PDF - MAHLE Aftermarket

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Paid
Toledo, Oh
permit no. 333
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Magazine for trade, workshop and engine repair
For a seed in a garden, successful growth involves many
factors. Fertile soil, exposure to sunlight, and plenty of water
are requirements for that seed to grow, blossom, and bear
fruit. Likewise, succeeding in aftermarket replacement parts
necessitates similar care, and the help of many more outside
factors. As players in the Automotive Aftermarket, MAHLE
customers already provide the care they need to make their
success grow – but they must lean on suppliers to offer the
soil, sunlight, and water as in the case of the seed. MAHLE
takes this role very seriously as proven in the latest edition
of the MAHLE Aftermarket news. Valuable brands, cutting
edge technology in products and services, as well as
dynamic eCapabilities highlight an array of factors designed
to help our customers achieve success. This edition delves
into some of the many factors MAHLE uses to succeed – as
well as ensure success for customers like BWP Distributors
(featured in the “Customer Portrait” on page 14). Enjoy this
edition and watch your mailbox in a couple months as the
next one is coming your way soon…
www.mahleclevite.com
prsrt std
u.s. postage
1/2008
Looking toward the future
success &
growth
is The plan!
More on page 2
Overview
2 Editorial
Arnd Franz, General Manager
MAHLE Aftermarket
3 clevite history
How the Clevite name came
about
4 highlights
An inside look at
MAHLE Clevite
6 motorsports
12 Events
8 featured products
14Customer portrait
10 pistons
15 On location
MAHLE Clevite news from the
tracks
Exciting MAHLE Clevite
products in the marketplace
These distinctive pistons require
special research & development
MAHLE Clevite shows it‘s
presence
BWP Distributors in the
spotlight
Now part of the MAHLE group:
Mopisan
16 ecapabilities
Improve your engine parts
knowledge with eLearning™
editorial
the mahle group achieves
worldwide growth!
(now MAHLE Mopisan) in Turkey at the beginning of this year. Meanwhile, all
these enterprises have become part of the worldwide MAHLE network and
have made significant contributions to the further development of our product
range for the independent spare part market.
This large number of activities demonstrates clearly that MAHLE opts for
growth in the replacement part business. Together with our partners in the
trade, we endeavor to further develop our product program according to the
demands of the market, to assure optimum availability and to offer you a priceperformance ratio that reflects both the original equipment quality of our products and the demands of the market.
Arnd Franz,
Director and General Manager
for the MAHLE Aftermarket Group
Dear readers,
MAHLE is programmed for growth. With products and services for all aspects
of the combustion engine, our company achieved last year a worldwide sales
revenue of 6.5 million dollars (5 billion Euro), which is 17% more than in the
preceding year. Important acquisitions such as that of the engine components
business of Dana and the takeover of the air filter division of Siemens VDO
have been crucial in this development, but so has the healthy organic growth
of our established sites.
Our independent replacement part business has also developed positively
compared with the previous year and has increased by 32% to more
than 800 million dollars (600 million Euro) in 2007. Acquisitions play also a
significant role in the aftermarket in rounding off our product range and our
sales channels. In addition to the acquisition of the Dana engine components
business, other important projects have been the acquisitions of Promec (now
MAHLE Componentes de Motores de México S. de R.L. de C.V.), the leading
piston ring and cylinder liner supplier in Mexico, the takeover of the valve
manufacturer Edival (now MAHLE Válvulas de Argentina S.A.) in Argentina and
Tri-Ring (now MAHLE Tri-Ring Valve Train (Hubei) Co., Ltd.) in China as well as
the majority acquisition of the piston and cylinder liner manufacturer Mopisan
AFTERMARKET
news
2
On the topic of original equipment quality: MAHLE is firmly committed to its
business policy of supplying the aftermarket according to the specifications
of the vehicle and engine manufacturers. This principle, is not only expressed
verbally, but also tangible in our products. And when we offer special repair
solutions, these will also conform to OE quality.
The leading position of MAHLE in the original equipment sector is not only
demonstrated in our worldwide presence at all important vehicle and engine
manufacturers, but also in the innovative strength of MAHLE. At the recent
IAA in Frankfurt alone, MAHLE has presented 17 innovations that will contribute to making the combustion engine fit for the future. Essential factors here
are emission and consumption reduction. You can find more about innovative
MAHLE products at www.mahle.com.
We use this technological advantage also to the benefit of our customers in the
aftermarket. Especially for recent engines, the complexity of components is increasing, as specific challenges are presented by direct injection systems, for
instance. Due to our experience in original equipment, we are best prepared
to face these challenges. Moreover, MAHLE Aftermarket meets the increasing demand for replacement parts of the independent aftermarket for recent
vehicles thanks to faster product introductions.
We shall be delighted with your success using MAHLE products and assure
you of our support. Please enjoy reading the MAHLE Aftermarket news.
Arnd Franz
clevite
history
category
The history behind the name...
cLEVITE.
Everything you ever wanted to know...
Starting in 1968, the company underwent a number of changes in ownership
as well as corporate name changes. These included Gould Inc, Imperial Clevite,
Clevite Industries, JP Industries, T & N Industries, Dana, and now MAHLE.
A brand dispute caused the creation of the MICHIGAN 77 brand; however,
market research showed CLEVITE to be one of the most frequently recognized
brand names in the automotive and heavy duty marketplaces. Consequently, the dispute was resolved and CLEVITE once again became the brand of
choice.
Have you ever wondered where the name “CLEVITE” came from or how
CLEVITE 77 became a famous brand name? It started in 1910 in Cleveland,
Ohio when an inventor named Ernst Dann developed a material for bearings
consisting of a Bronze strip with Graphite embedded in waffle like indentations
on the inside to make a “Self-Lubricating” bearing. After a failed initial enterprise,
new financing in 1919 enabled Ernst to launch the CLEVELAND GRAPHITE
BRONZE COMPANY (CGB).
