Deutsche Post AG
“Nice picture. Is it also available as poster?” – We have been
asked this or similar questions many times, for instance, at
trade fairs and exhibitions or when people take a look at our
advertising material. Of course, we also have a good reply:
“Yes, for instance here.” For this edition of the MAHLE
Aftermarket news we have printed and included an attractive
picture from our collection as a poster. It would be nice,
if you could find a place for it in your office or workshop – and
if this could remind you of our products now and then … Of
course, also in the actual magazine we have prepared some
Arnd Franz, General Manager
3 INDUSTRY NEWS
Brand theft – product piracy on
4 MAHLE INSIDE
Power ex works: recent vehicles
with MAHLE products
Formula Student – our way of
encouraging new engineering
A thorough health check: a
look at the MAHLE engine
8 NEW ON THE MARKET
Engine components and filters
A F T E R M A R K E T
MAGAZINE FOR TRADE, WORKSHOP AND ENGINE REPAIR
“eye-catchers” for you: we show you how speedy MAHLE
encourages the new generation of engineering recruits by the
example of the Formula Student. We have found out how
motor vehicle components suppliers in Turkey foster their
good relationships with their customers. We have joined a
bull on the ski slopes. Moreover, we shall take a look (from
different angles) behind the activities of brand pirates – and
give you some tips on how to protect yourself actively from
this type of fraud. But this is enough of an introduction – why
not just open the new MAHLE Aftermarket news!
10 PISTONS & CO.
Valves: new materials, new
12 FILTERS –
THE PURE TRUTH
This is how you recognise a
14 CUSTOMER PORTRAIT
Interview with Faruk Bilginoglu,
COUNTERFEIT MOTOR VEHICLE PRODUCTS –
A DANGER FOR TRADER, WORKSHOP AND MOTORIST.
More about this on pages 2, 3 and 12/13!
15 ON LOCATION
In continuous operation with
MAHLE: the PistenBully
Quick access to the right filter –
online and offline
For more than 8 decades, MAHLE has been a partner of industry, trade and
workshops. Our brand names – in Europe these are MAHLE Original, MAHLE
Filter and Knecht – have become synonymous for quality, technology, reliability
and service – and for the certainty that the right decision for engine and vehicle
has been made.
This certainty does not come by chance: 2,000 engineers work in our R&D
facilities in Stuttgart, Northampton, Detroit (Farmington Hills and Novi), São
Paulo, Tokyo and Shanghai on innovative products that provide for longer
engine service life under the hardest conditions. Accordingly, all MAHLE products
have to pass demanding assessments and tests during every development
and production stage.
No matter where a vehicle is used: with global presence MAHLE ensures that
the right spare part is available.
As partner with a comprehensive range of services for the vehicle component
trade and workshops, we provide you with the adequate product literature and
well-founded technical information material – in printed and electronic format.
In addition, our technical specialists welcome thousands of customers every
year in personal training sessions either in the field or as part of the MAHLE
training program at one of our sites. Furthermore, our customer advisors are
available everywhere in the world to answer your questions and point out the
best solution every time.
However, these efforts and investments are only feasible when our products
maintain their high recognition value – via our brands.
The Automechanika 2006 in Frankfurt am Main and other trade fairs during the
last year have demonstrated one more time that many suppliers cannot resist
the temptation to take advantage of this recognition value with illegal means,
by copying or even counterfeiting products and brands. As brand manufacturers,
we do not only see a threat to the bond of trust with our customers. This is
because the use of technically inferior imitations can frequently even endanger
engines, vehicles and passengers.
For your protection, MAHLE together with many others has taken on the fight
against product and brand piracy.
■ Individuals and companies that misuse one of our brands without permission
for their own advantage will be requested to restrain from such practice – if
necessary through legal proceedings. Counterfeit products will be confiscated.
Also criminal prosecutions shall be considered.
■ MAHLE has put together a network of specialists in the technical, marketing
and legal field to investigate possible infringements of the patent
and brand laws. From Saudi Arabia and China to South America: in the
interest of our customers we thoroughly investigate tip-offs about misuse.
We are recording successes all the time: for example, 8,000 counterfeit
pistons and just fewer than 3,000 counterfeit cylinder liners of the
brand Izumi, which is distributed by MAHLE in Asia, could be confiscated
recently in the Philippines. 900 counterfeit Izumi pistons have
been destroyed in Thailand.
■ For their identification, our products carry special security features
such as three-dimensional holograms. We are working continuously to
improve these security features – with the aid of state-of-the-art
■ As exhibitors at the trade fair in Frankfurt, we are involved in the project
“messe frankfurt against copying” for the fight against product and brand
■ Vehicle and component manufacturers are coordinating joint actions against
counterfeiters within the framework of the “Association of the German
Automotive Industry” (VDA) and other associations.
The protection of intellectual property rights is in the interest of everybody.
Together we can prevent harm to workshop, trade, industry and end-user and
ensure that efficient, high-quality and safe products are available also in future.
Also you can help in this fight against product and brand piracy. If you come
across incidents of abuse, please just send us a message. You can contact
our team by email: email@example.com. All information will be treated as
And now – please enjoy reading our new MAHLE Aftermarket news!
BRAND PIRACY is the illegal use of symbols, names, logos
and business terms that are used by the brand manufacturers
to identify their products on the market.
PRODUCT PIRACY defines the illegal copying and duplication
of goods for which the manufacturer has rights in respect of
invention, design and method.
