now abolished the distinction between engine components
and filters – and all MAHLE products are now called MAHLE Original.
WHAT DOES THIS MEAN FOR THE COLOURS OF
LOGOS AND PACKAGING?
The logo of MAHLE Original will become blue – in the colour of the MAHLE
group. However, since MAHLE engine components have been associated
with the colour red for decades, we have maintained this colour coding: The
packaging for MAHLE engine components remains red and the packaging of
MAHLE Filter stays blue.
AND ITS COMETS
KNECHT – TODAY AND IN FUTURE
THE STRONG EUROPE-WIDE FILTER BRAND
The brand Knecht has been part of the MAHLE brand family for
decades. The filter specialist stands Europe-wide for strong
brand values and strong customer relationships. Knecht is
therefore of great importance to us. For the next month and
years, we have therefore planned a range of activities to strengthen the brand
Knecht even further – throughout all trade levels up to the consumer.
PERFECT CIRCLE – THE ENGINE COMPONENTS BRAND
Perfect Circle is the well-established brand for piston rings with
a range that has been extended over the years by engine components
such as pistons and cylinder liners and is now being
expanded into bearings and valves. In future, exactly the same
range will be available under Perfect Circle as under MAHLE Original. Our customers
in the Maghreb countries and many other African countries in particular,
know and value Perfect Circle as a high-quality engine component brand, which
we will consistently maintain and in which we shall continue to invest.
CLEVITE – THE INTERNATIONAL SPECIALISED BRAND
FOR AMERICAN COMMERCIAL VEHICLE APPLICATIONS
Clevite is an American brand with one of the oldest
pedigrees and supplies pistons, assemblies, cylinder
liners, bearings and valves for American commercial
vehicles as well as construction and agricultural equipment applications. In
addition, it offers a comprehensive programme of products for the repair of
engines of the brands Caterpillar, Cummins, Detroit Diesel, Massey-Fergusson,
John Deere, Allis-Chalmers, International and White Farm. Engine components
from Clevite are available worldwide – through the relevant local MAHLE sales
organisations. Also piston rings will shortly be available under Clevite for the
spare part requirements of US American commercial vehicles.
MORE ABOUT OUR BRANDS
Do you still have questions about the MAHLE brands and about the MAHLE
brand structure in the aftermarket? Your MAHLE sales partner will be pleased
to answer your questions.
n e w s 3
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:33 Uhr Seite 4
EXTRA CLASS: THE ŠKODA SUPERB.
E X W O R K S
The second generation of the Superb redefines the established design of a large saloon: with the high-class interior, the smooth and precise steering and
a chassis that compensates supremely for any bumps in the road, the new flagship of Škoda claims a top position in the upper midrange. When it comes to
interior space, the Superb can even compete with higher range models: with a length of 4.84 m, a width of 1.82 m and wheelbase of 2.76 m. Incidentally,
the Superb is not the first model with this name: Already in 1934, Škoda launched a luxury model with the same name – which won promptly the first prize at
the “Concours d’Elegance” in Brünn in the year after its launch. The new model is equally successful: It has been awarded the “Goldenes Lenkrad 2008” by
the “Bild am Sonntag”, the national Sunday paper with the highest circulation in Germany.
SUPERB SAFETY CONCEPT
With 5 stars, the Škoda Superb has received the best possible result in the Euro NCAP crash test. Included in the comprehensive safety package are up
to 9 airbags that are especially optimised for the protection of the knee and thigh area. Or the Adaptive Front Light System – an electronically controlled
light system that adapts the geometry of the head light beams to the particular driving conditions and therefore achieves optimum illumination of the road
A choice of 6 engine versions is available for the luxurious saloon: 3 petrol engines – from the 1.4 TSI engine with 92 kW (125 hp) to the four-wheel drive
3.6 litre V6 model with 191 kW (260 hp). Drivers who prefer diesel power can also choose from 3 engine versions: the 1.9 litre TDI with 77 kW (105 hp) up
to the TDI DSG with125 kW (170 hp). The contribution from MAHLE to the driving dynamic and comfort of the higher class: pistons, valves, air filters, oil
filter modules, fuel filter modules and activated carbon canister modules.
MAHLE ENGINE COMPONENTS AND MAHLE FILTERS ARE USED IN VEHICLES AND ENGINES OF THE FOLLOWING BRANDS:
Alfa Romeo, Audi, BMW, Case, Caterpillar, Chevrolet, Citroën, Cummins, DAF, Deutz, Ducati, Ferrari, Fiat, Ford, GM, Harley Davidson, Hatz, Honda, Hyundai, Isuzu, Iveco,
Jaguar, John Deere, Kia, Komatsu, Lancia, Land Rover, Mack Trucks, Magna Steyr, MAN, Maserati, Mazda, Mercedes-Benz, Mitsubishi, Moto Guzzi, MWM International,
New Holland, Nissan, Opel, Perkins, Peugeot, Porsche, Renault, Renault Trucks, Saab, Scania, Seat, Škoda, Smart, Stihl, Suzuki, Subaru, Toyota, Volvo, VW, Zettelmeyer.
n e w s
In Focus: the
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 5
1 FORD FIESTA
The new edition of the Ford Fiesta is intended to combine quality and stateof-the-art
technology with a trendy lifestyle. The latter is also demonstrated
by the exterior colours Squeeze or Hot Magenta. Pioneering innovations are,
for instance, incorporated in the electric power assisted steering, the keyless
starting function and, of course, also in the new engines – specifically: pistons,
piston rings and pins, bearings, camshafts, valve seat inserts, air intake
modules as well as oil filters from MAHLE.