In 1929 the first thin wall, steel-backed insert bearings were introduced to the
industry transforming the once laborious task of replacing crankshaft bearings
into a simple operation. Early crankshaft bearings consisted of a steel backing lined with an alloy of lead, tin and antimony called Babbitt after its inventor
Isaac Babbitt. As the demands for a stronger bearing material increased in
trucks and buses, CGB rose to the challenge and created the first strip mill
capable of continuous casting molten bronze onto a steel strip in 1934. This
provided engine manufacturers with the first “Heavy Duty” bearing material.
Today, MAHLE Clevite Inc. supplies a full line of products used in rebuilding both
light vehicle and heavy duty engines. These products are sold domestically, as
well as exported to markets throughout the world. They service such popular
brands as Chrysler, Ford, General Motors, Caterpillar, Cummins, Detroit Diesel
and John Deere along with many others. Clevite® engine bearings dominate
motorsports throughout the world. TriMetal™ bearings are the bearing of
choice in NASCAR, NHRA, Formula 1, and Indy Car as well as “Grass Roots”
racing.
As Clevite has grown so has its ability to serve
the needs of its customers around the
world. The resources of MAHLE afford new opportunities to grow
even further and service its
customers more completely.
By 1941 bearing improvements started to come faster with the development
of the “Micro Babbitt” bearing employing a thinner lining resulting in a 70%
increase in strength. Then in 1944 the first “trimetal” bearing was introduced
as the process for overplating steel-backed, cast copper-lead bearings with
a very thin layer of Babbitt was developed. Further improvement was made
in 1948 when the patented nickel dam or barrier layer was added to prevent
interaction between the copper lead and Babbitt layers. This marked the birth
of what would later become CLEVITE 77 although at that time it was simply
referred to as Finished bearing material 77 or F-77 for short.
In 1952 the Cleveland Graphite Bronze Co. became known as Clevite, formed
from the words CLEVeland and graphITE. Now you know how the name originated.
In the mid-1950’s Clevite licensed Vandervell Products in the UK to make cast
copper-lead bearing material. Although rights to the casting process were covered in the agreement, use of the patented nickel dam was not included. Consequently, Vandervell bearings use a lead-indium overlay material that doesn’t
require a barrier layer. As a result of an acquisition some 35 years later these
two bearing business along with a third, the Glacier Bearing Co, would all
be merged into one. Since the formation of the Glacier Vandervell bearing
manufacturing division in the early 1990’s, the CLEVITE name has been used
exclusively for the North American aftermarket business.
Also during the 1950’s Clevite acquired The Monmouth Products Co, a supplier of service parts to the vehicle repair trade. Originally called “Clevite Service”,
this business is now a significant part of MAHLE Clevite Inc. Bearings sold in
the aftermarket, are stamped with the name CLEVITE and a material identification. It didn’t take long for users to associate the CLEVITE name with superior
performance. Hot Rodders and heavy equipment mechanics began to ask for
bearings with the CLEVITE marking.
AFTERMARKET
news
3
highlights
What’s Exciting with
mahle clevite inc.
MAHLE Acquires Prominent Share of Promec Stock
In second quarter 2007, MAHLE Industries, Inc. entered into a stock purchase
agreement with Grupo Condumex, S.A. de C.V., Mexico, acquiring 51% of the
shares of capital stock of Promotora de Industrias Mecánicas, S.A. de C.V.
(Promec). The acquisition included a total of approximately 1,100 employees,
three manufacturing plants and one aftermarket office in Mexico. The locations include Aguascalientes, Naucalpan, Ramos Arizpe and Santa Catarina,
Mexico.
MAHLE Componentes de Motor de México, S. de R.L. de C.V.
The subsidiary, now called MAHLE Componentes de Motor de México, S. de
R.L. de C.V (MCM), produces cylinder liners and piston rings – delivering to
both OE and Aftermarket customers. Just like the prestigious MAHLE brands
in the United States, Carpro commands the same loyalty in the Aftermarket
throughout Mexico. MCM supplies parts on the OE side to companies in
Mexico such as: Chrysler, General Motors, John Deere - plus authorized OE
rebuilder, Vege. On the aftermarket side MCM supplies parts to companies
such as: Exclusivas Sanchez, Grupo Autotodo, Grupo Rogelio, Mayoreo de
Autopartes and Grupo Morsa.
the specific catalog right for you
MAHLE Clevite has released three more manufacturer specific catalogs, bringing the total number of catalogs to five. These include AGCO, Detroit Diesel/
Mercedes, John Deere, Navistar, and Mack/Volvo. Cummins, Caterpillar and
several others are in development and will be available later in 2008.
These catalogs contain everything offered by MAHLE Clevite Inc. for the particular manufacturer in the respective book allowing for ease of use, a more
customized layout, and a more targeted distribution capability to specialized
customers. In the end, a John Deere specialist is not forced to use a massive
catalog with dozens of different manufacturers.
MAHLE Clevite takes pride in cataloging that goes way beyond what the competition offers. In each catalog you will find interchanges, specifications, technical information and a new feature - engine kits. We also include a complete
listing of non-engine specific items such as freeze plugs and universal repair
sleeves in every book.
MAHLE Clevite Canada Completes the Acquisition of
Engine Parts One
MAHLE Clevite Canada ULC (MCC) completed the purchase of Canadian
Engine Parts 1 Inc. on November 15, 2007. Engine Parts 1 served the
Canadian engine parts market with five warehouses across the country.
This important acquisition establishes MCC as the only nationwide engine
parts specialist warehouse operation in Canada. It allows the positioning of the
complete line of MCC products in key strategic locations so that an optimum
service level can be provided to the Canadian Market with same or next day
delivery.
The number one goal of the organization is superior customer service. MCC
is uniquely positioned with highly trained engine parts specialists offering the
customer base product and technical expertise. These specialists provide a
competitive advantage, ensuring the right parts are shipped the first time –
every time.
This acquisition was critical for MAHLE Clevite to achieve a larger share of the
Canadian engine parts market. New products are continuously added with a
focus on servicing the light vehicle and heavy duty engine parts aftermarket.
