14599_MAHLE_News_1_07_GB RZ

mahle.com

14599_MAHLE_News_1_07_GB RZ

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ALLEMAGNE

“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

OVERVIEW

2 EDITORIAL

Arnd Franz, General Manager

MAHLE Aftermarket

3 INDUSTRY NEWS

Brand theft – product piracy on

the increase

4 MAHLE INSIDE

Power ex works: recent vehicles

with MAHLE products

6 MOTORSPORT

Formula Student – our way of

encouraging new engineering

recruits

7 HIGHLIGHTS

A thorough health check: a

look at the MAHLE engine

test department

8 NEW ON THE MARKET

Engine components and filters

news

A F T E R M A R K E T

MAGAZINE FOR TRADE, WORKSHOP AND ENGINE REPAIR

“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

designs

12 FILTERS –

THE PURE TRUTH

This is how you recognise a

counterfeit filter

14 CUSTOMER PORTRAIT

Interview with Faruk Bilginoglu,

ROTAS/GÜZEL, Istanbul

1/2007

BEWARE OF

COUNTERFEITS!

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

16 MARKET

Quick access to the right filter –

online and offline

www.mahle-aftermarket.com


EDITORIAL

Arnd Franz,

General Manager

MAHLE Aftermarket.

Dear readers

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.

AFTERMARKET

news 2

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

technology.

■ 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

piracy.

■ 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: counterfeit@mahle.com. All information will be treated as

confidential.

And now – please enjoy reading our new MAHLE Aftermarket news!

Arnd Franz


PIRATE GLOSSARY

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

manufacturer.

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.

BRAND THEFT

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.

INDUSTRY NEWS

AFTERMARKET

news 3


© ams / MPI

MAHLE INSIDE

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.

AFTERMARKET

news 4

Power

In focus: Citroën C4 Picasso.

E X W O R K S


MAHLE INSIDE

1 2

3 4

5

6

© 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

modules.

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.

AFTERMARKET

news 5

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 •

7


MOTORSPORT

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.

AFTERMARKET

news 6

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 USA.

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

VERDICT

TECHNICAL COMPONENTS

■ Reliability also on long

distances

■ Safety

■ Acceleration

■ Braking power

■ Handling (for an amateur racer)

■ Fuel consumption

■ Aesthetics and comfort

■ Use of conventional series-produced

components

■ Ease of repair

ECONOMIC COMPONENTS

■ 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


A THOROUGH

HEALTH CHECK

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

attention.

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

AFTERMARKET

news 7

HIGHLIGHTS

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).

PRESSURE-RESISTANT

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

Mercedes-Benz engines.

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

double pack.

AFTERMARKET

news 8

SHOW TIME

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.

WELL DESIGNED

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:

VALVES

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

market.

Inlet and exhaust valves for MAN engines.

Part no. 227 VE 31032 and 227 VA 31033.

MULTI-TALENT AT

MERCEDES-BENZ

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

oversize pistons.

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

76832950 (Knecht).

OFF-ROAD PERFORMANCE

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.

ARIA BUONA!

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.

AFTERMARKET

news 9


PISTONS & CO.

MATERIAL

FACTS

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.

AFTERMARKET

news 10


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

designs.

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

later machined.

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 2

3 4

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.

AFTERMARKET

news 11


FILTERS – THE PURE TRUTH

COUNTERFEIT FILTERS:

IT’S ALL RIGHT UNTIL YOU TAKE THE

WRAPPINGS OFF

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

to counterfeiting.

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

counterfeits.

AFTERMARKET

news 12


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

fingernail.

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

sealing ability.

The end plate from the outside:

undistinguishable.

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

reinforcement corrugation.

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

clean side.

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

filter (right).

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

“Krarislofffilter”.

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

clean side.

The required radius has been

replaced with a sharp edge.

The result: leakage.

AFTERMARKET

news 13


CUSTOMER PORTRAIT

AFTERMARKET

news 14

“THE RIGHT

CUSTOMER CARE IS KEY

TO SUCCESS”

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

specialised?

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

Turkey.

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

Group.


THIS BULL LEAVES

ITS TRACKS

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

design.

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

quality.

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.

ON LOCATION

AFTERMARKET

news 15


MARKET

IMPRINT

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.

up2date?

Are you

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

Pragstraße 26–46

70376 Stuttgart - Germany

www.mahle-aftermarket.com

RESPONSIBLE FOR THE CONTENTS: Arnd Franz

EDITORS: Andrea Arnold, Yves Canaple, Christoph Dutschke, Paul

Grosvenor, Andreas Kimmerle, Hans-Ulrich Melchert, Peter Riedmayer,

Holger Roden

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.

AFTERMARKET

news 16

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

UPDATE FUNCTION

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.

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