PRODUCT PLAGIARISM means that products come on the
market with slightly varied brand names. Sometimes this
conceals products that are not even available from the original
SLAVISH COPY describes the attempt to copy the original
as exactly as possible: packaging and brand name are often
difficult to distinguish or cannot be distinguished at all.
CLASSIC FORGERY involves identical packaging and use of
the manufacturer name. The materials are of inferior quality,
not provided or even harmful.
THE CLAWS OF THE PIRATES: EVERY TENTH AUTOMOTIVE COMPONENT IS COUNTERFEIT –
AND THEREFORE DANGEROUS.
Imitation designer jeans or counterfeit high-class watches have been
around for quite some time. But in the meantime, products are counterfeited
on a large scale: mobile phones, drugs – and also automotive
components or even complete cars. What makes this especially dangerous
is the fact that copies can often not be recognised at first sight
… and also not at second.
Essentially, the entire automotive sector is affected by this brand and product
theft: whether brake lining, fuel filter or complete steering gear – there is hardly
an automotive component that is not counterfeited. Experts estimate that
Europe-wide 10 % of all spare parts and performance accessories are counterfeited.
This is often done that cleverly, that some versions and packaging
can only be distinguished from the original by experts – if at all.
Especially on trade fairs, copies are offered again and again. For example,
customs officers have inspected 500 exhibitors from none-EU countries at last
years Automechanika – and 144 counterfeit samples have been confiscated.
A DANGEROUS BOOM
The extent of this illegal production of goods is alarming: since 1998, the number
of counterfeit goods has increased tenfold. On a global scale, 10 % of the
international trade is conducted in illegal products – an estimated volume of
about 350 billion Euro. About 100 million counterfeit products are confiscated
annually at the external borders of the European Union. This takes its toll. Also
on workplaces: about 300,000 jobs are lost Europe-wide every year due to
product and brand piracy.
These counterfeit products – which come mainly from Turkey or China –
represent not only a cost factor. The illegal product copies are generally made
from low-grade materials – with serious consequences and fatal risks in road
traffic. Incidents have been reported in which counterfeit brake linings have
disintegrated and caused brake failure at the first emergency braking. Also
counterfeit fuel filters with housings that cannot withstand the pressure of the
injection pump have been reported again and again. The consequences: leaking
fuel, and therefore fire and explosion hazard in the engine compartment!
HOW YOU CAN PROTECT YOURSELF
Also trade and workshops are susceptible to the dangers of counterfeit
products. If the low price components fail, the repairer who has fitted them
may be liable for the entire costs!
Therefore, it is advisable to look thoroughly and check suspicious offers.
Supply routes that are different from the usual, different or no invoices or just
unusually attractive conditions are indications that copies may be put into
circulation. There is only one remedy to protect yourself and others from
extremely dangerous products: hands off pirate copies – and instead: use
automotive components in brand quality that have been provided by qualified
suppliers through familiar distribution channels.
Also worldwide renowned brands such as MAHLE Original, MAHLE Filter and Knecht are
not safe from counterfeiters. Some tips on how to distinguish, for instance, between
original filters and copies can be found on page 12/13.
© ams / MPI
DYNAMIC MIRACLE OF SPACIOUSNESS
THE “WOW!” EFFECT
6.4 m 2 of glass surfaces – this is a record. And it offers the driver of the French 7-seater a completely new outlook: the high-reaching, wide-angle panorama
windscreen of the Citroën C4 Picasso increases the driver’s angle of view to an enormous 70 degrees*. The impression of boundless freedom is made complete
by the A-pillar that consists of merely two slim struts and the optional panorama roof. Citroën describes the new C4 therefore as “VisioVan”– and explains that
the name stands “for more visibility, more light and more space”.
LESS IS MORE
To provide more space for the passengers, Citroën has decided to get rid of the centre console altogether. The automated six-speed transmission is instead
operated via a selector lever at the steering wheel and gear shift paddles at the steering column. The outcome of this stroke of genius: 4 large closed storage
compartments in the dashboard – the centre one with cooling and space for drinks. The passenger area on the whole has been designed with declared emphasis
on a feel-good ambiance and is presented with well thought-out fittings inclusive of foldaway tables and automatic lighting.
STORAGE SPACE & COMBUSTION SPACE
The 280 l storage space that is available in the van with full seating can be increased gradually up to 1,951 l. Also the combustion chamber has generous
dimensions: the two petrol versions come with 1.8 and 2.0 l displacement (more then 92 kW/125 hp and 103 kW/141 hp), the two diesel engines get their
power from 1.6 and 2.0 l (80 kW/109 hp and 100 kW/136 hp). Also in action: Pistons, piston rings and piston pins, camshafts, cylinder liners, air filters, oil filter
modules as well as carbon canisters from MAHLE.
* A comparison shows that only 35 degrees are available in a conventional multi-purpose vehicle.
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.
In focus: Citroën C4 Picasso.
E X W O R K S
© BMW AG
1 BMW M6 CABRIOLET
An incredible 373 kW (that’s 507 hp!) are produced by the V10 naturally
aspirated engine under the bonnet of the new BMW M6 Cabriolet – and they push
the dream car to 100 km/h in only 4.8 seconds. Top speeds of more than 300
km/h would be no problem for the Cabriolet, however, the engine is limited
electronically. At the heart of the high-performance engine: MAHLE pistons
and piston pins, cam shafts and connecting rods, complemented by MAHLE
air intake modules, air filters, oil mist separators as well as oil filter modules.