This structure also caters to the performance enthusiast, the machine shop
and the Warehouse Distributors’ needs.
This initiative assures Canadian customers a secure source for MAHLE
Original, Clevite, Perfect Circle and Victor Reinz products both today - and in
the future. The acquisition of the former Engine Parts 1 enables the delivery
of the industry’s finest brands, combined with the highest level of service and
engine expertise MAHLE Clevite is known for.
AFTERMARKET
news
4
When asked why MAHLE Clevite has gone to manufacturer specific catalogs
Jay Wagner, Coordinator IV – Marketing (Heavy Duty) at MAHLE Clevite, responded, “As we continue to add more parts to our line, the production of a
single Heavy Duty Catalog has become prohibitive based on the sheer size of
the catalog. More importantly, it gives us the ability to update the individual
catalogs more often based on new parts additions and not just an arbitrary
catalog cycle. This means that some manufacturer catalogs may be updated
every year and others may be good for up to five.”
HIGHLIGHTS
“It’s all about the
Data!
”
Providing customers with the cleanest data possible...
It has been championed, ‘its all about the data’, for many years in the
Automotive Aftermarket. The American Heritage Dictionary defines
data as: “Numerical or other information represented in a form suitable
for processing by computer.” In our industry, data no longer means
simple numerical data. The need for ‘other information’ has grown significantly to include things like digital images, features and benefits,
and application information that can easily be incorporated into dynamic web-based tools. Demands for richer, more detailed data with
as little delay as possible have continued to rapidly increase.
MAHLE Clevite Inc. recognized early that it was time to change the way data
was researched, managed and distributed. Years ago we were pioneers, setting up a system to electronically house catalog data. The Automated Data
Management System (ADMS) served us well over the past two decades, but
was beginning to get antiquated based on our customers’ continuously evolving needs.
To replace our system, several factors were considered in making the final decision. First, the Product Information Management (PIM) system should communicate seamlessly with the back-end production systems. The philosophy is
that people who are responsible for the information should only have to worry
about maintaining the data in one location and should be confident that their
changes will be systematically synchronized to all other required systems in a
timely fashion. Second, the creation and distribution of electronic data to customers and other trading partners should occur virtually real-time. The days
of 90-day turnaround times for data delivery are long gone. In this web-based
world, immediate delivery of data for new parts and corrections can easily
translate to thousands of dollars of found revenue.
The software offers the most robust and agile solution to address these and
many other cataloging, pricing and product management needs. It bolts right
on to the back-end system and allows the MAHLE Clevite Product Planning
team to have one interface for managing their lines. It also provides new
functionality right at their fingertips by integrating Polk® registration data and
Technologue™ OE research data into the system. Building electronic data
templates ensures the delivery of data electronically throughout the channel.
Integrated catalog templates make MAHLE Clevite solely responsible for
catalog production. Streamlining the process will increase speed to market
which will provide an increase in sales.
Once fully integrated, the system will deliver data in the most current industry
standard format and have the flexibility to continue delivering data in legacy
and customer-specified formats. This allows the continued high-level of service that customers expect both now and in the future.
The MAHLE Clevite systems have evolved over the years through many mergers and acquisitions resulting in a high level of complexity. The new software
replaces many disparate systems with one well thought out solution. Putting
valuable research data, both OEM and Vehicle Registration, in front of the experts as quickly as possible, allowing them to prioritize new coverage, evaluate
coverage holes, and address errors in a very straightforward, logical manner.
Our Mission is to provide complete and robust data improving every facet of
customer relationships. The ultimate goal is to deliver the right parts the first
time - every time. Project Firebird will accomplish this objective by providing
up to date information and put it into the hands of the technicians. Fewer errors and timely information means more sales for everyone. In the end, it is still
“all about the data”.
With shrinking margins and sales challenges, technology cannot stand in the
way of reaching the market rapidly. Finally, it is imperative that a system must
be agile enough to deliver whatever the customer dictates. Since customer requirements evolve, our system must be capable of evolving to meet customer
needs now and in the future.
AFTERMARKET
news
5
motorsports
category
The MAHLE tradition in motorsports is both expansive and successful. Global
success on the tracks of Formula 1, Rally Car, and LeMans join with North
American success on both circle tracks and straight tracks including NASCAR
and NHRA. MAHLE pistons power many NASCAR teams to victory lane every
year, now with Clevite® engine bearings and Perfect Circle® piston rings – the
portfolio of motorsports achievement is unprecedented. 2008 marks the dawn
of a new era in motorsports – particularly in NASCAR.
The 50th running of the Daytona 500 - February 17, 2008 - marked a historic
occurrence for MAHLE Clevite Inc. When Ryan Newman crossed the Start/
Finish Line after 500 miles at the Daytona International Speedway – he not
only gained the first victory in the Great American Race for Motorsports legend
Roger Penske – he gained the first victory for another Motorsports legend: the
MAHLE brand.
This event was the culmination of months of work behind the scenes at MAHLE
Clevite. Following the acquisition of Clevite Engine Parts, MAHLE Clevite made
the decision to transition to a new identity for its NASCAR participation. The
NASCAR penetration into Canada and Mexico, make this the perfect path to
communicate the MAHLE name across the United States border and around
the world.
nicating to NASCAR teams that the new MAHLE decal still covered everything
they knew about Clevite, and convey to customers that because the Clevite
decal was not there did not mean Clevite disappeared.
A comprehensive publicity program was developed to ensure each goal was
accomplished. The program consisted of two totally different components.
One directed at the NASCAR community, and one aimed solely at our customers.
A package was created for all NASCAR teams in all series and was distributed
in mid-January. The contents of the package included samples of the new
decal, multiple press releases announcing the expansion of the NASCAR contract, a visual representation of the new decal as placed on the race cars, as
well as the continued tie-in to the MAHLE Engine Builder of the Year and Engine Builder of the Race. While we did receive a couple questions from teams
throughout racing, the explanation was very well received and would prove its
worth within a month as virtually every car competing in the Daytona 500 carried the new MAHLE identity – including the winner.