2 OPEL INSIGNIA
New name, new design, new technologies – the Insignia is clearly distinguished
from its predecessor Vectra. Especially eye-catching is the dynamic swage
line at the side, which will influence the design of all future Opel models. Also
a look under the bonnet shows many novelties: 5 new petrol and 4 new
diesel engines cover a wide engine range conforming to the new Euro-5
standard – and are equipped with pistons, piston rings and pins, connecting
rods, camshafts, valves, valve guides and valve seat inserts from MAHLE.
3 VW SCIROCCO
The new VW Scirocco is not only presented as radically new from the outside.
Innovative and environment friendly TSI engines are doing their work under
the bonnet, and provide excellent torque characteristics also at reduced displacement
(and therefore lower consumption and emission values) thanks to
downsizing technology. Alternatively, a 4-cylinder TDI engine is available that
complies already with the Euro-5 standard. The contribution from MAHLE:
pistons, piston rings, piston pins, connecting rods, valves, valve seat inserts,
air filters, activated carbon canister modules and oil filter modules.
4 RENAULT MÉGANE COUPÉ
A locking system that unlocks the car as soon as the driver approaches
it with the special keycard in the pocket ... A high-end music system with
sound characteristics that are especially designed for the interior of the
vehicle ... These are only a few examples from the high-tech equipment
package of the new Renault Mégane Coupé. The sporty vehicle from France
comes with a choice of 3 innovative diesel and 3 petrol engine versions –
with fuel filters, valve seat inserts, bearings, connecting rods, pistons, piston
rings and piston pins from MAHLE.
5 NISSAN MURANO
More than 500,000 vehicles of the Nissan Murano have been sold worldwide
– a large number of these in the USA. The second generation of this futuristic
looking Japanese is now set to conquer other markets as well. The concept
behind this: a combination of comfort and refined handling. A 3.5 litre V6
engine with continuously variable automatic transmission that converts the
power smoothly into forward motion is working in the “elegant crossover”,
as Nissan calls it. Air intake modules, transmission oil filter modules, valve
covers, oil filters, oil coolers and activated carbon canister modules contribute
to the unspoiled ride comfort.
6 DACIA SANDERO
Spacious, practical and attractively priced – this is how Dacia describes the
new Sandero. It offers plenty of luggage space and good ground clearance,
is equipped with a robust chassis ... and is available for less than 7,000 Euro.
A choice of two engines with 55 kW (75 hp) or 64 kW (87 hp) is available
under the exterior of the compact Romanian, which already proved their worth
a million times over in the vehicles of Renault – with air filters, fuel filters, valve
seat inserts, bearings and connecting rods from MAHLE.
7 MERCEDES-BENZ GLK
Short body overhang at front and rear, plenty of ground clearance, permanent
four wheel drive and the matching engine range – 2 petrol engines with
170 kW (231 hp) or 200 kW (272 hp) and a 6-cylinder CDI engine with
165 kW (224 hp) – take care of driving pleasure in the new Mercedes-Benz
GLK also off-road. On permanent duty, on and off-road are oil filter modules,
oil filters, fuel filters, air filters, pistons, piston rings and pins, cylinder liners,
valves, valve guides and valve seat inserts from MAHLE.
n e w s 5
© ams / MPI
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 6
MAHLE AFTERMARKET –
PARTICIPATING AT INTERNATIONAL
As member of the top-30s of automotive suppliers and leading
automotive component manufacturer, MAHLE believes – especially
in changing times – that it bears the responsibility to show its presence
in international markets and to demonstrate its connection
with the markets. This all the more as markets with stagnating or
falling numbers of new registrations and therefore increasing vehicle
service life suggest a stable or even growing demand in the aftermarket.
We are going to introduce here two of the most important
trade fairs at which MAHLE will be present and support the local
n e w s
03 – 05 MARCH 2009 IN MOSCOW
The Russian motor vehicle market has registered the highest growth rate
worldwide in recent years. The market is driven by two developments: On the
one hand the vehicle imports of foreign brands are increasing and on the other
hand, more and more international car manufacturers open their own production
sites in Russia and produce locally. Whether Russia will take the leading
role in the European motor vehicle segment by 2011 at the latest, as experts
have forecast, remains to be seen – the financial crisis has also here left its
tracks. However, the current vehicle population of about 29 million represents
already an enormous potential for the aftermarket – especially, as every second
vehicle registered in Russia is older than 10 years and more than every third
vehicle is even older than 15 years. The well developed MAHLE Aftermarket
sales network in Russia ensures fast supply with spare parts – both for the
partly outmoded Russian brands and the vehicles of foreign brands, whose
numbers are constantly increasing.