2 SEAT ALTEA XL
The new Seat Altea is 18.7 cm longer than its predecessor – hence the “XL”.
What distinguishes the two models can best be seen from behind: the rear
lamps of the new Seat Altea XL reach far into the boot lid. The spacious
family car is initially available in 5 different engine versions: 2 petrol and 3 diesel
engines – fitted with pistons, piston rings and piston pins, connecting rods,
valves and valve seat inserts, air filters as well as oil filter modules from MAHLE.
3 LAND ROVER FREELANDER
State-of-the-art engineering makes the second generation of the Freelander
fit for any surface: “Terrain Response” is the name of the new system that
optimally adapts the chassis, the vehicle height or the gearbox of the all-terrain
vehicle at the touch of a button for different driving conditions such as motorway,
country road, forest path, mud or sand. Regardless of the terrain, the
new Freelander can rely on MAHLE camshafts, connecting rods and air intake
4 MERCEDES-BENZ AXOR
From January 2007, the Mercedes-Benz Axor is coming from the production
lines with a new engine – the 12.8 l six-cylinder in-line engine OM 460 EPA 07.
The reason for this is the exhaust emission standard Euro 4 that has just come
into force and the Euro 5, expected for 2009, which is aiming for a further
40 % reduction in noxious emissions for lorries. To comply with this regulation,
MAHLE makes a decisive contribution by providing the piston rings, piston
pins, cylinder liners, bearings, valve guides and valve seat inserts as well as
oil mist separators for the OM 460 EPA 07.
5 ŠKODA ROOMSTER
According to the manufacturer, the new Roomster is divided into two halves:
the “driving room” is allocated in the front – and in the back you have the “living
room” that offers three comfortable, individual seats for the passengers. If
extra large items need to be transported, the Varioflex seating system allows
additional variations in the storage space by folding, lengthwise and crosswise
shifting as well as removing of seats. The new Škoda is, for instance, powered
by a 77 kW (105 hp) 16V petrol engine with MAHLE pistons, piston rings,
piston pins, connecting rods and valves. Also on board are air intake modules,
air filters, oil filter modules and carbon canisters made by MAHLE.
6 HONDA CR-V
Honda calls the new CR-V “a classic full of dynamism”. The elegant four wheel
drive vehicle is available with a 103 kW (140 hp) 2.2 l CTDi diesel engine.
According to the manufacturer this engine delivers “the highest torque in its
class” (340 Nm at 2,000 rpm). Also a 2 l petrol engine with 110 kW is available,
which is described by Honda as offering smooth power delivery, responsive
revving ability and excellent fuel consumption and emission values. Also
on board: pistons, oil filter modules and oil filter elements from MAHLE.
7 NISSAN PATHFINDER
The new Nissan Pathfinder can pull its weight: the powerful 2.5 l Common Rail
turbo diesel engine with 126 kW (171 hp) can deliver 403 Nm torque and can
pull a hauling load of up to 3 tons. This allows it to pull trailers, boats or
caravans – and also to sprint from 0 to 100 km/h in 11.8 seconds … and reach
a top speed of 175 km/h. A look under the bonnet will show the engine
cover, fuel filter, intake manifold and air filter made by MAHLE.
HIGHLIGHTS FROM THE
• A S I A R
HIGHLIGHTS FROM THE
• A S I A R
© ams / MPI
A N G E •
A N G E •
What is the essence of a good engineer? Up-to-date technical knowhow,
consolidated by hands-on experience. And, of course … the often
mentioned “petrol in the veins” – the passion for the automobile. The
Formula Student, an international design competition between more
than 250 university and college teams combines all these components.
The contribution by MAHLE: the targeted promotion of engine design.
The Formula Student is a racing series that is organised by the “Society of
Automotive Engineers” (SAE) in cooperation with local promoters, in which
student teams from the whole world put their abilities to the test. Students
design their own racing cars and participate with them in races and other
events. The races are held in many different countries such as the USA, Great
Britain, Brazil, Australia or Japan. Apart from a few modifications, the same
rules apply internationally in order that teams everywhere can start with the
same kind of racing car. It is not the fastest car that wins, but the team with
the best overall package (see box).
Formula Student: from the campus straight to the race track.
In 2006, the Formula Student took place in Germany for the first time. From 3
to 6 August, 660 students from 10 countries (such as Russia, Scandinavian
countries or Canada) participated with 40 teams to prove the capabilities of
their self-made formula racing cars in a championship at the Hockenheimring.
MAHLE supports the Formula Student by closely cooperating with the universities.
An engine has been developed especially for the racing series – in
different configurations and versions with supercharging in different power
levels and torque characteristics. The team of the RWTH Aachen used the
MAHLE engine in 2006, and in 2007 it will also be on board of the monococks
of the University Stuttgart and the University of Applied Sciences Esslingen.
In addition, it is planned to make the engine available to two universities in
The growing number of participants as well as annual racing events is a sign
of the impetus that motorsport has on the motivation of university teams. This
is how the Formula Student can contribute to boost the enthusiasm for technology
– after a lack of such enthusiasm has led to a shortage of engineering
recruits in Germany for many years.
