product range

MAHLE
PRODUCT RANGE
PRODUCT INFORMATION
AFTERMARKET
MAHLE product range—engine components, turbochargers, thermal management, filters, and MAHLE Service Solutions
Table of contents
About us .............................................................................................................................Pages
4 – 5
Engine components
Pistons .................................................................................................................................Pages
6 – 9
Piston ring sets .....................................................................................................................Pages
10 – 11
Cylinder liners .......................................................................................................................Pages
12 – 13
Bearings ...............................................................................................................................Pages
14 – 15
Valve train components .........................................................................................................Pages
16 – 17
Turbochargers ...................................................................................................................Pages
18 – 19
Thermal management
Thermostats ..........................................................................................................................Pages
20 – 21
Filters
Air filters ................................................................................................................................Pages
22 – 23
Oil filters ................................................................................................................................Pages
24 – 25
Fuel filters .............................................................................................................................Pages
26 – 27
Cabin air filters ......................................................................................................................Pages
28 – 29
Air dryer cartridges ...............................................................................................................Pages
30 – 31
Urea filters .............................................................................................................................Pages
32 – 33
Filter media ...........................................................................................................................Pages
34 – 35
MAHLE Service Solutions A/C service units ..................................................................................................................Pages
36 – 37
Sales and service ...............................................................................................................Pages
38 – 39
MAHLE Aftermarket sales network .................................................................................Pages
40 – 41
3
WHERE
THERE ARE CARS,
THERE IS MAHLE.
4
About us
The MAHLE Group
In the beginning there was innovation: the first
light-alloy piston in 1921 was the prelude to the
MAHLE success story in all aspects of the combustion engine. This was followed by many more
market-defining innovations: for example, the
first aluminium engine block to be series-produced using low-pressure die casting in 1976, the
production of assembled camshafts in 1985, the
start of production for pistons with cooled ring
carriers for passenger car diesel engines in
2000, the first multifunctional oil filter modules
with plastic tubing in 2003, the first MAHLE complete engine in 2004, the manufacture of the first
fast-switching EGR valve prototypes for diesel
engines used in customer trials in 2009, and the
development of a range extender for increasing
the cruising range of electric vehicles in 2010.
As a development partner to the international au-
duct that can always be relied on—guaranteed.
tomotive and engine industry and ranking among
We supply the aftermarket with a comprehensive
the top three systems suppliers, we are not only
range of products under the brand names
represented in every second vehicle today, but
MAHLE Original, Knecht, Behr und Clevite, the
also on the racing circuits, where racers equipped
engine components brand for U.S. commercial
with MAHLE products regularly cross the finish
vehicle applications.
line in leading positions—for instance, in Formula 1,
the 24 Hours of Le Mans, or in truck racing.
Best references—worldwide
A brief look at our original equipment customer list
Together with approximately 64,000 employees
underlines the fact that more than 140 renowned
—of which 4,500 are engineers in research and
engine and vehicle manufacturers decide in favour
development alone—we are working to optimise
of engine components and filters from MAHLE.
existing technologies and develop new, future-ori-
Here a small selection:
All MAHLE production
locations are certified by
renowned vehicle manufacturers—and by all
relevant certification
authorities.
ented systems that will secure our innovative
edge. MAHLE has a local presence in all major
Alfa Romeo, Audi, BMW, Case, Caterpillar,
world markets with its 140 locations and ten major
Chevrolet, Citroën, CNHTC, Cummins, Dacia, DAF,
research and development centres.
Daihatsu, Detroit Diesel, Deutz, Dongfeng, Ducati,
Ferrari, FIAT, Ford, Freightliner, General Motors,
All of our customers benefit from this global pre-
Harley-Davidson, Honda, Hyundai, Isuzu, Jaguar,
sence—customers from the original equipment
John Deere, Kia, Komatsu, Lancia, Land Rover,
sector and the aftermarket alike. It makes no dif-
Mack Trucks, Magna Steyr, MAN, Maserati,
ference whether MAHLE manufactures a product
Mazda, Mercedes-Benz, Mitsubishi, MWM
for the automobile industry or for the indepen-
International, Navistar International, New Holland,
dent aftermarket: our products always meet the
Nissan, Opel, Paccar, Perkins, Peugeot, Porsche,
same high standards. The automotive industry,
Renault, Renault Trucks, Scania, SEAT, Škoda,
trade, and repair shops can therefore be assured
Smart, Steyr, Stihl, Subaru, Suzuki, Toyota,
that a product from the MAHLE Group is a pro-
Vauxhall, Volkswagen, Volvo, Yamaha.
5
OUR COMPETITION DOESN’T WANT TO
BURN THEIR FINGERS
IN THE
FORMULA 1.
6
Engine components
Pistons
Our pistons have to withstand extreme pressures,
as their working conditions have become significantly tougher in recent years. For example, the
thermal loads (with temperatures in the combustion chamber reaching 2,600°C) and the average
ignition pressures have greatly increased. Also the
inertial force loads have increased due to highspeed concepts and a tendency to larger piston
strokes. Naturally, the demands on our pistons
have risen progressively at the same time: they
should be lighter, consume less oil, and be absolutely safe—even under extreme conditions such as
hot and cold load capacity testing and thermoshock endurance testing.
We also benefit greatly in this field from our successes in motorsport—after all, we are the only se-
The effects of these demands: the overall height
ries manufacturer who is gaining its experience
or compression height of the pistons has decrea-
from Formula 1. As the world’s largest manufactu-
sed continuously. New solutions such as the
rer of pistons, MAHLE is operating an intensive re-
ECOFORM piston concept developed by MAHLE
search programme for future products, and
allow further weight reductions. And with
already today offers solutions for almost every
MONOTHERM pistons, which are single-piece
engine—fast, reliable, and around the globe. With
steel pistons that are machined accordingly, it is
our pistons, we offer aftermarket customers the
possible in the meantime to achieve the same
opportunity to benefit from products of the original
weight as with pistons made from aluminium.
equipment sector and from the inherent safety of
However, significant improvements have also
products that have been tried and tested in
been made with aluminium pistons such as the
practice under the most gruelling conditions. A
MAHLE pistons with cooled ring carriers.
promise you can count on.