Though the Clevite engine bearings brand is not going away, the familiar blue
decal is. With a family of brands like Perfect Circle piston rings, Victor Reinz®
gaskets, and MAHLE Original® engine parts, the MAHLE identity encompasses
much more than just Clevite engine bearings.
On the aftermarket industry side, a media tour was assembled and press kits
were distributed as part of industry roundtables in different cities around the
country. The press kits contained everything included in the team kits, but
also contained a USB drive with a recorded press conference at Hendrick
Motorsports (now available to view at mahleclevite.com). The sole purpose of
this was to drive home through value-added media that Clevite is now part of
a bigger whole in the engine parts world.
The Clevite decal possessed tremendous brand equity because of the highest
level of participation by NASCAR teams. This presented a challenge to the
MAHLE Clevite Marketing Team on two different levels – the first was commu-
Certainly questions will still be asked and need answered, but in the meantime,
Ryan Newman’s trip to Victory Lane answered a lot of questions – MAHLE
Clevite is still here, and stronger than ever.
the legend
Lives on!
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motorsports
category
The 2008 NHRA season started in Pomona, CA the weekend of February 9th
amid more than the usual amount of pre-season turmoil. The series largest individual sponsor, Evan Knoll of Knoll Gas/Torco Racing Fuel announced in midJanuary, without warning, that he was suspending his sponsorship support
from numerous teams for the 2008 season. At least seven NHRA professional
teams were affected to the tune of $30 million and were left scrambling.
were at 330 mph. One constant that remained the same is the teams’ allegiance to Clevite and Perfect Circle. These parts are the standard for the drag
racing circuit, and are used by all teams; they offer the security in knowing they
will make the full ¼ mile. When dealing with V-8 engines generating over 8,000
horsepower burning a mixture of nitro-methane and ethanol there is no margin
for error.
Knoll attributed this action to serious health problems after suffering a nearfatal car accident in 2004. Knoll and his mother own Knoll Gas, one of the
largest heating oil and propane suppliers in the Eastern United States. Volatility
in those energy markets certainly didn’t make things any easier for Knoll and
his mother as they were faced with many difficult decisions. Evan was, and will
remain, a most enthusiastic supporter of the sport of drag racing.
Other exciting news was the official announcement of a 24th national event for
NHRA in 2008. Motorsports pioneer, Bruton Smith, announced construction
of a drag racing track adjacent to Lowe’s Speedway in Concord, NC. This national event is scheduled for September 2008 and promises to be a huge draw
in the heart of NASCAR country.
Amid all this early-season mayhem, numerous other events occurred. John
Force, 14-time National Champion and NHRA’s most popular icon, was back
in his Castrol Top Fuel Funny Car traveling over 330 mph after a horrific accident in late 2007. NHRA implemented numerous rule changes for 2008 after
a series of accidents in 2007 that left the sport wondering how safe the cars
Over 32 million fans follow NHRA drag racing, making it the #2 motorsport,
trailing only NASCAR in the United States. Typical event attendance is 125,000
per weekend with an additional 1.2 million television viewers.
In the next issue, we’ll look at grass-roots drag racing in the US market.
2007 Showdown Champions, Dennis Borem and Darrell Hoffman of Pro Motor Engines
Engine builders representing the following teams will compete in 2008. Roush
Yates Racing Engines (Ford), RCR/DEI (Chevrolet), Hendrick Motorsports
(Chevrolet), TRD (Toyota), Bill Davis Racing (Toyota), Joey Arrington (Dodge),
Chip Ganassi (Dodge), Penske Racing (Dodge), Gilette Evernham Racing
(Dodge) and the 2007 champions Pro Motor Engines (independent).
The MAHLE Engine Builder Showdown, beginning the first week of May, celebrates its ninth year of competition in 2008. The contest, held in the heart of
NASCAR country, pits teams of two professional engine builders against each
other in a test of both skill and speed – both racing to see who can assemble
and run a NASCAR racing engine in the least amount of time. MAHLE Clevite
expects well over 20 teams – an all-time Showdown record – to start the
competition. The final round on May 20th decides who takes home the Randy
Dorton Memorial Trophy as the 2008 Champions.
A live audience of over 1,500 people, including many MAHLE Clevite customers, witnessed the 2007 finals held at the NASCAR Technical Institute in
Mooresville, NC. In addition to the live audience, national televised shows
aired four times in 2007 on SPIKE TV’s Horsepower TV. Expectations are for
an even larger crowd in 2008.
This will be the last year building on the Ford engine. 2009 will bring a move
to the brand-new R07 Chevrolet supplied by General Motors and Hendrick
Motorsports. Teams elevated the building of the Ford motors to a science,
evidenced by winning times in the 16-minute range. The Chevy racing engine
promises to be a bit more complicated to assemble. MAHLE Clevite experts
estimate the winning time wil be in the 20 – 25 minute range.
Associate sponsors of the popular contest are true giants in motorsports;
including COMP Cams, CALICO Coatings, HM Elliott Coatings, Jesel cam
drives/valve train, Kimberly Clark, Castrol Oil, Snap-On Tools, ARP Fasteners,
Auto Meter Gauges, MSD Ignition, Carrillo Industries and CV Products.
Visit www.mahleclevite.com for the latest Showdown information, brackets
and results as they happen.
AFTERMARKET
news
7
featured products
Dodge sprinter
MAHLE Clevite has proudly released both in-frame and overhaul engine kits for
the popular Mercedes-Benz® 2.7 Liter OM612DE engine used in the Sprinter.
The 8 new kits address the specific requirements of tapered or straight connecting rods and a reduced compression height feature that ensure the proper
compression ratio is maintained when the engine requires oversized pistons.
Part No.
286090 &
286150
Part No.