Also this year, MAHLE will be present as exhibitor at the Automechanika
Moscow, acknowledging the increasing importance of the Russian market – but
also supporting the trade fair, which is only in its third year, to get established
in the industry. On about 50 m 2 , we will inform you about our comprehensive
engine component and filter programme, especially also for the East European
brands, and provide an outlook on the new brand strategy of MAHLE.
16 – 19 APRIL 2009
The Automechanika Istanbul is the most important automobile trade fair for
Turkey and the Near East. More than 29,000 people interested in the automobile
(ca. 30 % more than before) came in 2007 to get plenty of information from
658 exhibitors from 30 countries on 14,000 m 2 . The main topic of the comprehensive
supporting programme this year: to join the Arab market, inclusive
of the tax and legal implications.
MAHLE has the strategic objective to open up the growth markets of this
region with extra effort. The joint venture with the piston and cylinder liner
manufacturer Mopisan (today MAHLE Mopisan), based in Izmir and the construction
of a central warehouse by MAHLE Aftermarket at the same site, are
part of this drive. The entire range is now available on a floor area of 12,000 m 2
– from pistons and piston rings, cylinder liners, assemblies, bearings, valves
and valve train components to oil, air, fuel and cabin filters. Our customers
from Armenia, Azerbaijan, Georgia, Iraq, Jordan, Kyrgyzstan, Kazakhstan, the
Lebanon, Syria, Tajikistan, Turkmenistan, Uzbekistan and Turkey can therefore
benefit from a wider capacity and shorter delivery times – and from our comprehensive
additional support, for instance, in the area of technical training or
MAHLE will be represented at Automechanika Istanbul with a stand of almost
200 m 2 . The main features are the comprehensive product programme of
MAHLE Aftermarket, the new brand strategy... and, of course, MAHLE
Mopisan. We look forward to many interesting conversations in hall 3, stand
C 160 – especially also with our new customers added through MAHLE
Mopisan. A warm welcome!
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 7
You may remember: 7 years ago, the block exemption regulation came into
force. This agreement between automobile manufacturers and companies in
the maintenance and repair market had the principal objective of strengthening
the independent automotive spare part trade and the independent workshops
in the market. This agreement will come to an end in 2010. This leaves the
involved partners with the challenge to jointly find a new, agreeable solution for
If the independent component market wants to maintain its status as an equally
good alternative to the maintenance in branded workshops, it requires access
to the motor vehicle products and technical information of vehicle manufacturers.
The companies in the motor vehicle aftermarket appeal therefore to the
car manufacturers to open up to the independent market – in the interest of
consumers and the preservation of fair competition.
The motor vehicle aftermarket associations have started a Europe-wide
campaign to define and realise their interests and objectives: Under the motto
“Right to Repair”, the entire value chain of vehicle repair and maintenance
including the motorist is informed about the necessity of further liberalisation
of the market.
Like almost every well-known motor vehicle component manufacturer, MAHLE
has joined this initiative and supports the request of the independent automobile
businesses and dealers, to provide motorists with the freedom of choice
in acquisition, repair and service of their vehicles also in future. This is, after all,
one of the essential prerequisites to assure that the quality and workmanship
of the MAHLE products that are available in the aftermarket are exactly the
same as those that are supplied to the automobile industry.
You find more information about “Right to Repair” on the Internet: www.r2rc.eu
“RIGHT TO REPAIR”
– WHO IS SUPPORTING IT?
The International Association of Vehicle Body Repairers (AIRC)
The European Council for Motor Trades and Repairs (CECRA)
The European Garage Equipment Association (EGEA)
The International Automobile Federation (FIA)
The International Federation of Automotive Aftermarket Distributors (FIGIEFA)
The International Association of Engine Rebuilders and Remanufacturers (FIRM)
Almost all renowned automotive component manufacturers, including MAHLE.
“RIGHT TO REPAIR”
– AN INITIATIVE IN FAVOUR
OF A FREE MARKET ECONOMY IN THE
AUTOMOTIVE COMPONENTS SECTOR.
n e w s 7
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 8
NEW ON THE MARKET
In the MWM LT 35 and VW LT 28 D, 35 D as
well as the 46 D, a 2.8 litre 4-cylinder diesel
with 3 valves is used. The piston is equipped
with ring carrier and recess for the oil cooling
jet – and the liner is pre-machined. For
the repair of the engine, the matching engine
components are now available.
The air filter element LX 1915 is a filter with fleece element and surrounding
plastic moulding. Therefore an especially tight seal is achieved.
It is fitted as original equipment to the Chevrolet Aveo from model
03/2006 and Chevrolet Kalos from model 03/2005 as well as Daewoo
Kalos from model 09/2002 – and can now be replaced expertly.
Ring set for Peugeot and
Citroën. Part no. 040 17 NO
(MAHLE Original) or
47 91010 0 (Perfect Circle).
n e w s
Engine components for
VW LT 2.8. Piston: part
no. 151 12 00 (MAHLE
Original) or 56 04168 0
Liner: part no. 151 WV 32
(MAHLE Original) or
64 00798 0 (Perfect Circle).
Also available as assembly:
part no. 151 12 90
(MAHLE Original) or
76 04161 0 (Perfect Circle).