®
®
The only series manufacturer of pistons in the
Formula 1: MAHLE.
On the piston crown, you
will find the company or
trade mark, the maximum piston diameter,
the mounting clearance,
and the fitting direction
according to the respective specifications of the
engine manufacturer.
7
Engine components
The optimum piston for every engine.
ECOFORM ® pistons with
pivoted side cores
Weight-optimised pistons for passenger car petrol engines. These pistons offer low weight with high structural rigidity thanks to a special casting technology.
8
AUTOTHERMATIK®/
HYDROTHERMATIK® pistons
These pistons are used predominantly in passenger car petrol and
diesel engines subjected to heavy
loads. They feature cast-in steel
strips, but are not slotted. This gives
the piston a uniform body with
greater strength.
AUTOTHERMIK®/
HYDROTHERMIK® pistons
These smooth-running pistons are
mainly used in passenger car
engines. They feature cast-in steel
strips and are slotted at the transition
from the ring belt to the skirt area.
Cast solid-skirt pistons
Piston crown, ring belt, and skirt
form a robust unit. Such pistons
have a long service life and are used
in petrol and diesel engines. Their
applications range from model
engines to large engines.
Forged solid-skirt pistons
These pistons are predominantly
fitted in series production engines
subjected to heavy loads, as well as
in motorsport engines. The manufacturing process gives these pistons
increased strength and allows for
smaller wall cross sections and a
reduction in piston weight.
Pistons with cooled ring carrier
With these pistons, the ring carrier
and cooling gallery are combined to
form one system in a special manufacturing process. This provides the
pistons with significantly improved
heat transfer properties at the first
ring groove.
Ring carrier pistons with
pin bore bushings
These pistons for diesel engines feature ring carriers made of special
cast iron that are cast into the piston.
This increases wear resistance, particularly in the first groove. Pin bore
bushings made from a special material increase the pin bore’s load
capacity.
MONOTHERM ® pistons
This single-piece, forged steel piston
has an extremely high structural
rigidity and was developed for modern combustion chambers with pressures of more than 250 bar. The version with connected skirt in combination with a short piston pin makes
its weight comparable to that of an
aluminium piston.
Ring carrier pistons with cooling
gallery and crown reinforcement
These pistons are used in diesel
engines subjected to heavy loads.
For added protection and in order to
prevent cracks on the bowl rim and
the crown, these pistons feature a
special hard-anodised layer (HA
layer) on the piston crown.
FERROTHERM ® pistons
These pistons comprise a steel pis­ton crown and an aluminium piston
skirt that are connected with the piston pin. Due to increased strength
and a low wear rate, these pistons
make it possible for diesel engines
subjected to particularly high loads to
comply with low exhaust and emissions limits.
Ring carrier pistons with
cooling gallery
Ring carrier pistons with cooling gallery are used where particularly high
operating temperatures arise. To
reduce the high temperatures in the
piston crown and ring belt, intensive
cooling is achieved by circulating oil
in the cooling gallery.
Two-stroke pistons
Pistons made from special aluminium alloys. These are resistant to the
high mechanical and thermal loads
of two-stroke engines.
9
THESE MAINTAIN THEIR
SEAL
—THIS YOU CAN COUNT ON.
10
Engine components
Piston ring sets
In modern engines and for high continuous per-
The ideal ring set for every piston
formance, our piston rings take reliable and pre-
We offer different versions of piston ring sets in
cise care of the welfare of their carriers. As the
original equipment quality, or especially for engi-
leading manufacturer of pistons, we consistently
nes that have already been running with the aim
work to optimise the performance and running
to reduce compression losses and to regulate oil
properties of our piston rings. And we set quality
consumption. We can supply piston ring sets for
standards also in this field with state-of-the-art
almost every petrol and diesel engine for passen-
production facilities. With decades of experience
ger cars as well as for commercial vehicles, at
in development and production, we can assure
diameters from 52 to 160 mm.
optimum interplay between our pistons and piston rings, and can meet the highest demands.
Materials
The MAHLE “N” piston
ring set offers you the
piston rings that are also
used as original equipment. The MAHLE “V”
piston ring sets have been
developed especially for
engines that have been
running for some time.
Only high-grade materials are used for our piston
Piston rings have three important functions in mo-
rings. For normal or heavy loads, lamellar graphite
dern engines:
cast iron materials are used, and for the highest
■■
They seal the combustion chamber from the
demands, nodular graphite cast iron materials or
crankcase.
steel materials are employed.
■■
They limit and regulate oil consumption.
■■
They dissipate the heat that is taken up by the
Ring face coatings
pistons during combustion to the cooled
Special coatings can be applied to the ring face of
cylinder working surfaces.
piston rings to increase resistance to wear and
scuffing. For instance, chromium coatings or
In order to satisfy these requirements, the piston
plasma spray coatings of metallic or ceramic ma-
rings must fit tightly to the cylinder wall over their
terials are used for this purpose.
entire circumference, even if the cylinder deviates
slightly from its ideal form. Due to the high inertial
forces and combustion pressures, as well as the
high wear-producing loads, the piston rings have
to satisfy high demands with respect to piston ring
It is essential that the TOP
markings are observed.
Rings with TOP markings
have to be fitted with these
markings facing upwards
towards the piston crown.
material (strength/temperature stability) as well as
surface finish and shape.
11
WE ARE
STRICT WITH OUR
TOLERANCES.
12
Engine components
Cylinder liners
The steadily rising demands on internal com-
Materials
bustion engines require continuous improve-
In addition to aluminium, cast iron alloy is used as
ments also in the area of cylinder working sur-
a material for cylinder liners.
faces. The precise matching of the honed cylinder liners with the pistons and piston rings leads
Lamellar graphite cast iron is alloyed with phos-
to improved results in the engine. It is therefore
phorus. Additional alloy materials improve the
necessary for cylinder liners made from cast
wear properties and can strengthen the matrix
iron to have optimum surfaces that contribute to
due to bainite and very fine perlite formations.