Also this year – probably from 8 to 12 August – hundreds of students will meet
at the Hockenheimring to compete with contestants from home and abroad
and to make valuable contacts with the industry, their potential employers. We
can't wait – and look forward to motivate young people with passion for
technology to work together with us to face the challenges of automobile
and engine development. Admittedly, this is not without thinking of our
own interests – after all, our ambitious R&D projects always need new and
committed engineering recruits …
SUPPORT FOR ENGINEERING RECRUITS IS
WINNING THE RACE
FORMULA STUDENT – AFTER-
WARDS, THE JURY GIVES ITS
■ Reliability also on long
■ Braking power
■ Handling (for an amateur racer)
■ Fuel consumption
■ Aesthetics and comfort
■ Use of conventional series-produced
■ Ease of repair
■ Expense budget – maximum
price for the prototype: 25,000
US-Dollar (extrapolated to a
small series of 1,000 units)
■ Sales presentations
■ Time and project management:
planning, design and production
within 12 months maximum
In addition to simulation calculations and component testing outside
the engine – the test of the running engine is the most important source
of information for a developer of engine components. MAHLE operates
a total of 78 engine test benches and 8 roller dynamometers in 7
international R&D centres.
ENGINE TRIAL: CENTRE FOR INFORMATION INTERCHANGE
The engine trial is of central importance to MAHLE: In addition to actual
product development for worldwide engine and vehicle manufacturers up to
production approval – also the engine-related developments of our own innovative
products are of great importance. The interchange of data and findings
with other areas such as design, computation and off-engine bench tests is
therefore an essential part of the daily business. The close cooperation of all
production lines with the engine trial is the foundation of the overall expertise
of MAHLE and makes the company a valued development partner for the
complex engine systems of vehicle and engine manufacturers.
TEST BENCHES FOR ANY SITUATION
The engine test department in the company headquarters in Stuttgart/Germany
has 32 test benches at its disposal that cover a large number of different
engine types and can perform all necessary tests. 16 test benches are available
for passenger car engines (petrol and diesel engines), 9 test benches for
commercial vehicle engines (including marine and stationary applications such
as generators), 3 test benches for small engines, 1 test bench for friction loss
investigations, 1 cold chamber and 1 anechoic test bench chamber for
acoustic investigations. Thanks to flexibility and individuality in test bench
configuration, MAHLE offers its customers considerable benefits – engine
manufacturers will not have nearly as many different engine types available in
their own test facilities.
24 HOUR NON-STOP OPERATION
In order to operate the engines under load on the test benches the mechanical
output of the engines has to be braked. For this purpose, 3 different types
of test bench brakes with different braking powers are used: eddy-current
brakes with maximum braking power of 160 kW to 250 kW for passenger
A look at the cold chamber: cold start test of an engine at –30 °C.
cars. Water whirl brakes with a maximum braking power of 400 kW to
1,200 kW for large passenger cars and heavy commercial engines. And the so
called cradled dynamometers, typically asynchronous motors that can brake
the engine but can also drive the non fired engine in motored operation. Their
maximum brake and drive power is between 200 kW and 700 kW. The test
benches can run fully automatically if required and fitted with carefully selected
measuring equipment they can operate 24 hours a day without operator
Test bench operating panel with the measuring system
developed by MAHLE for the detection of piston temperatures.
ACID TESTS AND IN-HOUSE DEVELOPMENT RESPONSIBILITY
In order to deliberately reach critical operating behaviours of engines and to be
able to assess the resulting problems qualitatively and quantitatively, it is essential
to adhere to specific test procedures that are often also stipulated by the
engine or vehicle manufacturers.
The engine test department in Stuttgart has the responsibility for developments
in its own area. This gives rise to a variety of tasks with continuous need for
development such as the design and optimisation of a Power Cell Unit (PCU) –
i.e. the functional system piston, pin, rings, cylinder liner, connecting rod and
bearings – or maybe the testing of complete valve systems or intake modules.
THIS HAPPENS AT THE MAHLE ENGINE TEST DEPARTMENT
■ Verification of function and component strength
■ Investigations into oil consumption and oil separation
■ Examination of carbon deposits and formation of various residues
■ Investigation of cooling and temperature distribution at components
■ Optimisation of acoustic and vibration characteristics
■ Optimisation of fluid mechanical systems
■ Minimization of friction losses and component wear
■ Examination of combustion effects and exhaust emissions
■ Dialogue with the engine or vehicle manufacturers and, if necessary,
quick and uncomplicated support in the event of unexpected
technical challenges – inclusive of measurements for the analysis
of causes and preparation of possible solutions
Acoustic analysis in the anechoic chamber.
NEW ON THE MARKET
Hydraulic spin-on filters HC 97 for
wheeled loaders and compressors
from Atlas Copco and Demag.
Part no. 70323665 (MAHLE)
or 70323663 (Knecht).
The hydraulic spin-on filter HC 97 is used in wheeled loaders and compressors
of Atlas Copco and Demag. As the hydraulic systems works with pressures
up to 40 bar, the HC 97 is designed with thicker walls and a more
stable end plate.
VALVES FOR MERCEDES-BENZ DIESEL
These inlet and exhaust valves are used in 3 Mercedes-Benz
engines: the 4-cylinder engine OM 604 (2.0 l), the OM 605 with
5 cylinders and 2.5 l as well as the OM 605 (6 cylinder, 3.0 l). This is
just to let you know in case the diesel powered MB models C 200,
E 250 and E 300 arrive at your door.
Inlet and exhaust valves for
Part no. 001 VE 30926
and 001 VA 30927.
Active carbon cabin air filters LAK 292/S for
Mercedes-Benz S class from model 09/05
upward. Part no. 70325569 (MAHLE)
or 70325568 (Knecht).