486-1000
to 1003, &
486-5000 to
5003
dodge truck 5.9L cummins 24v 6 cyl. Turbo diesel
All MAHLE Original® pistons feature computer-designed, high-strength
piston castings, CNC machining accuracy, automated and inspector
verified quality control, and outstanding piston to piston weight and
size consistency. Available for 1999 - 2002 VIN 6 and VIN 7 Dodge
Trucks in STD., 0.50, 1.00 mm
KL149 Fuel Filter
/ regulator
The KL149 is a high performance fuel filter with
built-in pressure regulator used in many BMW
3 Series automobiles
in the USA. As a result
of continuous research
and development in
fuel filter modular design and media efficiency, using MAHLE Filter
high efficiency fuel filters like the KL149 will
help maintain maximum
engine performance, a
trouble-free fuel system
and prolong engine life.
Available for specific
models of BMW 325Ci
2.5L, 325Xi 2.5L, 330Ci
3.0L and the BMW Z3
from 2001.
Tractor-pulling bearings
Tractor-pulling runs engines at 4,500 rpm, and puts out 3,500 lbs. worth of
torque. Clevite introduced H-Series bearings for the IHC and John Deere
466 CID 6 cylinder. These H-Series tractor-pulling bearings use the same
technology as the light vehicle engines and are geared towards the more
intense performance these engines generate.
U-Flex™ oil ring
Perfect Circle, the world leader in piston ring technology, provides
professional motorsports one piece U-Flex oil rings that offer many
advancements over its three-piece predecessor. Constructed from
lightweight spring steel and featuring fewer moving parts on the
piston, U-Flex one piece oil control rings lower oil consumption,
lower friction, increase horsepower and offer significant improvements in oil ring technology over traditional three piece oil rings.
Part No. MS16340 & MIS16340
GM Gen III & IV V8 Intake Manifold Gaskets
Upon GM’s recommendation of utilizing a newer designed replacement gasket for the engine, Victor Reinz developed a fluoroelastomer (FKM) rubber.
FKM, also known as Viton®, can resist oils, solvents, gasoline, and E85 fuels;
much better than silicone rubber. Victor Reinz “Application Engineered” this
gasket for the Gen III and IV intakes to incorporate FKM sealing beads, making the latest OE technology available in the aftermarket. Available for GM
Truck 294 (4.8L), 325 (5.3L), 365 (6.0L) for 1999-2006.
AFTERMARKET
news
8
featured products
You can find detailed information about the entire mahle clevite family
of p r oducts at th e follo w i ng w e b s i t e :
w w w . mahle c le v i te . c o m
Honda 2157cc (2.2L) H22A1 VTEC
DOHC 4 cyl (1993 – 1996)
2157cc (2.2L) H22A4
VTEC DOHC 4 cyl (1997 – 2001)
OX345D Oil Filter – the new fleece media
honda 2157cc
The hottest-selling high performance import bearing. These are offered in H-series as
well as K-Series (TriArmor™). H-series bearings have a medium level of eccentricity, high
crush, a hardened steel back, thin overlay, and are made without flash-plating for better
seating. TriArmor bearings offer the strength and durability of the legendary Clevite®
TriMetal™ bearing construction coupled with the latest in coating technology.
Fleece media is a multi-layer, high-performance filter media
utilizing a microscopic fiber structure that is up to four times
more efficient than conventional filter media. The OX345D for
example, used in many Mercedes applications in the United
States, is a new fleece oil filter that can withstand the ultralong drain intervals of the Mercedes MB 229.5 specification
synthetic oils.
chrysler 3.3L & 3.8L intake manifold gaskets
Victor Reinz has “Application Engineered” some gaskets out of Performaseal®,
in this case with a special graphite material. Complementing the gaskets are
polymer sealing beads around critical port areas. There’s not a better sealing
material available for the 3.3L and 3.8L intake gasket than Performaseal. See
Catalog for application information and availability.
Part No. MS15984,
MS19206 & MS19223
Part no. 599880 & 599890
GM 6.6L Duramax v8 turbo diesel
MAHLE Original® Duramax pistons include design features such as:
internal gallery-cooling channel, tin-coating to resist scuffing and
cast-in struts to control thermal expansion. The result is reduced
piston-to-wall clearance and less engine noise.
Part No. 41904CP
custom-tailored oil clearance
Clevite introduces high performance undersize bearings allowing
the engine builder using a .010” or .020” under crankshaft to
custom tailor the oil clearance. Combining the different sizes allows
clearance to be controlled to .0005”. For example you could use a
.010” bearing shell with a .011” bearing shell to reduce oil clearance
by .0005”. When using these bearings always install the thicker shell
on the loaded side. See our new 2007-2008 Clevite Performance
Bearing catalog for part numbers and more installation and fitting
tips.
CP-20™ PISTON RINGS FOR Dodge 5.7L
Due to the high demand of Dodge vehicles, it’s no wonder that our 41904CP
ring set for the Dodge 5.7L Hemi® (2003 – 2005) is one of the most popular
sets in the aftermarket. Having a moly top ring, a gray-iron RBT second
ring, and a CP-20 oil ring assembly doesn’t hurt either. .20”, .30”, and .40”
oversizes are also available.
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pistons
category
Performance pistons:
Maximum performance
perfected!
Due to the appropriate machining tolerances of the forged blanks, it is possible
to carry out undercuts during finish machining of the performance piston in
3D milling. These undercuts allow further weight reduction of roughly 40%
compared to an OEM production piston of the same diameter.
Also, with a few exceptions, these low compression height pistons are designed
for two piston rings for racing conditions. The rings, which are very low in axial
height, have special ring face profiles and small tangential tension to keep the
friction low even under high engine speeds.
The demands on pistons in Original Equipment Manufacturer (OEM)
production and in motorsports have some similarities. Both applications
require low weight, good functional values, safety and reliability as
well as competitive pricing. However, in terms of prioritizing these
properties, the differences between OEM and racing pistons are
significant.