Lamellar graphite.
lower oil consumption and low blow-by, reduce
wear, and allow shorter running-in times and
Honing methods
therefore enable a longer service life.
Good honing has a positive effect on piston ring
wear, particle emissions, oil consumption, and
MAHLE produces cylinder liners for international
friction. With further developments and innova-
engine manufacturers, both for series production
tions in the honing of cylinder liners, it is attemp-
and the aftermarket—always according to the
ted to keep the running-in phase of the cylinder
same strict quality standards. We manufacture our
(engine) as short as possible and to achieve
cylinder liners with very strict tolerances, thereby
improved tribological properties. An important
ensuring, among other things, that the cylinder li-
prerequisite for good and regular honing of the
ners can be optimally fitted into the engine block.
cylinder liners is high material quality. This entails,
Additional important quality characteristics of our
cast materials free of voids, with homogeneous
cylinder liners are the materials, structure, and
structure, and uniform hardness, as well as suita-
surface quality. In close co-operation with engine
ble pre-machining of the bore.
manufacturers, we determine the composition of
Honing
Method of machining, in
which the tool carries out
reciprocating and rotating movements. With this
method, a cylinder form
error below 10 μm and an
even surface roughness
can be achieved.
Tribology
The science of friction,
lubrication, and wear of
bodies in relative motion.
the melt, the treatment of the melt, and the machining process.
The most important honing methods in single processing steps
Description
Honing process
1 operation
2
Normal honing
1
2
3
Diamond
Diamond
Ceramic
Diamond
Ceramic
Ceramic
Plateau honing
1
2
3
Diamond
Diamond
Diamond
Diamond
Diamond
Ceramic
Diamond
Diamond
Ceramic
Series petrol pass. car
Series diesel pass. car
Series commercial vehicle
Brush honing
1
2
Diamond
Diamond
Diamond
Ceramic
Brushing
Brushing
Series passenger car/
commercial vehicle
Diamond
Diamond
Liquid honing
Microfinishing
Series diesel pass. car
Diamond
Diamond
Laser structure
Diamond/ceramic
Ceramic
Laser structure
Ceramic
Experimental/motorsport
Liquid honing
Laser honing
1
2
nd
operation
Application
Version
st
3 operation
rd
4 operation
th
Series petrol pass. car
Series diesel pass. car
Series commercial vehicle
13
OUR
BEARING
LAYERS
ARE EXTREMELY
ROBUST.
14
Engine components
Bearings
Bearings form the basis for a largely wear-free
Materials and production methods
and low-friction partnership between the engine
Material development is extremely important in
casing or connecting rod and the rotating shafts
order for bearings to meet the high demands.
such as the crankshaft, camshaft, rocker arm
Thanks to years of experience and development
shaft, and balancer shaft. The mechanical
work, MAHLE has at its disposal a large number
stress in internal combustion engines is extre-
of bearing alloys such as aluminium and bronze
mely high. Our bearings thus have to meet a
alloys. Depending on the application, our bea-
number of quality characteristics: they have to
rings consist of a high-strength steel backing that
be fatigue-resistant, adaptable, highly loadable,
is coated with different bearing metals. With re-
and wear- and corrosion-resistant.
gard to their applications, the bearing materials
are chosen such that their properties compliment
In co-operation with engine manufacturers, we
We offer you a comprehensive range of bearing
bushings.
one another optimally.
develop and test the bearings for every single engine type. Ongoing fundamental research and
During the production process, we use different
further development of materials and production
coating methods depending on the relative bea-
technologies ensure economically and technically
ring loads, for instance.
optimised products of the highest quality.
Sputtering
Coating method that works
on the principle of cathode
sputtering, in which atoms
are knocked out from a
metal cathode due to the
impacting ions from a gas
discharge process. The
resulting atomised metal
condenses on the running
surface of the bearing as
a uniform layer.
Our product range encompasses bearing shells,
flanged bearings, bushings, and thrust washers
with diameters from 27 to 140 mm, as well as bushes with diameters from 6 to 105 mm.
Types
Solid bearings
Solid bearings are made completely
from a special bearing metal that
consists of special alloys.
Two-component bearings
Two-component bearings are used
for low to medium loads in petrol and
naturally aspirated diesel engines in
passenger cars. They consist of a steel
backing, an intermediate layer, and a
layer of bearing metal. Mainly aluminium
alloys are used as bearing metal.
Three-component bearings
Three-component bearings are predominantly used in high-performance engines.
They consist of the steel support shell,
a bearing layer, a barrier layer, and the
overlay. The performance of these bearings is enhanced by sputtering. Sputter bearings are special three-component bearings with significantly increased
hardness, load capacity, and wear resistance thanks to a special production process (sputtering). These properties make
sputter bearings ideal for supercharged
engines with intercooling, and can now
also be found increasingly in passenger
car diesel engines.
15
SMALL CAUSE,
BIG EFFECT.
16
Engine components
Valve train components
Not many components in engines are under as
We employ state-of-the-art production technolo-
much load and tribological stress as valves and
gies as part of our large-volume production to se-
their attached parts. At temperatures of up to
cure our quality standards. For example, we use
800°C, the red-hot exhaust valves strike the valve
plasma powder methods in raw part production,
seats more than 70 times per second and must
or high-speed grinding methods for mechanical fi-
withstand the hot and corrosive exhaust gases
nishing. In order to make valves resistant to high
that surround them. At every valve lift, enormous
loads, our valves feature hard-faced seats, are
acceleration and retractive forces occur due to the
hardened, chrome-plated, or nitrided according to
strong valve springs.
the respective requirements. A wide range of ma-
Tribology
The science of friction,
lubrication, and wear of
bodies in relative motion.
terials is available for every application. For special
Valves form a closed system together with valve
applications with extreme demands, sodium-filled
seat inserts and valve guides, which has to with-
valves are also available to reduce thermal loads.
stand highest loads and stresses. We thus have
not only valves in our product range, but also their
Valve guides and valve seat inserts
tribological partners, valve seat inserts and valve
The valve guides centre the valves on the valve
guides. The combined development of these pro-
seats and compensate for the lateral forces acting
ducts in one system allows us to attain advanta-
on the valve shafts. In addition, they need to dissi-
ges with respect to wear characteristics and cost
pate the generated heat towards the cylinder
of the components.