ACTIVE CARBON FOR THE S CLASS
Active carbon cabin air filters are designed with 3 layers: an active carbon
layer is sandwiched between two fleece layers. An outstanding example is
the LAK 292/S for the Mercedes-Benz S class from model 09/05 upward in
The fuel spin-on filter KC
200 is a filter with water
separation which gets fitted
with a screw-on sight glass
at its lower opening. It is
used in 6 Mercedes-Benz
models: in the Tourismo,
Tourino, Travego, Axor,
Actros and Unimog.
Fuel spin-on filters KC 200 for
Mercedes-Benz Tourismo, Tourino,
Travego, Axor, Actros and Unimog.
Part no. 76832430 (MAHLE)
or 76878730 (Knecht).
Ring set for MAN D 2876,
R6 (460–530 hp).
Part no. 229 05 N0.
MAN: HEAVY LOAD SERVICE
TG 460, 50.464 and F 2000 are only 3 of the well-known MAN models that
carry out their heavy load services on roads all over the world. The pistons in
the engines of the MAN series D 2876 are supported by 6 times 3 piston rings
to produce their 343–395 kW (460–530 hp) from 12.8 l displacement. The ring
set, which is now available on the market, consists of one 4 mm high keystone
ring with chromium/ceramic coating, a 3 mm taper-face ring and a 4 mm thick
coil-supported bevelled-edge oil ring – both chromium plated.
For the Mercedes-Benz SLK from the 06/04 model upward, a
special design of the active carbon cabin air filter is available: the
LAK 246 consists of 2 interconnected filter elements that can be
folded up to ease fitting.
Active carbon cabin air filters LAK 246 for
Mercedes-Benz SLK from model 06/04
upward. Part no. 76887111 (MAHLE)
or 76887103 (Knecht).
GERMAN ITALIAN FRIENDSHIP
Opel and Fiat have jointly developed the two 4-cylinder diesel
engines Z 1.3 DT and M 733 AT 12 Z with turbocharging, intercooling,
16 valves and 51–56 kW (69–75 hp). Since 2003 they are
used in the Fiat Doblo, Idea, Panda, Punto and Gingo. For Opel
they power the models Agila, Corsa, Combo, Tigra and Meriva.
In addition, they are used in the Subaru Justy, the Suzuki Ignis
and the Vauxhall Meriva. The matching valves are available from
the MAHLE range for professional repairs.
Valves for Opel Z 1.3 DT and
Fiat M 733 AT 12 Z, R4 (69–75 hp).
Part no. 011 VE 31042 and 011 VA 31043.
Cabin air filters with active carbon elements
LAK 295/S for Mercedes-Benz R class
for the 01/06 models upward.
Part no. 70325629 (MAHLE)
or 70325628 (Knecht).
TAKE A DEEP BREATH …
Thanks to the MAHLE cabin air filters with active carbon elements, the
7 passengers in the Mercedes-Benz R class are protected from dust,
exhaust fumes, high ozone concentrations and unpleasant smells. Available
now: the LAK 295/S for the 01/06 models upward.
MAN AND VW:
The engines D 0824 and
D 0826 of the medium
sized MAN series produce
between 76 and 154 kW –
and they are used in the
MAN 7.153 and 24.232 as
well as in various VW
models. The valves in
original equipment quality
are now available on the
Inlet and exhaust valves for MAN engines.
Part no. 227 VE 31032 and 227 VA 31033.
The engine OM 611 is used in
the Mercedes-Benz C, E and
V class of the 1998 to 2003
models – in three different
versions (960, 961 and 980).
The matching pistons for this
diesel four-cylinder in-line
engine with 2.2 l displacement
have a lot to offer: an
ingenious combustion cavity
topography, ring carriers,
cooling channels, spray jet
cooling and a suitable ring
set. The repair range of 1 mm
is covered very adequately
by the standard piston and 3
Cabin air filters
with and without
active carbon elements
for Alfa Romeo 159 and Brera
(from 09/05 models upward):
LA 297, Part no. 70327616
(MAHLE) or 70327606 (Knecht)
and LAK 297, Part no. 70327634
(MAHLE) or 70327632 (Knecht).
Kolben für Opel
Omega Pistons V6-2,6 for Mercedes-Benz l
OM 611, R4
(82–143 hp). Part no. 001 36.
NEW ON THE MARKET
Inline fuel filters
KL 473 for BMW X5 3.0 l D.
Part no. 76832968 (MAHLE) or
Unspoiled driving pleasure in any situation – with the MAHLE
inline fuel filters. Now available: the KL 473 for the 3.0 l diesel
engine of the BMW X5.
Cabin air filters with and without active
carbon elements clean the air, ease the
load on the blower, protect the heating
and air conditioning and prevent misting
up of the windows. This is also true for
the Alfa Romeo 159 and the Brera: LAK
297 and LA 297 are now available for the
09/05 models upward.
PISTONS & CO.
VALVE PRODUCTION: IT IS THE MATERIAL THAT MATTERS.
Valves have to perform in harsh conditions: under heat, high pressure, friction – and sometimes without sufficient lubrication. Of course, they are
expected to work as long and reliably as possible. At the same time, they are supposed to get lighter with every new engine generation. In short:
valves have a tough job. The challenges for the designers are accordingly huge. High-tech materials offer convincing solutions … and design ideas.
The individual components of the valve train system are subject to different
influences. The valves have to endure the highest mechanical, thermal and
resulting tribological stresses in this system. And as moving masses they
affect directly the mechanical loads in the valve train and the friction losses.