Air filter element LX 1915 for
Chevrolet and Daewoo.
Part no. 70350351 (MAHLE) or
The cabin air filter element LA 280 is equipped with a particulate filter
that is fitted with a foam seal at the front face – to take care of optimum
filtration. It has been designed for the Landrover Discovery from model
10/2004 onwards and the Range Rover from model 02/2005.
Cabin air filter element LA 280
for Landrover. Part no.
70327591 (MAHLE) or
Engine components for MAN
D 2842. Piston: part no.
227 07 00 (MAHLE Original) or
56 02208 0 (Perfect Circle).
Liner with seals: part no.
227 WN 34 (MAHLE Original)
or 64 00698 0 (Perfect Circle).
Assembly: part no. 227 07 90
(MAHLE Original) or
76 02201 0 (Perfect Circle).
The matching engine components are now available for the MAN D 2842,
LE 202 V 12 Diesel with 21,930 cm³ and 446 – 587 kW (607 – 798 hp) with
turbocharger and intercooler. The pistons have ring carriers, cooling
channel and graphite coating. In addition, a so-called wet liner is available
(i.e. a liner that is directly surrounded by the coolant flow) as well as
the corresponding seals. The set is also available as complete assembly.
LORD OF THE RINGS
“EW 12 J4; Ø 86; R 1,2 IFMO; NM 1,5 FE; 3S
2,5 CR”: The insider recognises here clearly the
piston ring set for a Citroën/Peugeot engine
EW 12 J4 with the bore Ø 86 – comprising a
rectangular ring (height 1.2 mm) with molybdenum
plating and internal bevel, a taper-faced
Napier ring (height 1.5 mm) with Ferrooxide
layer and a chromium coated multipart oil
scraper ring (height 2.5 mm). The ring set is
suitable for the petrol engines with 2,330 cm³
und 116 kW/158 hp that are used in the Citroën
C8 or Peugeot 406, 407, 607 and 807.
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 9
YOU CAN FIND DETAILED INFORMATION ABOUT NEW PRODUCTS IN THE ONLINE CATA-
LOGUES AT WWW.MAHLE-AFTERMARKET.COM, WHICH ARE UPDATED CONTINUOUSLY.
Polo, Lupo, Golf, Bora, Passat, Phaeton, A4, A6,
Alhambra, Cordoba, Ibiza, Leon, Fabia, Octavia,
Superb ... in short: all Volkswagen diesel engines
1.2/1.4/1.9/2.4/5.0 TDI with the bore 76.5/79.5/
81 mm, a power range of 45 – 230 kW or 61 –
310 hp can be repaired with this valve set: the
inlet valve is made in mono-metal, in 3-grooved
version and with induction hardened seat. The
exhaust valve has also 3 grooves, however, is
made from bimetal and features a hard-faced seat.
Valves for VW diesel
engines. Inlet valve: part
no. 029 VE 30914 000
(MAHLE Original and
Perfect Circle). Exhaust
valve: part no. 029 VA
30915 000 (MAHLE
Original and Perfect
Bearing sets for Peugeot
(MAHLE Original and Perfect
Circle). Main bearing set:
part no. 039 HS 20282.
Connecting rod bearing set:
part no.039 PS 20284.
part no. 039 AS 20286.
Oil filter cartridge OX 418 D Eco for Fiat, Lancia, Opel,
Suzuki and Vauxhall. Part no. 70365417 (MAHLE) or
TWICE AS TIGHT
The oil filter cartridge OX 418 D Eco is fitted
with a double seal between dirty and clean
side. It is used in various 1.3 litre diesel
engines from Fiat, Lancia, Opel, Suzuki and
Vauxhall (engine designation D, JTD, CDI,
DDIS and CDTI).
Oil spin-on filters OC 571
for Opel Antara. Part no.
70366670 (MAHLE) or
Inline fuel filter KL
440/8 for Nissan
Qashqai. Part no.
70364352 (MAHLE) or
Opel has once more entered the four-wheel drive
class in 2006 – with the 5-door Sports Utility
Vehicle Opel Antara. For the professional oil filter
change of the 3.2 litre V6 engine (from model
05/2006 onwards), the oil spin-on filter OC 571 is
With 8,017 cm² filter surface,
the air filter element LX 1622 is
among the high-performance
models. It is used in the Sports
Utility Vehicle Sedici 1.9 D from
Fiat and the Urban Cross Car
Suzuki SX4 1.9 D – a mixture of
compact car and light all-terrain
The “race version” of the all-terrain vehicle
Suzuki Grand Vitara can be recognised by the
engine designation “2.7 i”. For expert service,
the oil spin-on filter OC 331/1 is available.
NEW ON THE MARKET
Air filter element LX
1622 for Fiat Sedici
and Suzuki SX4.
Part no. 70355970
The inline fuel filter KL 440/8 provides
space for 160 ml water – and therefore
for reliable pre-heating of the diesel
fuel that is sensitive to low temperatures.
The filter is delivered complete
with water drain plug and pre-heating
valve and is ready-to-fit to the unconventional
“City-SUV” Qashqai from
Nissan with the engines 1.5 dCi, 2.0
dCi as well as the X-Trail dCi.