head. Depending on the engine design, identical
or different valve guides are used for the intake
Any kind of valve
and exhaust side. The range of materials reaches
MAHLE manufactures valves for internal com-
from grey cast iron and brass to sintered materials
bustion engines at several production locations
of various alloys.
worldwide. Our product range includes valves of
diverse designs and types for passenger cars
The valve seat insert together with the valve seals
and commercial vehicles with stem diameters
the combustion chamber from pressure loss. In ad-
from 5 to 12 mm and valve lengths from 80 to
dition, it is responsible for heat transfer and prevents
210 mm. Thanks to the extensive technical ex-
the valves from impacting into the softer cylinder
pertise, high productivity, and the outstanding
head material. Valve seat inserts are predominantly
quality of these products, MAHLE is now one of
made from chromium-steel alloys. Sinter materials
the world’s most important valve manufacturers.
are now being used to an increased extent.
Materials
Austenitic steels
Martensitic steels
Types
Mono-metal valves
Bi-metal valves
Valve seat
Plasma powder facing
Induction hardening
Valve tip induction
hardening
Profile hardening
Through hardening
Tip surface hardening
Hollow valves
Stem size: > 6 mm
Bore sealing:
n Laser welding
n Friction welding
Sodium filling
Fillet profile
Turned, ground
Contour-forged
Valve tip geometry
1–3 grooves
Special designs
Head top surface
Machined
Forged
With or without dish
Valve length
80–210 mm
Valve head diameter
18–65 mm
Valve stem diameter
5–12 mm
The greatest challenge
is to determine the design of the valves. Our
valves are designed for
a wide variety of operating conditions in order
to withstand the extreme
mechanical, chemical,
and thermal loads, and
to assure optimum heat
dissipation.
Surface treatment
Salt bath-nitrided
Hard chrome-plated
(coating thickness: 3–35 µm)
17
WE
TURBOCHARGE.
18
Turbochargers
Exhaust gas turbochargers
Exhaust gas turbochargers represent a key tech-
stantly expanded with the focus firmly set on mar-
nology to enhance performance, reduce fuel
ket requirements. Moreover, a corresponding
consumption, and lower exhaust emissions,
mounting kit is available or is being prepared for
which is why MAHLE is a long-standing business
every turbocharger.
partner to international automotive and engine
manufacturers in the development and produc-
MAHLE Original turbochargers are state of the art
tion of high-performance turbocharger compo-
and manufactured in line with standards appli-
nents. Our far-reaching competence in engine
cable across the Group, using the latest proces-
components opens up specific potentials to
ses in ultra-modern facilities:
increase efficiency, because this essentially
■■
greater balancing precision, optimised
depends on how well the components involved
stability, and reduced running noise.
—such as the turbocharger, fuel injection technology, variable valve train, exhaust gas recircula-
High-speed compressor wheels provide
■■
Double piston rings on the rotor shaft reduce
oil consumption and enhance protection
tion, and intercooling—are harmonised.
against foreign particles.
MAHLE OE technologies for the aftermarket
■■
achieve greater thermal stability and longevity.
Nearly every diesel engine rolling off the production line in Europe, North America, and Japan fea-
Turbine housings made of high-tech materials
■■
Functionally process-controlled centre
tures turbocharging technology. Turbochargers
housings attain progressive balancing of the
are also being increasingly fitted in passenger car
rotor shaft, enhanced running performance,
reduced abrasion, and less noise emission.
petrol engines to increase efficiency. In order to
drive this development forward, in 2008, Robert
Bosch GmbH and MAHLE GmbH formed the joint
MAHLE Original exhaust
gas turbo­charger.
■■
Electron-welded rotor shaft and wheels
guarantee high strength.
venture Bosch Mahle Turbo Systems (BMTS),
which develops and produces tailor-made exhaust
Cutting-edge quality through integrated
gas turbochargers for the automotive industry.
development and manufacturing processes
The highest development and manufacturing
The turbocharger market segment is posting
skills are needed to ensure high efficiencies over a
enormous growth rates even in the automotive
broad engine map area at speeds of far more
spare parts business. It is therefore critical for
than 300,000 rpm and exhaust gas temperatures
trade and repair shops to have access to this
in excess of 1,000°C. MAHLE thus employs the
technology of the future. Highly efficient turbo-
latest simulation tools in the initial phase of its
chargers are available to the automotive aftermar-
integrated development processes, for example,
ket under the MAHLE Original brand. The devel-
to ensure the required thermo-dynamic and
opment process for these products takes place in
thermo-mechanical component properties.
MAHLE Original
turbocharger add-on kit.
close cooperation with BMTS and is adapted accordingly. Initially, the turbocharger range focused
Computer-controlled production equipment gua-
on commercial vehicles; now, around 70 per cent
rantees the utmost of precision when machining
of all fast-moving applications are covered.
casing components, as well as the no-compro-
MAHLE Original passenger car turbochargers
mise casting quality and balancing accuracy of the
have also been on the market since the beginning
turbines. This ensures that you can rely on the
of 2012, encompassing applications such as
long-lasting, consistent performance of MAHLE
Volkswagen, Renault, BMW, and Mercedes-
Original turbochargers even under extreme condi-
Benz—and covering around 95 per cent of the
tions—to satisfy the high quality standards we
fast movers. The product range is being con-
place on all of our products.
19
FOR THESE MANAGERS,
DEGREE
CELSIUS
IS THE MEASURE
OF ALL THINGS.