THE BASIS OF VALVE PRODUCTION: METAL ALLOYS
Depending where valves are used (at the inlet or exhaust side, in turbocharged
or naturally aspirated engines) they are made from different materials. The
standard material is a chromium silicon alloy (X 45 Cr Si 9-3). For the highly
stressed exhaust valves, the MAHLE developed nickel super alloy Nimonic
80A © is used, which also sets new standards in terms of malleability, weldability
and temperature resistance.
The micrograph of the MAHLE developed
super alloy Nimonic 80A © for highly
stressed exhaust valves.
MAHLE valve seat with armouring.
MONO, BI OR HOLLOW?
Different loads require different valve characteristics – and therefore different
The mono-metal valves consist of only one material or alloy, mainly the above
mentioned chromium silicon alloy or the nickel super alloy.
Bimetal valves are made from two different steel types as the name implies.
The shaft of the valve is connected to the valve head by friction welding.
The head is made from highly alloyed and high-temperature resistant steel,
while the shaft is made from a different alloy steel that can be hardened.
The friction welding joint connects the valve shaft with the valve head.
An innovative design is the hollow valve with optimum cooling characteristics:
the valve cavity is partly filled with sodium, which becomes liquid at 97.5 °C,
and then dissipates the heat better from the hot head to the shaft.
The hollow valve: temperature control thanks to the sodium filling.
WELL PROTECTED WITH STELLITE
In order to cope with extreme stresses such as high temperatures and
chemical corrosion, highly stressed valves are “armoured” with an additional
stellite layer. This layer based on cobalt and chromium is first welded on and
The valve head – prepared for stellite facing ... and with stellite layer welded on.
The different production stages of a bimetal valve.
THE FUTURE OF VALVE DESIGN: LIGHTER AND LIGHTER?
The future of engine components production is characterized by further weight
reductions. Valves offer here a great potential: if the mass of valves is reduced,
the components driving them such as camshaft & co. can also be designed significantly
lighter. With conventional valve steels the intended weight optimisation
is limited by the demands for component strength. New materials with very
favourable ratios between strength and density are still in the trial stage. As
trendsetter in engine component development, MAHLE follows an alternative
and innovative design approach: the MAHLE lightweight valves. To make these
valves, different moulded and formed metal parts and a solid valve shaft end are
joined together using precision laser and friction welding technology.
A HOT TOPIC: A LOOK AT VALVE PRODUCTION
1. A spherical thickening is produced by means of electrical upsetting 2. The valve shaft and
the valve head are joined together by means of friction welding. 3. The valve is heated inductively
and then quenched to harden. 4. Laser labelling of a MAHLE valve.
PISTONS & CO.
FILTERS – THE PURE TRUTH
IT’S ALL RIGHT UNTIL YOU TAKE THE
A bonanza for counterfeit products. More and more dubious companies copy high-quality products of renowned brands down to the packaging
– in the hope, to make easy money by illegally using good names and bad materials. As top-brands, MAHLE Filter and Knecht are not immune
Counterfeiting of automotive components is not a harmless crime but a real danger: the examples shown here are not only damaging to the reputation
of the copied brands but also to the engine – and therefore to everyone in the supply chain who sells or is fitting such components. However, the counterfeits
are not easily recognised – from the outside, the illegal copy is often inconspicuous. This is why our experts have looked inside of two rather impudent
THE OIL FILTER: THE COUNTERFEIT IS NOT OPERATIONAL
TESTED AND NOT PASSED
The filter, allegedly an OC 257, which a retailer sent to MAHLE Aftermarket
for investigation, did initially not look conspicuous. After a simple scratch
test at the printed label matters
became more doubtful: the paint
could easily be removed with the
MISSING CORRUGATION: CAUSE FOR LEAKAGE
After opening the filter, a look at the end plate: in the counterfeit the second
corrugation is missing. In the original, it serves to reinforce the cover plate
to prevent distortion under load which causes the sealing ring to loose its
The end plate from the outside:
At the left, the original with abrasionresistant
printing. At the right, the
counterfeit, where the printing could
be removed with the fingernail.
But internally the counterfeit lacks the
FILTER ELEMENT: SHORT AND BAD
Now the actual filter element: this is 10 mm shorter than in the original. This
results in about 9 % less filter surface – and therefore less filter performance
and reduced dirt pick-up. Furthermore, the element has only 60 pleats instead
of 80! The lower number of pleats alone leads to a reduction in filter surface
by 25 %. This means that together with the 9 %, the dirt pick-up is reduced
by 34 % and the service life is reduced by 34 %.
Also the irregular pleat geometry is noticeable: sections of the filter paper are
folded very tightly – just short of block forming. However, in other areas the
distances are much too wide. Furthermore, the adhesive bond is missing at
some areas between pleat star and metal plate, with the disastrous result that
oil is here flowing directly from the dirty side to the clean side!
At the left, the original, right the counterfeit: a shorter filter element and irregular pleating.
In detail: the pleating is inadequate – and partly not glued on properly.
ANTI-DRAIN VALVE: NOT SO CLEVER
A particularly critical part is the seal between the dirty and clean side in the area
of the anti-drain valve. In filters of the brands MAHLE and Knecht, the filter
element is distinguished by a clean radius that, in connection with a precision
moulded rubber part, serves as a perfect anti-drain valve. However, in the
counterfeit filter, a sharp metal edge can be seen and the oil is flowing directly
pass its sharp, cracked edge – without filtration – from the dirty side to the
The original: a precision seal. At the right, the counterfeit with sharp, leaky metal
edge through which the unfiltered oil can flow.