General Conditions
In naturally aspirated engines, the power values of racing engines are up to
300% higher than production engines. This means significantly higher thermal
loads, yet the required service life is dramatically shorter than pistons in
production vehicles. A clearer example is the relative RPM’s difference. A
Formula 1 engine turns approximately 20,000 RPM compared to 6,000 RPM
for a typical passenger car engine.
Due to the fact that blow-by gases reduce the available engine power, every
effort is made to optimize the piston ring system in respect of gas tightness.
However, oil consumption cannot be ignored. Low tensioned, single or
multipart oil scraper rings with very special profiles are utilized to address this
requirement.
Piston cooling to reduce the high thermal loads plays another important role in
achieving good fatigue strength for performance pistons. Keeping in mind the
typical time of operation is eight hours in Formula 1 and up to about 50 hours
for long distance applications, special attention is paid to seek the optimum
ratio between required piston cooling, oil volume flow and the resulting driving
and churning losses.
This demonstrates that the optimum design of performance pistons must
be very precise and complex to be successful – despite its shorter expected
service life – making the product very costly.
In an effort to implement a low-weight design with good functionality, the piston
pin and the geometry of the pin-bore play a vital role as well. Since the gas
force is transmitted from the piston head to the pin-bore; the piston pin to the
connecting rod; and finally the crankshaft, the design of this bearing position
requires special attention. Great care must be taken to achieve good lubrication
and an even load distribution in the pin-bores.
Custom Design of Racing Pistons
Performance pistons from MAHLE have been produced for many years as
forged pistons in the so-called “box-in-box” design. The strong, yet thin-walled
ribbing in the thrust / anti-thrust direction and in the longitudinal direction of the
engine allows designs with extremely low compression-height / diameter ratio
while minimizing wall thickness of the piston crown.
For the piston pins, diamond-like carbon coating (DLC) is used to reduce any
seizing tendency and to optimize friction properties. The shapes of the actual
piston pins as well as the pin-bores are optimized with the aid of a computer
program. For example, the stiffness of the piston pin, which is cylindrical at the
outside, is varied over a special internal shape to assure acceptable distortions
at the lowest possible weight.
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pistons
category
Modern Calculation and Simulation Methods
3D Finite Element analysis has been an established method in the development
process of performance pistons for many years. Programs for temperature field
calculations, strength analysis and the determination of relative durability as
well as shape optimization for pin-bores and piston pins are used as standard
methods to simulate the thermo-mechanical loads on pistons. In addition,
programs for the simulation of the piston lateral motion and the skirt wear
patterns are used.
Material Development for Top Performance
The choice of the “right” material for a particular application is critical to the
function of the piston system. Application specific aspects must be accounted
for regarding thermal load, type of wear and required running time. Material
properties such as density, thermal conductivity, fatigue strength and wear
resistance as well as creep and deformation properties are also considered.
The actual material development process, which requires significant financial
effort and time, must be completed before the project is started. Therefore, it
is extremely important to utilize new and improved methods. With our highly
proficient R&D Centers, MAHLE is perfectly positioned to lead the way.
Successes in Motorsports
The MAHLE resume for motorsports domination is extensive and not limited
to Formula 1. The proof lies in the record books throughout NASCAR, NHRA,
and grass roots racetracks around North America. The legacy of motorsports
supremacy attained by Clevite® engine bearings, Perfect Circle® piston rings,
and Victor Reinz® gaskets joins the rest of the MAHLE family of products.
Since the 1930’s, MAHLE has been involved in motorsports – an extremely
successful combination. In 2007, nine out of a total of 17 Formula 1 Grand
Prix races were won using MAHLE engine components. In 2008, eight out
of 11 Formula 1 teams put their trust in the performance and reliability of our
motorsports components including Ferrari, BMW Sauber, Renault, Toyota,
Williams, Red Bull Racing, Toro Rosso and Force India. To further the point,
since the inception of NASCAR, every Champion has crossed the finish line
with MAHLE components under the hood. And if you are into going real fast
in a straight line, just ask the top NHRA racers what they use… they all use
MAHLE!
AFTERMARKET
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events
Where we’ve been...
Where we are going...
a Look at the mahle clevite industry involvement!
Tradeshows are an integral part of the marketing year for MAHLE
Clevite Inc. From the first stages of preparation, to the last day of the
show, each step is a critical part of the tradeshow experience. A plan is
developed during the preceding year and the details are implemented
as the year progresses.
The 2007 tradeshow season concluded with three big shows for MAHLE
Clevite – SEMA, AAPEX and Performance Racing Industry (PRI). All three
shows differ, but all are very important for every company. Take a look into the
success of all three shows with a review of each respectively.
The 2008 tradeshow season started off successfully at the Heavy Duty
Aftermarket Week (HDAW) in Las Vegas, Nevada, and continued with the Hot
Rod and Restoration Show (HRR) in Indianapolis, Indiana. Next, take a look
at the lineup of shows and conferences, which are PERA, AERA and PAACE.
Flash forward in 2008 and get a preview of the MAHLE Clevite show schedule
for the next series of shows.
HDAW
The HDAW show occurred January 21st – 24th in Las Vegas, Nevada. The
show had many unique changes incorporating new ideas for 2008. The first
area that was changed for this year was the enhanced scheduling of activities.
The activities allowed the attendees to participate in all of the week’s events.
The second improvement for 2008 was the extra time allotted for networking
and discussion. With scheduled breakfasts and luncheons, attendees could
gather in one central location. Private lounge areas were also added for
discussions. The final addition to this year was the industry awards luncheon.
The event recognized individuals who made contributions to the heavy duty
aftermarket during 2007.
HRR
The 10th annual HRR show was held in Indianapolis, Indiana, February 28th March 1, 2008. The tradeshow and educational forum is the world’s largest
hot rod, street rod, and muscle car performance and restoration trade show.
HRR attracted thousands of buyers, and had over one hundred exhibitors.
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The 2008 AERA E85 Power Shootout was sponsored at the 2008 HRR show.
The E85 Power Shootout is real world, street performance engines running
on E85 that are street legal and drivable. There were several different teams
taking their own approaches on building street legal engines.