For the repair of the engines DW10ATED,
DW10AFAP, DW 10ATE, DW10TD – used in
the Peugeot models 206, 306, 307, 406, 607,
807, 806 as well as Partner Combi and Expert
– the suitable bearing sets are now available:
the half-bearing fitted to the pressure side of
the connecting rod bearings are sputtered and
therefore especially wear-resistant.
Oil spin-on filter OC 331/1
for Suzuki Grand Vitara.
Part no. 70361105 (MAHLE)
or 70361108 (Knecht).
n e w s 9
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 10
KOLBEN PISTONS & CO.
TIME FOR BEARINGS!
THE PERFORMANCE OF BEARINGS – IS A QUESTION OF
MATERIALS, ALLOYS AND SLIDE LAYERS.
In addition to their actual function of supporting moving parts, bearings
in engines have another important task: the accommodation and
embedding of abrasion particles. These abrasive particles are generated
during normal engine operation and are so small that they cannot
be separated by the oil filter, and – if not embedded – can lead to
increased wear. These key functions of bearings in achieving concentric
running and low-wear operation of the engine require special
Bearings in engines are subject to several different friction states. For this
reason, they are designed to withstand the wear intensive mixed friction that
exists during cold start as well as the high pressures of the combustion. Due
to these different demands, bearings are generally made from several materials:
n e w s
On the one hand a material has to be chosen that is highly wear resistant, on
the other hand it must still provide sufficient embeddability.
IT IS THE MATERIAL THAT MATTERS
MAHLE bearings consist of a high-strength steel backing that is coated with
different bearing metals depending on the particular application. The bearing
materials are selected so that the different positive properties of the materials
complement each other and the combination is optimal for the particular
application. Material development takes therefore a key role in meeting
today's and future demands on bearings. Thanks to years of development
activities and experience, MAHLE disposes over a large number of high-quality
bearing alloys such as aluminium and bronze alloys.
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:34 Uhr Seite 11
Strength, good close fit, good running quality – these are
demands that are contradictory in terms of material technology.
The solution: multi-layer bearings, designed according to the
principle of work-sharing. This is because the basic performance
of bearings, above all their dynamic load capacity, is not only
influenced by the material, but also by the structure and thickness
of the layers as well as design measures such as the bearing
surface configuration. The base of a MAHLE bearing is a
high-strength steel backing that is coated with different bearing
metals depending on the particular application. Here is an
overview of bearing designs.
Solid bearings are made completely from one kind of metal,
mostly a hard bronze alloy. These bearings are often used in
large engines, however, they are also used in passenger cars as
piston pin bushings, thrust washers or camshaft bearings.
Two-material bearings consist of a steel backing, an intermediate
layer and a layer of bearing metal. Aluminium alloys are
used mainly for the bearing metal. Two-material bearings are
used in petrol and naturally aspirated diesel engines under low to
medium loads in passenger cars - depending on the alloy, as
piston pin bushings, valve rocker bushings, thrust washers,
camshaft bearings, main bearings or connecting rod bearings.
Three-material bearings consist of a steel backing, a bearing
layer, a barrier layer and the slide layer. The bearing layer is
mainly made from a type of lead bronze and is generally applied
through an electro-plating process. Three-material bearings are
predominantly used in engines subject to higher loads – as large
piston pin bushings, connecting-rod bearings, main bearings
and crankshaft bearings.
Sputter bearings belong to the bearing types of the highest
quality. In terms of their structure, they are also three-material
bearings and are made from the same materials. However, an
extremely resistant aluminium layer is deposited onto the bearing
material – by means of a special production method, the sputter
process (see box “Sputter process”). Due to this coating, these
bearings feature significantly greater hardness and wear resistance.
The bearings are especially suitable for high-performance
engines such as turbocharged engines in passenger cars and
commercial vehicles and are then used especially in the connecting
rod and crankshaft area.
Supply of argon
In the sputter process, the bearings that consist of the steel backing,
the bearing layer and the barrier layer, are placed in the sputter machine
under a vacuum. The material of the slide layer is deposited on the
bearing shells by means of cathode sputtering. This produces the
extremely hard and wear resistant slide layer of the half-bearings.
SPUTTER BEARINGS: PERFECT WORK-SHARING
The sputtered slide layer is extremely hard and wear resistant,
however, embeddability for the above mentioned abrasion particles
is therefore low. In order to provide embeddability, only one
half-bearing of a sputter bearing is sputtered. The other half of
the bearing is a three-material bearing with conventional coating
that can accommodate the abrasive particles perfectly.
IMPORTANT: TO KNOW WHICH IS UP OR DOWN
The sputtered half-bearing is always fitted to the side subject to
the higher load. For example, the sputtered half-bearing has to
be fitted to the upper half circle of the big end of connecting
rods, as this is where the combustion pressure has its effect (see
picture 1). At the crankshaft, however, the combustion pressure
affects the half-bearing that is directed downwards. The sputtered
half-bearing can be recognised by the labelling “Sputter”
on the outside of the bearing. For safety reasons, the sputtered
bearings are often packaged and sealed separately.
CAUTION, OIL HOLE!