BREAKDOWN AT THE BYPASS
The bypass valve of the counterfeit oil filter concludes its disqualification.
This important part has the task to ensure the oil supply of the engine under all
conditions – for instance, also when an element is completely blocked or at
extremely low temperatures (resulting in highly viscous oil). In the counterfeit, this
valve is completely non-operative: the spring tension is so low that it stays open
even under normal operation … and the oil flows permanently to the engine
without filtering. This means that the copied oil filter cannot do its job – with the
result that the engine will be damaged in a relatively short period of time.
THE FUEL FILTER COPY: NO FILTRATION
FILTERS – THE PURE TRUTH
In the original, the anti drain valve
is made with a precision moulded
rubber part. At the right, however, the
counterfeit with a simple, punched
out rubber disk that does not fit
tightly to the sealing surface. The result:
depending on the fitting orientation
(filter fitted horizontally or on its
head), the filter can drain entirely
after the engine is stopped – and it
has to be filled again completely at the next start of the engine. Until this happens, the
engine is not supplied with the necessary oil (pressure). In the long run, this will lead to
increased wear at the different lubrication points in the engine such as crankshaft bearing,
camshafts or cylinders.
The MAHLE bypass valve (left) – and the non-operative counterpart in the counterfeit
PLASTIC INSTEAD OF ALUMINIUM
The counterfeit KL 72 arrived at MAHLE Aftermarket in a rather impudent form:
in old Knecht packaging that was obviously a fake. When opened, it became
quickly clear that it had to be a counterfeit: while the fuel filter is normally made
from aluminium, the cheap imitation was made from plastic. Furthermore, it
had the wrong designation: instead of the German word “Kraftstofffilter” it read
We make the KL 72 from aluminium. The counterfeiters are content with plastic – and
spelling mistakes on the housing (see picture).
NOT TIGHT AT ALL
The filter element was inconspicuous at first sight but showed a significant
flaw: the sharp edge is completely unsuitable for sealing the dirty side from the
clean side – a radius is required here.
Also the difference in size between
the hole in the filter element and its
counterpart is so large that no seal
can be expected: the fuel flows
unfiltered from the dirty side to the
The required radius has been
replaced with a sharp edge.
The result: leakage.
CUSTOMER CARE IS KEY
INTERVIEW WITH FARUK BILGINOGLU, MANAGING DIRECTOR OF ROTAS/GÜZEL, ISTANBUL
ROTAS Oto and GÜZEL Oto are the leading
companies in the supply of components for
import vehicles on the Turkish market. The
companies, which are still family run, were
founded in Istanbul in 1927. They are part of the
ROTAS Group of companies, which is also active
in the insurance and banking business. However,
the companies have their key interests in the
spare part business.
MAHLE Aftermarket news: Mr. Bilginoglu, with
ROTAS Oto and GÜZEL Oto, the ROTAS Group takes
a leading position in the Turkish motor vehicle aftermarket.
In what areas have the two companies become
Faruk Bilginoglu: GÜZEL Oto imports the automotive
spare parts – the company is based in the free trade
area in Istanbul/Catalca. ROTAS Oto is based in Istanbul/Topkapi
and distributes as wholesaler the range of
GÜZEL Oto, which comprises products of leading
manufacturers such as MAHLE, LuK, Bilstein or Contitech.
The two companies employ a total of 88 employees and
have a storage area of just under 5,000 m 2 in the free
trade area and just under 4,000 m 2 in Topkapi.
MAHLE Aftermarket news: There are two other
companies that are active in the spare part business that
belong also to the ROTAS Group.
Faruk Bilginoglu: Yes. First there is Bilgin Oto, our
retail trade branch and then there is Bilgin Otomotiv, the
authorized SEAT dealer.
MAHLE Aftermarket news: This means that the ROTAS
Group is represented at every trade level. What role does
MAHLE play with its brands MAHLE Original and Knecht?
Faruk Bilginoglu: The cooperation with MAHLE began
1950. Until 1980, ROTAS and MAHLE were the market leaders
for engine parts, but later the business was no longer
profitable due to the Turkish customs regulations. However,
we have resumed the cooperation with MAHLE in 2002. This
time, the focus is on the filter business. And this has been the
right decision. The brand Knecht has been a great success:
Knecht filters are now our best-selling products.
From the water pipe party to the cultural trip: customer
care is rated very highly in the ROTAS Group.
MAHLE Aftermarket news: Success – a good cue. How do
you secure your success also in future?
Faruk Bilginoglu: We have been in business long enough
to know that one is no longer competitive these days without
good service. Important is here the prompt availability of goods.
12 logistics centres and concessionaires ensure that the parts
are at the customers within 2 hours in 95 % of cases. However,
customer care and the building of personal relationships is nearly
as important in a country characterised by hospitality such as
MAHLE Aftermarket news: And what does this customer
care involve in practice?
Faruk Bilginoglu: For example, we organize cultural trips
for our customers at home and abroad, seminars and guided
tours of the company. In addition, we organize events such as
barbecues, water pipe parties or also backgammon competitions.
Sometimes, we also invite our suppliers to join, in order to
strengthen our good relationships throughout all levels of trade.
Of course we are also involved in conventional marketing such
as advertisements in print media or participation in trade fairs.
And we are active in cultural and sport sponsoring. Extremely
important are also our ca. 50 sales people who look after workshops
in the whole of Turkey – and are always receptive to suggestions
and criticism. This allows us to be best prepared for
the demands of the market and to offer that certain extra in performance.