AAPEX/SEMA and PRI
The North American show season was in full swing last fall with the three
largest industry exhibitions. “Industry Week” in Las Vegas, comprised of the
SEMA and the AAPEX shows in late October, once again provided a record
number of industry attendees and buyers checking out the latest in aftermarket
products and technology. The two shows combined make up the largest
convention week for the city of Las Vegas. PRI show is held in Orlando, Florida
in early December – and is the premier tradeshow for hard-core performance
enthusiasts.
MAHLE Clevite Inc. presented with an expanded exhibit to make room for
the new brands and the wider product offerings - and the traffic during the
four days bordered on overwhelming, especially with export customer visits.
AAPEX appeals to the needs of traditional distributor customers and takes
place annually at the Sands Expo Center.
For the first time, MAHLE Clevite Inc. and MAHLE Motorsports Inc. shared a
booth at the SEMA show taking place at the Las Vegas Convention Center
simultaneously with AAPEX. This show not only occupies all the available
indoor space but the parking lot as well. SEMA crowds are very large and very
diverse in their interests. All MAHLE customers found what they were looking
for in this shared booth that will also be utilized for PRI.
The three-day PRI show is the biggest single event for both MAHLE Clevite
and MAHLE Motorsports for the entire year. The show brings well over
100,000 racing-focused attendees under one roof. Booth traffic was heavy,
with nearly 75% of our key racing and motorsport customers attending each
year. Many NASCAR teams fly their engine builders down on their private jets,
and most drag racing customers attend as well. Add to those two markets
everything from land speed record holders and seekers, to tractor pullers, dirt
modifieds, as well as drag bikes. This venue provides an excellent backdrop
for presenting the MAHLE Machinist of the Year Award. 2007 winner, Kenny
Burns, was chosen from a long list of distinguished entrants.
category
events
Performance Engine Rebuilder’s Association (PERA)
Conferences
The objective of the PERA annual conference and spring tech meeting was to
provide an arena for the development and sharing of ideas and experiences
conducive to the advancement and improvement of the industry and the
individual businesses. The programs were devised to stress the importance
of good communication between all levels of the industry as well as the
general public, the necessity for continual education in order to remain alert to
changing conditions in the international business scene, and the significance
of maintaining proper management philosophies which will perpetuate the
member companies on a profitable and productive basis.
MAHLE Clevite sponsored two guest speakers at the PERA Sprint Tech
Conference in Branson, Missouri on March 5th - 7th. The first speaker was
Wolfgang Rein from the MAHLE facility in Farmington Hills, MI. Wolfgang
spoke on how rapidly piston technology has changed and how important it is
for remanufacturers to understand those changes. Some of those changes
included: changes in design, manufacturing, coatings and tolerances. The
second speaker sponsored by MAHLE Clevite was Mark Ferner from Shell Oil.
Mark spoke on the role lubricants play in modern engine remanufacturing.
CONEXPO – CON/AGG Show
The CONEXPO – CON/AGG Show was held March 11-15, 2008 at the Las
Vegas Convention Center in Las Vegas, Nevada. Exhibits covered more than
2.28 million net square feet with nearly 2,000 exhibitors, making this a record
year for the show. CONEXPO had exciting changes for the 2008 attendees.
The mixer driver world cup was the first ever international competition of
concrete mixer truck drivers, sponsored by the National Ready Mixed Concrete
Association, which took place on-site at the show on March 12th. Antique
Equipment was displayed, to compare the changes in equipment over the
past decades. A 5K run/walk was offered to all exhibitors in conjunction with
the Association of Equipment Manufacturers that partnered with Destination
ImagiNation, Inc. to develop the future construction workforce. A free seminar
on small fleet management was offered the last day of the show. MAHLE
Clevite had several positive meetings during the show with prospective Heavy
Duty clients. The meetings were a huge success, as the MAHLE story was
conveyed.
Looking Ahead….
Automotive Engine Rebuilder’s Association (AERA) Tech &
Skills Conferences
There are six AERA regional conferences planned for 2008. Some of the
locations include: Miami, FL; Las Angeles, CA; Charlotte, NC; Seattle, WA; and
Dallas, TX. Each conference will include approximately 80 to 120 participants
at each location.
PAACE Automechanika Mexico
PAACE Automechanika Mexico is Central America’s most important automotive
trade show. Held annually in Mexico City, the event draws more than 17,800
attendees, from 31 countries, in the automotive industry. The show runs
from July 9th through the 11th and is for the Automotive Aftermarket, OE
Manufacturing and the Service Industry.
Held in conjunction with the International Week of the Automotive Industry and
with the support of important industry associations, PAACE Automechanika
Mexico has become a growing platform for automotive business in the
Mexican and Latin American markets. With more than 500 exhibitors,
PAACE Automechanika Mexico is the ultimate platform for sourcing domestic
and international products and suppliers. In addition to the thousands of
products, services and resources available on the exhibit hall floor, PAACE
Automechanika Mexico provides valuable education and training, unmatched
business solutions, exciting networking events and more.
Mexico City: Constitution square and the Metropolitan Cathedral
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customer portrait
category
bwp
distributors
focused on success!
“MAHLE offers us unequaled quality, availability and service, coupled with a true partnership
that is beneficial to all parties.”
CARQUEST and its members constitute the single largest customer for
MAHLE Clevite Inc. From humble beginnings of just three members
and 100 stores in 1974, CARQUEST has grown to five member companies and over 3,400 stores serving the United States and Canada.
CARQUEST Auto Parts is the
premier supplier of replacement
products.
Product categories
include accessories, supplies and
equipment for virtually all makes of
automobiles, light and heavy-duty
trucks, off-road equipment, buses,
recreational vehicles and agricultural
equipment in North America. MAHLE
Clevite is proud to spotlight one of
CARQUEST’s leading members BWP Distributors, Inc.