20
Thermal management
Thermostats
To operate efficiently while minimising wear and
the operating element’s expansion material.
emissions, a combustion engine requires the
Consequently, these thermostats can be electri-
temperature to remain as constant as possible
cally activated, and thereby have a considerably
within a specified range. Thermostats are used
faster effect on the engine temperature to keep
exactly for that purpose, as they regulate the
the engine within the optimum range in various
engine temperature with coolant. They are equip-
load and operating conditions. The result: impro-
ped with a wax core. As the coolant temperature
ved engine output, a longer service life, as well as
increases, the wax starts to liquefy and expand.
reduced consumption and emissions. An opera-
This activates a dowel pin, which in turn controls
ting map stored in the engine control unit defines
a valve that opens the flow of coolant. When the
when and how heat is added.
engine temperature drops, as does the coolant
temperature, the wax solidifies and interrupts the
MAHLE Aftermarket offers a variety of different
coolant circuit.
thermostats and other components for regulating
temperature: from expansion elements, thermostat
Map-controlled thermostats
inserts, thermal switches, and thermocouples to
Engine efficiency can be further enhanced with
integrated, housing, and sleeve valve thermostats,
the use of map-controlled thermostats: an elec-
transmission oil, and EGR thermostats all the way
trical heating resistor is additionally integrated in
to map-controlled thermostats.
No wear—yet important
revenue mainstays
Thermostats are not
standard wearing parts.
There is, however, considerable demand for
spares. When carrying out any work that requires access to the cooling system (whether
due to an accident or as
part of repair or maintenance work), the temperature managers should always be replaced at the
same time. Because any
loss of functionality or
even complete failure can
have severe consequences. If the thermostat is always open, the engine
will be cooled too much.
If the thermostat is always
closed, then the engine
will not be cooled at all
and will overheat.
Plug
Heating resistor
Valve disc
Compression spring
Case (operating element)
Elastomer insert
Working piston
Guide (bypass valve)
Housing
© Behr Thermot-tronik GmbH
Cross section of a map-controlled thermostat
with electrical connections and heating resistor
integrated in the wax element.
21
A GOOD SET OF
LUNGS:
VITAL FOR THE SPRINT
AND THE LONG HAUL.
22
Filters
Air filters
Clean air intake is one of the most important con-
the engine or chassis and are stabilised with glue
ditions for optimal engine power, high torque, low
beads at the dirty side and support grits at the
fuel consumption, and minimised pollutant emissi-
clean side, depending on the specifications of the
ons. With MAHLE air filters up to 99.9 per cent of
vehicle manufacturer. For dust-rich areas, an ad-
dust, soot, and tire wear particles are filtered out.
ditional pre-cleaner in the form of a foam mat is
At the same time, an optimal air/fuel mixture is
placed at the dirty side. For higher surface loads,
assured. The high particle uptake capacity ensu-
metal or plastic support studs are used.
res long service life even under extreme conditions
such as heat, cold, or chemical influences. Our
In commercial vehicles, robust and at the same
quality filters prevent premature wear of the valves,
time weight-optimised air filter systems made from
cylinder working surfaces, piston rings, bearings,
recyclable plastic are used that also serve to re-
and other engine components. To ensure perfect
duce air intake noise. In order to achieve a large
and lasting filter performance, all filters must be
filter surface at high stability, they are mostly desi-
replaced within the replacement intervals stipula-
gned in a cylindrical shape. To improve efficiency,
ted by the vehicle manufacturers.
radial sealing and axial supports are employed.
Additional safety inserts in the form of special
In the passenger car sector, round and panel ele-
fleece cylinders protect the clean side of the filter
ments are fitted in air filter housings mounted to
element during maintenance and replacements.
Our air filters are
completely sealed
Uncleaned air in the intake
passage can contaminate
the air flow mass meter
and distort the measuring
results, cause malfunctions of the fuel injection,
and contribute to wear of
engine components. To
prevent bypass air, our filter cartridges are fitted in
exactly and the seals are
selected carefully.
PUR seals made from
specially developed PU
foam ensure continuous
sealing between dirty and
clean side. These seals
are resistant to aging,
chemical effects, and are
temperature-stable. Their
flexibility is designed to fit
exactly to the geometry of
the sealing area.
23
RUNNING LIKE A
WELL-OILED
MACHINE.
24
Filters
Oil filters
The engine oil reduces friction and wear of the
cold start or at low temperatures, and also for
engine, cools the engine components, protects
strongly contaminated filter elements when the re-
the inside of the engine from corrosion, and
placement intervals have been exceeded. An anti-
seals the combustion chamber with a thin oil film
drain valve prevents the draining of the filter when
between piston, piston ring, and the working
the engine is switched off and secures fast oil
surface of the cylinder, as well as in further cru-
supply when the engine is started. High-grade
cial areas of the engine. The oil is thus constantly
sealing materials and custom-fit connecting pie-
subjected to stress: combustion residues, dust,
ces guarantee the reliable separation between
carbon, soot, abrasion particles, and condensa-
contaminated and filtered oil.
tes can contaminate the oil and promote premature wear of engine components.
An important condition for the correct functioning
Oil filter cartridges
With filter cartridges from
the OX and OX-Eco range,
we offer particularly economical solutions for repair
shops: instead of replacing the complete filter,
only the dirty filter element
has to be exchanged. An
ecologically sensible solution that saves material and disposal costs. In
the OX-Eco version, the
cartridges are metal-free
and can therefore be fully incinerated. Oil filter
cartridges are available for
all oil filters with housings
that can be split.
of the oil filters, however, is that filters are replaced
MAHLE oil filters reliably prevent dirt particles
within the maintenance intervals stipulated by the
from entering the lubricant circuit and maintain oil
vehicle manufacturer.
quality as well as the performance and efficiency
of the engine. Thanks to stable pleat geometry,
cold-start stability is assured. Load peaks of up to
20 bar are compensated through the high pressure resistance of the housing. A pressure relief
valve guarantees the oil supply under all condi-
Oil filter cartridges: the
ecologically sensible and
economical solution.
tions—for viscous oil as it is encountered during
More efficient
replacement
Housing
Spring
Bypass valve
Internal
support frame
Filter element made
of special paper
Spin-on oil filters
OC spin-on oil filters can be replaced with ease. The deep-drawn
steel sheet housing with powdered
coating has a multi-faced collar to
facilitate fast loosening of the filter.
The cover plate has a thread for
the screw-on spigot and a groove
for the seal. The filter element
features an internal frame as support against the oil pressure that
is directed from the outside to
the inside.