An additional error source during fitting of bearings is the fitting
position. For most half-bearing pairs, only one half-bearing has a
hole. If the bearing site is lubricated via a lubrication hole (as for
instance with crankshafts), it has to be assured that the hole in
the half-bearing is positioned exactly over the hole of the corresponding
seat. If the half-bearings are fitted the wrong way
round, the bearing site is not at all or only insufficiently supplied
with lubrication oil. The result: severe seizing, which can cause
the bearing to weld to the journal due to the enormous heat that
is generated. (Picture 2 shows such welding of the bearing to the
PISTONS KOLBEN & CO.
Consist of one bearing metal made from
The steel backing is complemented by an intermediate
layer and a layer of bearing metal –
used for engines subject to low and medium
Consist of steel backing, bearing layer, barrier
layer and slide layer (for sputter bearings
with a special coating) – used, for instance,
in supercharged engines.
A safe indication for sputter bearings: the “Sputter”
stamp on the back.
In the connecting rod, the sputtered half-bearing
is fitted to the upper half circle, where the
combustion pressure results in the higher load.
The result of a fitting error: As the half-bearings
have been fitted the wrong way round, the
lubrication bore was blocked – and this led
to seizing with extreme heat generation,
causing the bearing to weld to the crankshaft.
You can find an overview of the complete MAHLE bearing programme in the MAHLE bearing catalogue – and online at www.mahle-aftermarket.com.
n e w s 11
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:35 Uhr Seite 12
FILTERS – THE PURE TRUTH
FIRE AND FLAME
Air filters are all-round talents. They take care of clean intake air, prevent premature wear of engine components, ensure optimal air/fuel
mixture – and when equipped accordingly, can even extinguish fires.
n e w s
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:35 Uhr Seite 13
One of the most important requirements for optimum engine performance, high torques, low fuel consumption
and minimised pollutant emission: clean intake air. This, however, depends very much on the air filter, which has to
prevent dust, soot and tyre wear particles from entering the intake system.
THE ESSENCE OF A GOOD AIR FILTER
An important quality characteristic is the so-called collection efficiency.
It is measured in percentage and indicates the proportion
of particles from the intake air that remains in the filter.
MAHLE and Knecht air filters achieve here up to 99.9%. This
means that practically everything that can affect the function
and service life of the engine is filtered out by them – and this
creates the conditions for long engine service life even under
extreme temperatures or chemical effects.
FIRE HAZARD: THE DISCARDED CIGARETTE-END
However, air filters are subject to not only dust, soot, heat, cold
and various chemicals during their operation. In addition, there is
the threat of another hazard: that of catching fire – caused by the
widespread nuisance by some car drivers of disposing of a burning
cigarette end through the open window of the moving vehicle.
If the burning heat of 500°C gets into the intake system of a
vehicle travelling behind, its air filter can be set on fire – with the
disastrous result of a fire in the engine compartment. The most
well-known example for this is probably the catastrophe in the
Mont Blanc Tunnel, in which a lorry caught fire that was proved
to be caused by a discarded cigarette end.
However, a survey of workshops indicated that the majority of
engine compartment fires are smouldering fires that are often not
recognised as such when they are taking place. In the event of
such a fire parts of the air intake system, which is mainly made
from plastic, will generally melt. When the vehicle does not start
the next morning, only a glance under the bonnet will often
explain that there has been a fire.
FOR INCREASED ROAD SAFETY:
THE FLAME-RETARDANT DESIGN
In order to prevent engine compartment fires, the car manufacturers
have taken special design measures. These include grids
in front of the air intake opening or suitable positioning of the air
intake duct. Another option for fire prevention is the design of filter
elements with flame retardant properties such as those developed
by MAHLE in cooperation with car manufacturers and paper
makers. Such filter media with flame retardant properties are
mandatory in the specification books of car manufacturers for
future vehicle generations.
THE THREEFOLD SAFE EFFECT
The basis for achieving flame retardant properties is a special resin
used to impregnate the filter paper. The resin proportion for filter
media with flame retardant treatment is between 25 and 30% (for
normal filter paper this is only 15 to 20%). The paper treated in this
way can catch fire, but extinguishes very soon afterwards. The
effect is based on three fire extinguishing measures:
Release of nitrogen (N 2) to smother the fire as an inert gas.
Release of water to quench the temperature to below the combustion
Release of acid to oxidise the cellulose fibres so that they
FILTERS – THE PURE TRUTH
ON TEST: NORMAL FILTER PAPER
VS. FLAME RETARDANT FILTER MEDIA
The air flow that can be expected in the engine
compartment of a driving car is simulated via a
blower. With an open flame, it is then attempted
to set fire to a filter fitted to an opened filter
None flame-retardant paper
1 The filter has been ignited with an open flame:
the flame spreads rapidly. (The experiment
was aborted afterwards to extinguish the fire
2 Here it can be seen clearly how the flame
spreads rapidly towards the clean side
(engine) – with all the undesirable consequences.