BWP is services the busy northeast
corridor with Distribution Centers
in Armonk, NY (New York City),
Delran, NJ (Philadelphia) and Sutton,
MA (Boston). BWP Distributors, Inc. represents an American success story.
Family-owned through three generations, their successes are attributed to
hard work and uncompromising dedication to honesty and integrity towards
their customers, suppliers and associates.
The original family business was a single “Flying A” gas station run by Ray &
Stan Stockel and their father Herman. By 1962, they moved into the automotive jobbing business which eventually led to their purchase of Bobro Products
in 1982. Bobro Products was one of the original three CARQUEST members.
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Through a series of warehouse and jobber acquisitions, BWP grew steadily
over the years to become a recognized leader in the automotive parts distribution business - and an important member of the CARQUEST family.
In addition to their distribution centers
in Armonk, Sutton, and Delran, BWP
serves 232 CARQUEST Auto Parts
stores throughout 10 states in the
northeast. The Company Store Division represents 123 of those stores.
Today, Irwin, Neil, Jon and Andy
Stockel are joined by a strong and
seasoned management team in guiding the future of BWP Distributors.
“BWP has relied on MAHLE Clevite
for all of our sealing and engine parts
needs for a very long time. MAHLE
offers us unequaled quality, availability and service, coupled with a
true partnership that is beneficial to
all parties,” noted Rich Pallai, BWP’s
Vice President of Marketing when asked to describe the relationship between
BWP and MAHLE Clevite.
MAHLE Clevite Inc. proudly supplies BWP with CARQUEST® gaskets by Victor
Reinz®, in addition to MAHLE Original® engine parts, Clevite® engine bearings,
and Perfect Circle® piston rings.
oncategory
location
capabilities
expansion through acquisition
optimum addition to the piston and cylinder liner program thanks to
the majority share acquisition of the mopisan group.
MAHLE acquired the majority stake in Turkish piston and cylinder liner manufacturer Mopisan group effective January 2, 2008. Under the
name MAHLE Mopisan, the business will be integrated into the worldwide production system of the MAHLE group. It will play a crucial role
in small batch production for the demands in Europe and around the
world. For MAHLE Aftermarket including MAHLE Clevite, this will provide increased flexibility and speed to market for new applications.
With recent manufacturing capacity of 1.5 million pistons, MAHLE Mopisan
specializes in the production of small and medium sized batches, with a wide
product range in particular demand in the aftermarket. The two production
sites in Izmir and Konya manufacture mainly for export into more than 70 countries. With a comprehensive product range of more than 800 piston types,
MAHLE Mopisan is among the most important suppliers globally, especially of
diesel applications.
Customers include various vehicle and engine manufacturers, as well as numerous customers in the aftermarket – all utilizing the highly integrated development process and the fast production input, especially for spare part re-
quirements. MAHLE Mopisan also distinguishes itself with a quality assurance
process throughout all production stages conforming to original equipment
requirements.
The integration into the MAHLE group will increase the manufacturing capacity of the two production sites significantly to cover the increasing demand for
MAHLE Aftermarket pistons. The intended expansion of the production facilities will directly improve capacity for passenger car as well as commercial vehicle applications. Also the product development - the tool-making and other
operations required for the component production will be extended in Konya
and Izmir. This will provide MAHLE in each of the two production sites with a
highly integrated value added process, specialized in small batch production,
and allow reliable supply with a broad range of engine components.
This acquisition further extends the MAHLE engagement in Turkey. MAHLE,
together with the Turkish injection molding specialist Farplas, built a production site for air management systems in Gebze/Turkey in 2003. With a vehicle
production of currently more than 1 million units, Turkey is one of the most
dynamic manufacturing countries in the automobile industry.
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ecapabilities
sharpen your engine parts
knowledge
with our elearning programs!
The eLearning™ program has been a MAHLE Clevite staple for more
than four years. Core products covered include Clevite® engine bearings, Perfect Circle® piston rings, Victor Reinz® gaskets and Clevite®
heavy duty engine parts. The courses consist of at least six separate
chapters, covering company history, product features and benefits,
choosing the proper product, installation tips and procedures and an
explanation of the catalog and how to use it.
eLearning visitors and users include MAHLE Clevite employees as well as direct and indirect customers. In addition, since it’s free and available on the
Web, the public can also take advantages of the classes. Those scoring over
80% on the final exam of each course can even print their own certificate.
MAHLE Clevite Canada is running a NAPA Gasket promotion for 2008, rewarding customers who complete the gasket class and receive their certificate. One
of the features of eLearning is an ability to create distinct user groups, and allow supervision over the group; enabling the team in Canada to monitor progress of customer groups they care to set up.
Imprint
MAHLE Aftermarket news 1/2008
editing MAHLE Aftermarket news
MAHLE Clevite Inc.
1350 Eisenhower Place
Ann Arbor, Michigan 48108
www.mahleclevite.com
responsible for the contents: Jesse Jones
editors: Melissa Kirk, Ted Hughes, Tonia Kaczmarek, Dave Murray
additional contributors: Bill McKnight, Richard Odom
printing and distribution: Hecks Direct Mail & Printing, Toledo,
Ohio
All rights reserved. Reprinting and publication of any kind, including in electronic media, in
full or in parts, only with prior expressed written consent from MAHLE Clevite Inc. For further
information and additional copies, please contact your MAHLE Clevite sales representative.
AFTERMARKET
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Bill McKnight, Team Leader - Training for MAHLE Clevite, is responsible
for the development and revisions for the eLearning program. It is of the
utmost importance to make sure that we communicate the most up to date
information in our courses. That being said, both the gasket and engine
bearing classes received technical updates in December 2007. The piston
ring eLearning will be updated in spring 2008.
The newest project for MAHLE Clevite eLearning is a comprehensive
course on pistons. McKnight recruited content experts, Wolfgang Rein,
Ray Falkenrath and Eric Miller to provide technical direction and guidance.
The course is scheduled for completion second quarter 2008 – to take the
courses, visit www.mahleclevite.com and find eLearning under Training.