The new MAHLE oil filter
module for commercial
vehicles is highly versatile in terms of integration
on both the oil and coolant
side. Thanks to the high
level of integration, the
number of interfaces and
sealing points has been
reduced. Both weight and
costs have been lowered
by employing high-performance plastics.
Anti-drain valve
clean side
Anti-drain valve
dirty side
Cover plate
Sealing
25
WE TAKE CARE OF
ANY DIRT
LEFT OVER.
26
Filters
Fuel filters
Modern fuel injection concepts require extremely
Water separation is carried out in two phases. In
clean, homogeneous, and pulsation-free fuel
the first phase, alongside the actual particle filtra-
supply. However, foreign particles can get into
tion, fine water droplets are also coalesced into
the fuel during the production and transport pro-
larger ones. In the second phase, a hydrophobic
cess and must be filtered out. MAHLE fuel filters
fabric separates these larger water droplets by
hold back foreign particles reliably. Thanks to
preventing them from entering the injection sys-
high-quality filter media, the fuel system is pro-
tem with the clean fuel.
tected from smallest dirt particles, and therefore
from corrosion damage. This safeguards the en-
The second filter phase comprises a water sepa-
gine function and assures the efficient operation
rator, whose hydrophobic fabric divides the now
of the vehicle. The required constant fuel supply
barely stable emulsion, thus separating the water.
is achieved with pressure regulation and recircu-
As this occurs on the clean side of the filter, it is
lation of the surplus fuel from the injection pump
referred to as a clean-side water separation.
to the tank. Pulsation damping compensates for
the pressure fluctuations caused by the fuel
Emulsion
after pump
pump. Our fuel filters comply with the correspon-
Filtrated
fuel
dingly high safety standards of the vehicle manufacturers and ensure sealing tightness even in the
event of accidents.
An important condition for the correct functioning
of the fuel filter is that filters are replaced within the
maintenance intervals stipulated by the vehicle
Particle separation and agglomeration of water
droplets
Clean diesel with
water droplets
manufacturer.
Diesel fuel filters
In order to prevent paraffin separation and clog-
Hydrophobic fabric
Water collection volume
ging of the filter at low ambient temperatures, our
fuel filters rely on pre-warming with electric heating
elements or recirculation of fuel that has been war-
Schematic diagram of a two-stage filter element with integrated water separator.
New and innovative:
the fuel filter module
developed by MAHLE
specifically for commercial
vehicle applications. The
multi-stage patented
MAHLE filter element
provides effective water
separation. In the first
stage, the solid particles
are filtered out. In the
following stages, the
microfine droplets
coalesce to form larger
droplets and the water is
separated. MAHLE has
developed the automatic
water disposal system
BlueDrain® specifically for
diesel fuel with a high
water content, which will
be available in the future as
both a stand-alone system
and an integrated system
unit in MAHLE fuel filter
modules.
med by the engine.
Inline fuel filters
Newer filter generations also come with efficient
Inline fuel filters are mounted in line with the fuel
water separation in order to fulfil the increasing
line, as the name indicates. They are made from
demands placed on fuel preparation.
steel sheet with corrosion protection, stainless
steel, aluminium, or plastic. Optional functions
If diesel fuel contains water, corrosion and cavita-
such as pressure regulation, pre-heating, cooling,
tion damage may occur in the injection system.
and water separation are available.
27
DESIGNED FOR
FRESH AIR.
28
Filters
Cabin air filters
Cabin air filters are very efficient. During only one
Our cabin air filters do not produce harmful
hour of driving, an air volume of up to 100,000 litres
emissions, as solvent-free methods are used for
is blown into the vehicle interior. All the more im-
their manufacture.
portant is the regular replacement of the filters.
MAHLE recommends changing the filters every
Cabin air filters with activated carbon (LAK)
15,000 km—at least once per year. Because if the
Cabin air filters with activated carbon keep back
cabin air filter fails or when it is clogged up, the pol-
harmful exhaust fumes, dirt, and dust, as well as
lutant concentration in the interior of the vehicle
high ozone concentrations and unpleasant smells.
can increase up to six times of that of the outside
The media block used in these filters comprises
air. MAHLE cabin air filters supply the driver and
three layers: an activated carbon layer is embed-
passengers reliably with cleaned air to breathe and
ded in two layers of fleece. The use of adhesives
thus safeguard their health, well-being, and power
containing solvents is consistently avoided.
of concentration even in the event of smog or a
high pollen count. They also reduce the load on the
Depending on the vehicle type, pure activated
blower, protect heating and climate control from
carbon canisters (LKK) are also available, which
contaminations, improve air circulation, and pre-
can be used to supplement conventional cabin
vent dangerous misting up of the windows. In addi-
air filters.
tion, the inside of the windows and fittings remain
clean for a longer period of time.
The pleat geometry of our cabin air filter elements
is designed to provide a long service life. The low
flow resistance minimises the load on the blowers.
Thanks to the accurate fit of the filter elements into
the housing, bypass air is eliminated.
In vehicles with an increased
service life and that are
operated in heavily contaminated surroundings, an
additional pre-filter (LAP)
made of polyester foams or
fleece matting is frequently
used. By absorbing coarse
particles, these pre-filters
prevent the surface of the
cabin air filters from clogging up prematurely. As a
consequence, the tool life
of our LA/LAK filters is prolonged considerably.
29
WE WORK
BEST UNDER
PRESSURE.
30
Filters
Air drying cartridges
Especially for commercial vehicles
To guarantee the operational safety of the air brake
Many control and closed-loop control processes
system, it is imperative that air dryers are replaced
in commercial vehicles work with compressed
according to the regulations of the manufacturer.
air, as is the case in brake systems, for instance.
Air contains moisture, however, which in turn can
Air dryer cartridges from MAHLE operate irres-
cause damage in piping and containers, conta-
pective of the temperature. They contain a drying
minate lubrication films, and freeze at low tempe-
agent that is regenerated under system control. At
ratures. Air dryers are used in order to assure
the same time, contamination and condensation
failure-free operation of the safety systems. They
water are removed from the pre-filter. Our air dryer
remove moisture from the air, prevent corrosion
cartridges are resistant to corrosion on both the
in pipes and containers, and guard against pre-
inside and outside, and work reliably even under
mature wear and malfunction.
the most difficult of conditions.