3 The paper has been ignited with an open flame.
4 However, the fire is extinguished after a few
n e w s 13
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:35 Uhr Seite 14
The company ABS-auto is very well-known
in Russia. The renowned automobile components
dealer in the south of the country
has been trading for more than 10 years and
supplies workshops and specialist dealers
reliably with high-quality spare parts for
passenger cars that conform to the highest
European standards – such as engine components
and filters from MAHLE. We have
met up with the founder, General Manager
Konstantin Aslanidis, in order to find out more
about this extremely active and expansive
company – and, perhaps, even to get behind
the secrets of its success.
n e w s
“THE TREND IS TOWARDS
– IN EVERY RESPECT”
MAHLE Aftermarket news: Mr. Aslanidis, what are the basic
principles that guide you in your work? Or, let me rephrase this:
what is the key to your success?
Konstantin Aslanidis: Well, on the one hand we see our success
in the quality of our products – and in the professionalism of our
staff on the other. A look at our product range shows only such
product lines that are supplied by motor vehicle suppliers to
renowned vehicle manufacturers such as Mercedes, BMW or
VAG – or even to the high-end sector of the motor vehicle industry:
the formula 1, for which MAHLE also develops and manufactures
products. We are therefore pleased to see the MAHLE logos on
the formula 1 racers. On the whole, we endeavour to work only
with the professionals from the automobile sector who make top
quality products. We think that our success is for the most part
due to this uncompromising commitment to quality.
MAHLE Aftermarket news: Please tell us a little about your
Konstantin Aslanidis: The modern building complex here in
Stawropol, in which we are sitting, was opened in 2007. In this
complex, we offer our customers a competence centre for
repair and maintenance on a total area of 5,000 m². A highly
professional team represents us as one of the top companies of
the country in the sector of automotive services. The site serves
also as a training centre, in which various training courses and
workshops are taking place. In this way, we transmit two of the
most important assets of our time to our partners: information
MAHLE Aftermarket news: What are the problems that
confront you in the market?
Konstantin Aslanidis: Let us look at it from the position of our
end customers, the motorists: they are spoiled for choice and
have the problem of finding the right dealer. We need to offer
therefore something that is in line with economic trends and also
meets the wishes of the motorists.
Our company has been in the Russian spare part market for
the past 13 years. During this time, we have made some bad
experiences with automotive components: with the products of
different manufacturers both from well known and less known
brands. After the 1998 economic crisis, the demand for cheap
products, even those of recognisably inferior quality, increased
enormously. We could counteract this trend actively by providing
professional explanation and consultation. Today we can
say: the products have to meet the highest demands, function
reliably, have a long service life and offer relevant product service.
MAHLE Aftermarket news: Can you give us your market
Konstantin Aslanidis: We observe a tendency towards quality
and innovation – and we think that the businesses in our sector
will have to take measures in order to meet the demands of their
customers in this respect.
MAHLE Aftermarket news: Will you tell us about the plans
of ABS-auto for the near future?
Konstantin Aslanidis: In order to expand further, we are planning
to extend our technical customer service through a workshop
concept and are especially interested in the location
Sotschi, the venue of the Olympic Games 2014, as we see
promising potentials in this region.
We intend to continue expanding our sales of automotive spare
parts in the Russian market. We shall start a large advertising
campaign in Russia with the aim to increase customer awareness.
In addition, we will be represented at the established
regional and nationwide exhibitions. At the Automechanika
Moscow, we will only be present as visitors – there we want to
wait and see how the market is responding. This exhibition will
develop most probably into a major trade fair in future, thanks to
its international status and its excellent organisation.
MAHLE Aftermarket news: Do you also have a message for
the readers of the MAHLE Aftermarket news?
Konstantin Aslanidis: We would like to see that all companies
that are active in consultation and sales of automotive spare
parts or in the repair and maintenance of vehicles can work successfully
and expand their businesses. In addition, I would like
to appeal to the owners and managers of these companies:
“Please offer your customers quality – also in respect of your
employees. Turn your attention to their development and further
training. Make an extra effort to enable them to widen their technical
horizon. A well trained employee is not only more committed
and generates better sales – he or she has also a significant
effect on the company image as seen by partners and customers
and contributes therefore to the success of the com -
pany in the long term.”
MAHLE Aftermarket news: Mr. Aslanidis, we thank you for
this conversation – and wish you great success in the implementation
of your immediate and long-term objectives.
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 14:20 Uhr Seite 15
MAHLE FIGHTS AGAINST PATENT RIGHT INFRINGEMENTS AND
PRODUCT COUNTERFEITING ON LOCATION – IN THE MIDDLE OF
THE INTERNATIONAL AUTOMECHANIKA IN FRANKFURT.
The topic of product counterfeiting has been dominating
the industry for quite some time. In the meantime, the
problems and safety risks that are caused by counterfeit
products are well known in the entire motor vehicle value
chain. Educational work is required, is important. But this
is not enough. In order to set a clear example, it is time to
act and not only talk. MAHLE has therefore – in cooperation
with German customs – initiated a raid at the Automechanika
2008 for the first time. With success: 250 products
have been found that are based on stolen patents
and are therefore illegal. The counterfeits were confiscated
immediately by customs – and MAHLE initiated legal
proceedings against the involved stand holders.