I belief, it is simply the sum of the individual measures
that is decisive in long-term customer relationship management.
MAHLE Aftermarket news: Do you have plans in respect
of your market position?
Faruk Bilginoglu: Well, the spare parts business will also
in future remain the main business of the ROTAS Group. In order
to expand further in this area, we are planning to create a chain
of workshops. We also want to extent our product range further
– with high-quality products, of course. MAHLE Original and
Knecht are certain to play an important role in this development.
MAHLE Aftermarket news: Of course, we are pleased to
hear this. Mr. Bilginoglu, thank you for the interesting conversation
– and we wish you continuous success for the ROTAS
THIS BULL LEAVES
A large PistenBully weighs in with more than 9 tons – and it is powered
by a 430 hp diesel engine that allows it to prepare snow and ice masses
for the winter sport even on extreme slopes, difficult terrain and in
inhospitable weather conditions.
PistenBullys prepare ski slopes, lift and cross-country trails. As ski taxis they
make even the remotest regions accessible – as for instance in the Japanese
skiing area Gala near Tokyo. They maintain the right surface on the icy vehicle
test track in Greenland. They clear mountain passes from ice and snow. And
even if there is no mountain in sight, PistenBullys are working without fail – as
for instance in the Alpincenter Bottrop, which has the world’s longest skiing
hall, measuring 640 m.
This flexible, robust and extremely capable powerhouse is the speciality of the
Kässbohrer Geländefahrzeug AG. With a market share of more than 50 %, the
company is a world leader in trail and ski slope preparation as well as fun park
Their product range reaches from agile 3.6 ton vehicles to the heavy crawlertype
version for extreme conditions weighing 9 tons (without superstructures
and special accessory!). A wide range of special equipment makes them
extremely versatile: for instance, the winches that can be rotated by 360° also
on steep slopes. Or the SnowCutter that can, in one pass, break up icy
sections of ski slopes, crush the lumps and use them to prepare a usable skiing
surface with its rear tiller.
With the models PistenBully 100, 200 and 300, Kässbohrer covers an enormous
range of applications. They are all powered by low emission Mercedes-
Benz engines. In the smallest version, the PistenBully 100, a 177 hp diesel
engine with 4,250 cm 3 displacement is fitted. This engine already develops its full
torque of 675 Nm close to its start-up speed. The PistenBully 200 is equipped
with a 330 hp engine with 7.2 l displacement that develops a torque of 1,300
Nm at 1,200–1,600 rpm. Even under extreme conditions, the PistenBully 300
gets plenty of power from a 430 hp engine with 12 l displacement and a torque
of 2,000 Nm at 1,200 rpm. Also on board of this Kässbohrer vehicle range is
MAHLE technology with pistons, bearings, connecting rods, bucket tappets,
valve guides, valve seat inserts, oil filters, air filters and fuel filters.
PistenBullys are practically indestructible: even after 15 years, many of them
are still working reliably. Naturally, during such long service life, some parts will
have to be replaced. Of course, also in this case MAHLE is a reliable partner
for the local workshops – with engine components and filters in original equipment
Whether in snow covered Scandinavia, in the vast expanse of Canada, on Japans
peaks, in icy Greenland, in the snowy Alps … or in the industrial Ruhr area of Germany:
PistenBullys are used worldwide also under extreme conditions – with MAHLE engine
components and filters.
Intelligence on a disk: the MAHLE Filter CD-ROM
provides all functions of the online catalogue –
in addition, it offers an integrated update request option.
QUICKLY AND UP-TO-DATE TO THE CORRECT FILTER – WITH THE MAHLE FILTER DATABANK.
MAHLE FILTER CATALOGUES: ALSO AVAILABLE ON THE
INTERNET OR CD-ROM
Are you looking for the best suitable air, oil, fuel or cabin air filter? Then we
recommend a brief visit to www.mahle-aftermarket.com – and then just click
on “filter online catalog” With the convenient search function the required filter
MAHLE Aftermarket news 1/2007
EDITING MAHLE Aftermarket news
MAHLE Aftermarket GmbH
70376 Stuttgart - Germany
RESPONSIBLE FOR THE CONTENTS: Arnd Franz
EDITORS: Andrea Arnold, Yves Canaple, Christoph Dutschke, Paul
Grosvenor, Andreas Kimmerle, Hans-Ulrich Melchert, Peter Riedmayer,
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: 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.
Printed in Germany.RR.02/07
can be found in seconds by entering a choice of different search criteria: the
name, the eight figure identification number, the OE part number, the competitor
number, the vehicle or the actual engine. Also a search for key numbers
is available. And as an extra, an overview of the current new additions can be
accessed. The operation is intuitive and self-explanatory – therefore our tip:
just try it out, straight away!
THE NEW MAHLE FILTER CD-ROM WITH AUTOMATIC
All information available in the online databank is also available on CD-ROM.
To make sure that laptops and other computers without Internet connection
can be as up-to-date as possible, the new MAHLE Filter CD-ROM has been
provided with an update option. When the data files have been transferred
from the CD-ROM to the hard disk, the user can check with one click at the
next Internet session if a newer version of the catalogue is available in the
meantime – and can get an update immediately. It has never before been that
easy to get up-to-date, don’t you agree?
AS EVER AVAILABLE: THE PRINTED CATALOGUE.
No computer in the vicinity? Then the printed MAHLE Filter and Knecht catalogues
can help you out – with clear structure and all relevant information. In
the passenger car sector they are up-dated annually and in the commercial
vehicle sector every two years.