31
CLEAN AIR
WITHOUT
COMPROMISE.
32
Filters
Urea filters
Nitrogen oxides (NOx) contribute to the formation
is constantly increasing; and with it the amount of
of smog and acid rain and increase the green-
urea solution required. This is leading to increas-
house effect. In order to reduce nitrogen oxide
ingly complex storage and transport processes,
emissions from vehicles, AUS32 fuel is used, which
which is inevitably raising the risk of contamina-
is a 32.5 per cent urea solution. Urea thereby plays
tion. The result: the sensitive components that
a significant role in ensuring that the increasingly
come into contact with the solution—for example,
stringent legal limits, even beyond EURO 6 and
the injection nozzles, catalytic converter, and
Tier 2 Bin 5 (United States), are not exceeded. A
other system components—get dirty, wear out,
common, though technically complex and applica-
or break down completely. This can be expen-
tion-intensive, method for reducing nitrogen oxide
sive, especially if the catalytic converter becomes
emissions is to transform them into harmless nitro-
ineffective as a result of contamination and needs
gen (N₂) and water (H₂O) by means of selective cat-
to be replaced.
alytic reduction (SCR) systems.
In order to prevent the urea solution from conAUS32 is aqueous, clear, non-toxic, safe to han-
taminating the system, the MAHLE Aftermarket
dle, and does not present a risk to humans and
product range now includes urea filters in proven
the environment. The urea solution is sold under
original equipment quality. Their fine-pored filter
the following trademarks: AdBlue in Europe, DEF
media make an important contribution to the
in North America, and ARLA 32 in Brazil. Its con-
proper long-term functioning of the SCR systems
sumption is about 5 per cent of a vehicle’s fuel
and protect even the most sensitive parts of the
consumption, it can be easily topped up at service
vehicle from wear.
stations or obtained through accessory suppliers.
Well equipped for the future
SCR system processes
Until recently, SCR systems were fitted mainly in
The urea solution is stored in a separate tank and
commercial vehicles. Now, vehicle manufacturers
sprayed directly into the exhaust gas flow directly
are increasingly building on these proven tech-
in front of the SCR catalytic converter in a con-
nologies in passenger cars, merging particulate
trolled manner by injection nozzles. Then thermol-
filters and SCR systems and further developing
ysis takes place: the urea solution is divided into
the exhaust gas after-treatment system.
ammonia and isocyanic acid by the hot exhaust
gases. Aided by the water contained in the solu-
MAHLE is closely involved in these developments,
tion, the isocyanic acid is then split into ammonia
providing innovative, future-oriented solutions in
and carbon dioxide (hydrolysis). Only then can the
this area, too. One example of this is a filter me-
nitrogen oxide present in the exhaust gas system
dium made from a fully synthetic material, which is
react with the ammonia in the catalytic converter
characterised by extreme temperature resistance:
and be converted into harmless nitrogen and wa-
it can withstand more than 1,000 freeze cycles
ter vapour.
without damage—with a consistently high filtering
performance. In this way, MAHLE contributes to
The problem of contamination
the field of exhaust gas after-treatment, making
—the solution from MAHLE
vehicles even cleaner.
With the tightening of legal regulations, the percentage of vehicles equipped with SCR systems
33
CATCHING
THE LOT.
34
Filters
Filter media
Our filter media range consists of specially trea-
Filter fleeces
ted papers, fleeces, or multi-layer filter media,
Fleeces, on the other hand, consist of plastic
depending on the specification and application.
fibres with thicknesses in the μm range: the finer
the fibres, the better the collection. The fleeces
Filters made of paper
are applied in layers, whereby the density and
The paper for our filters is made of high-grade cel-
fineness of the fibres increase from the dirty to
lulose fibres impregnated with special resins. The
the clean side. This so-called funnel effect al-
material is treated in a special production process:
lows efficiencies of up to 99.9 per cent with low
special pre-warming prepares the paper for the
flow resistance.
embossing of vertical ridges. The paper is then folded according to the respective requirements. Af-
For some years now, fleece has been used for ca-
terwards the impregnation is cured to make the
bin air filters as well as for new developments in
paper mechanically stable and resistant to chemi-
the oil filter sector. Recently, fleece has also been
cal and thermal influences. The outcome: filters
increasingly used in air filters—with the advantage
with stable pleat geometry that prevent the drea-
of up to 40 per cent increase in filter performance
ded forming of blocks (see right column) even un-
and longer service life. Fleece also finds applica-
der high loads and ensure that air, oil, or fuel can
tion to an ever greater extent in fuel filters, mostly
flow freely through the paper at all times. The fine-
combined with stabilising base paper.
ness of the filters can reach 1 μm, depending on
the requirements, and offers safe conditions for
Multi-layer filter media
highest dirt elimination.
These media are combinations of fleece and pa-
Funnel effect of the filter
fleece: density and fineness of the fibres increase
from the dirty to the clean
side.
per that have been fused in a complex production
Filters made of paper are used in air, fuel, oil, and
process. They are characterised by a dirt collec-
hydraulic filters.
tion capacity that is up to 40 per cent higher than
that of conventional paper filters at a dirt collection
efficiency of 3 to 5 μm.
Multi-layer filter media are used for modern diesel
fuel injection systems (in turbo diesel direct injection, common rail, or pump injector technology).
➡
The impregnated cellulose
fibres under the microscope.
Dirty side
Meltblown
Filter paper after embossing.
➡
Readily pleated paper for use in filters.
Clean side
Cellulose
Multi-layer filter medium with plastic fleece at the dirty side and
paper at the clean side.
Block forming in air
filters—an expensive
phenomenon
When the pleat geometry is insufficiently stable
and the folds are too
close together, no air or
not enough air can flow
through the filter in these
areas. This increases
the flow resistance, the
filtration deteriorates, the
life span of the filter is
reduced, and the fuel consumption and pollutant
emissions increase significantly.
In order to prevent loss of
stability and shape, our
filter papers are impregnated with special resins
as part of a complex
treatment process.