Oil and air filters such as the patented Eco oil filter from MAHLE
were the focus of the operation. One of these filter elements is
equipped with a specially developed oil draining device, the socalled
PIN and a fleece end plate that serves as a seal. It is one
of the best-selling MAHLE filter products and therefore also the
favourite object for thieves of product ideas.
The raid had been planned long beforehand and was organised
accordingly in a professional manner: Already months before the
start of the exhibition, MAHLE staff checked the list of
exhibitors, had conversations with patent lawyers, informed
customs and involved the police. Even product training for the
customs officers in Frankfurt was organised – after all, they
needed to know what they were looking for.
On 17/09/08 at 9.00 hours the action started. Several groups
comprising customs officers, lawyers and armed police, caused
quite a stir in the exhibition halls. Together, they searched thoroughly
through about 50 stands for which tip-offs regarding
product piracy had been received. During the investigation, the
brazenness of some stand owners was demonstrated in different
ways: some exhibited the counterfeit products clearly visibly
in showcases, others kept them under the counter or they were
only shown in brochures. But the customs officers knew the
tricks – and were relentless: every drawer, every box and every
small corner was thoroughly searched, games of hide-and-seek
and excuses were not accepted.
This resulted in the confiscation of 253 counterfeits from 19
stands. 114 of these were oil filters, of which 98 were discovered
thanks to tip-offs from MAHLE. Incidentally, the majority of
dubious stand operators came from Asia. However, counterfeit
products have also been found at dealers from Turkey, Morocco,
Tunisia and Egypt. The responses of the affected individuals
varied between ostentatious stubbornness and attempts to talk
their way out of it with astonishing creativeness. However, the
customs inspector in charge and his team were insistent – and
MAHLE brought charges against the implicated exhibitors.
This action has demonstrated once again the extent that product
piracy has reached in the meantime – and how important it
is to persecute patent infringements. The Automechanika was
an ideal platform for making the public even more aware of this
topic: the action caused such a stir, that a local TV station
broadcasted a detailed report that same evening. This showed
the raid in impressive footage with armed police officers, surprised
stand owners and confiscated counterfeit oil filters – and
informed the wider public therefore about the dangers of illegal
With this type of conspicuous crime fighting, a decisive action in
the continuous fight against product piracy has been initiated
and a clear signal set in the industry: to be noticed by the producers
of counterfeit products, the automotive industry and the
aftermarket ... and finally also the end user.
n e w s
In cooperation with other partner organisations
and customs, the “Messe Frankfurt” started the
initiative “Messe Frankfurt against Copying”
already in 2006, and the raid at the Automechanika
took place in this context.
Dramatic moments at the Automechanika 2008:
Where normally sales conversations are held in a
relaxed atmosphere, customs officers and police
cause quite a stir when they searched 50 stands
for product counterfeits.
Measures against brazenness: The counterfeiters
offered their goods at the renowned trade fair
Automechanika – and customs confiscated more
than 250 counterfeit products.
MAHLE_News_1_09_GB.qxp:MAHLE-News_1-09_GB 04.02.2009 13:35 Uhr Seite 16
“Important reading, valuable contents and appealing design” – “100% facts” – “acclaimed by experts”
The experts rarely have been in such agreement as when it comes to the new
MAHLE Aftermarket catalogues for engine components and filters. This is
because the new reference material is informative, clearly structured and offers
fast and safe access to all relevant data. The 2009 issues are now available
hot off the press and up-to-date for “Pistons/Cylinders/Assemblies”, “Piston
ring sets”, “Bearings” and “Valve train components” each one in the versions
MAHLE Original and Perfect Circle.
Also a new issue of the passenger car
filter catalogue is available – both for
MAHLE Filter and Knecht.
Awarded for outstanding data preparation
as TecDoc Certified Data Supplier: MAHLE
MAHLE Aftermarket news 1/2009
EDITING MAHLE Aftermarket news
MAHLE Aftermarket GmbH
Pragstraße 26 – 46
70376 Stuttgart – Germany
RESPONSIBLE FOR THE CONTENTS: Arnd Franz
EDITORS: Andrea Arnold, Yves Canaple, Christoph Dutschke,
Eckart Fritz, Paul Grosvenor, Andreas Kimmerle,
Hans-Ulrich Melchert, Peter Riedmayer
n e w s
The catalogue data are also available
in TecDoc. MAHLE Aftermarket GmbH
has actually been awarded with the
quality seal “TecDoc Certified Data
Supplier” for the outstanding quality of data preparation and maintenance. In
addition to compliance with the TecDoc standards, the evaluation criteria
include also the quality of additional information, the use of text modules and
their availability in the six core languages German, English, French, Spanish,
Italian and Dutch. Another condition for awarding the sought-after certificate:
a minimal error rate for article and link tables (maximum 1%) as well as
answering at least 99% of the error notifications received.
The catalogues, hot off the press, are now available free of charge from your
MAHLE sales partner. And everyone who prefers to work with electronic media
can order the two CD ROMs “Product range filters 2009” and “Product range
engine components 2009” - of course, also free of charge. Alternatively, the
daily updated electronic catalogues can be accessed via the Internet at
EXTERNAL EDITORS: Ingrid Münzer, 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: Raff, 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.
Printed in Germany.Ra.02/09