35
OUR
SERVICE
TEAM
IN THE FIELD.
36
MAHLE Service Solutions A/C service units
Whilst HVAC systems were considered a middle-
and the MAHLE ArcticPRO product line for R134a
and upper-class “luxury accessory” until just a few
and R1234yf. Both units meet the highest stand-
years ago, today they are standard equipment in
ards (SAE J 2788 and SAE J 2099) and limit re-
the compact car segment. The repair and mainte-
frigerant loss during an A/C service to the lowest
nance requirements also continue to increase ac-
technically feasible amount. They offer a high de-
cordingly. As one of the world’s leading systems
gree of user-friendliness, accuracy, and service
providers of vehicle air conditioning with 25 years
efficiency, such as fully automatic operations,
of experience in A/C service units and over 65
quick service processes that allow parallel work,
years of experience in the development of A/C
intuitive menus on the display, high-performance
systems, we want to help our repair shop custom-
vacuum pumps, and automatic separation of re-
ers to tap into this market potential—with the
frigerant and oil.
equipment and expertise necessary for a professional, safe A/C service.
MAHLE is also well prepared for the utilisation of
CO₂: as a sought-after original equipment partner
The different refrigerants
in the development and testing of new A/C sys-
Whether it occurs because of a leak in the refrig-
tems based on CO₂ refrigerants, we can incorpo-
erant circuit or during an A/C service using
rate our expertise directly in the development of
equipment that no longer complies with the latest
our A/C service units and provide our customers
standards: it is not always possible to prevent re-
with the right unit at the right time, according to
frigerant escaping into the environment. The re-
their requirements.
frigerant R134a, used thus far, is very damaging
to the environment: it has a GWP of 1,430, which
Playing it safe
means that its global warming potential is 1,430
Since R1234yf is more demanding to handle than
times higher than CO₂. However, because the le-
R134a, MAHLE ArcticPRO provides the repair
gal limit is 150 GWP, the refrigerant R1234yf is
shop with a sophisticated safety concept. It in-
being used in the A/C systems of many new vehi-
cludes, among other things, a fully automatic
cles. With a GWP of only 4, only the natural gas
safety and leakage test before each A/C service,
CO₂ is less damaging. Therefore, several auto-
automatic refrigerant detection via an analysis
mobile manufacturers are also working on new
unit, and a monitored ventilation system inside
A/C systems that are designed to use CO₂.
the unit, and immediately stops the unit in the
event of malfunctions. The service unit is certified
Well equipped for any situation
by TÜV Rheinland, fulfils the requirements of the
The MAHLE Aftermarket range has a solution tai-
“Arbeitskreis Klima” (Working Group on Climate)
lored to the needs of repair shops for both of the
of German automobile manufacturers as well as
refrigerants currently being used: ACxpert from
the strict U.S. standards, and is recommended
MAHLE Behr service for the refrigerant R134a
by leading automobile manufacturers.
Mobile added value: the
external analysis unit supplied with the MAHLE
ArcticPro 200yf allows the
refrigerant to be tested
easily, quickly, and accurately—enabling it to also
be flexibly deployed in the
reception bay or while the
service unit is being used
on a different vehicle.
37
EVERYTHING ELSE THAT COMES
WITH ALL OF OUR
PRODUCTS.
38
Sales and service
Global network
The best vehicle spare parts are of little use if they
online offering, such as the online catalogue,
are not available at the right place at the right
which is also accessible via smartphones. Or the
time. In more than a dozen logistics centres and
MAHLE Aftermarket app, which provides quick
numerous regional bases at strategic locations in
access to technical brochures and electronic cat-
Europe, North and South America, as well as
alogues. Or the QR code on the labels of engine
Asia, MAHLE Aftermarket is therefore striving to
part, turbocharger, and thermostat packaging,
provide an optimal flow of goods and conse-
which is directly linked to the respective product
quently the best possible availability. This forms
in the online catalogue—and simultaneously to a
the basis for the worldwide supply network of the
wealth of information about the spare part. Fur-
international MAHLE Aftermarket organisation.
thermore, we provide our partners in trade and
repair shops with a regular technical newsletter
MAHLE products are among the most sought-after
containing repair-related information and assem-
products on the automotive parts market, by
bly tips, and offer a demand-driven training pro-
genuine buyers and forgers alike. Engine part,
gramme and practical sales material.
turbocharger, and thermostat packaging now
comes with the special MAHLE security label,
In addition, we are involved in repair shop co-
thus allowing you to quickly verify whether a part
operations and participate in individual adverti-
is genuine or a counterfeit. It combines several
sing campaigns.
security features, such as VeoMark and MAPP
code, that are linked together to provide the max-
Comprehensive public relations and our presence
imum possible protection against counterfeiting.
in the relevant trade and consumer media also assure that we are widely recognised and contribute
There is, however, more to consider in addition to
to the excellent image of our brands.
product quality and availability. Competent support and consulting, for example, or a convincing
service package. At MAHLE Aftermarket, this
starts with a broad range of information, which includes, among other things, our comprehensive
39
MAHLE Aftermarket sales network
MAHLE AFTERMARKET.
AN INTERNATIONAL
NETWORK.
THE WORLDWIDE DISTRIBUTION NETWORK ASSURES OPTIMUM AVAILABILITY.
Bilston, GB ■
Burlington, CA ■
Farmington Hills, US
•
■
Poissy, FR
■
Décines,
York, US ■
Olive Branch, US ■
Alcalá de
Henares, ES
■
Lerma, MX ■
Limeira, BR ■
Buenos Aires, AR ■
■ Logistics centre
• Sales office
40
Stockholm, SE •
■ Krotoszyn, PL
■ Obninsk, RUS
Stuttgart, DE
•■ Schorndorf,
DE
• Kiew, UA
FR
■ Izmir, TR
■
Tokyo, JP
Shanghai, CN ■
•
Dubai, AE
■
Gurgaon, IN
■
Chennai, IN
Singapore, SG ■
Port Elizabeth, ZA
•
41
42
43
000007626E.Ra.XX/14
www.mahle-aftermarket.com