A F T E R M A R K E T MAGAZINE FOR TRADE, WORKSHOP AND ENGINE REPAIR We have shifted into turbo mode in this edition of MAHLE Aftermarket news – with a number of pages dedicated to this component. We were present at some MAHLE engine tests, where turbochargers have to pass the toughest load tests on ultra-modern test benches. We tell you why the turbocharger is also a turbo source of income (and reveal what MAHLE turbochargers have that others do not). We show you some tips and tricks from our turbo experts for a or three highlights before you whizz through the magazine: we spoke to ATR Management Board Member Roland Dilmetz, who provided us with some interesting insights and outlooks. Sources of income which you may not have heard about are fitted into buses (and many other commercial vehicles). The on-time supply of filters to the European aftermarket is coordinated in the new MAHLE logistics centre in St. Michael. And in September the Automechanika opens its doors again, fast and safe replacement of the sensitive components. And we have included our turbo-check poster, which is bound to help you in your everyday work, as a little extra. Another two where we will be pleased to discuss all of these topics (and many more) with you personally. We are looking forward to your visit. 2/2010 COMPETENCE CENTRE COMBUSTION AREA MAHLE DEMONSTRATES SYSTEM COMPETENCE IN AND ON THE COMBUSTION ENGINE. FOR EXAMPLE AT THE AUTOMECHANIKA IN HALL 5.0, STAND B 46 Read more about it on page 7 (as well as 3, 6 and 10). OVERVIEW 2 EDITORIAL Arnd Franz, General Manager MAHLE Aftermarket 3 INDUSTRY NEWS Turbocharger as sales factor, safety factor mounting kit 4 MAHLE INSIDE Power ex works – current vehicles with MAHLE products 6 HIGHLIGHTS Turbo on the test bench: a look at MAHLE engine tests 7 EVENTS Automechanika 2010 – an invitation 8 NEW ON THE MARKET Engine parts and filters 10 PISTONS & CO. Turbo check: tips and tricks for maintenance and replacement 12 FILTERS – THE PURE TRUTH A bit rough: cabin air filter mats as pre-filters 14 CUSTOMER PORTRAIT Interview with Roland Dilmetz, Member of the Management Board at ATR International AG 15 ON LOCATION The new MAHLE filter logistics centre in St. Michael, Austria 16 MARKET Turbo info: product literature and works of reference www.mahle-aftermarket.com n e ws EDITORIAL DEAR READERS The technological change in the powertrains of road vehicles caused by consumer behaviour and the legal requirements when registering new vehicles is in full swing and is also beginning to kick in on the aftermarket. For example, the legislative body has prescribed a CO2 reduction for cars to 120 g/km as of 2012 and 2015 for initial registrations in the European Union. The efficiency of car engines is to be improved by 33 % in the United States. Car manufacturers in Japan are also facing tougher requirements, where cars will have to comply with a limit of 138 g/km from 2015 onwards. This will lead to a significant change in the technology of combustion engines in the foreseeable future. On the one hand, direct-injection technology and the downsizing of engines will continue, and on the other there will be a widespread use of turbochargers to improve the performance and efficiency of combustion engines. At the same time various technologies will become more popular in engine peripherals: these include exhaust gas recirculation (EGR) in diesel engines, more complex cooling concepts for intake air, EGR electricity, oil and fuel supply as well as the widespread use of controlled or electrical auxiliary ancillaries. Arnd Franz, General Manager MAHLE Aftermarket. “ ” OUR RANGE OF PRODUCTS WILL MAKE ANY ENGINEER’S HEART SKIP A BEAT. For workshops and dealers this means a bigger challenge: new components have to be added to the range, technical personnel trained. If nothing else, final customers have to receive a qualified diagnosis and advice. But at the same time this technological change promises opportunities for growth. The increasing modularisation of engines and an increasing share of ancillaries in the engine environment also offer opportunities for extra business in the workshops. Some interesting fields for growth also arise for engine rebuilders through bespoke system solutions for workshops who are unable to build up suitable competences for this complex topic. of the repair business. In our estimates the market for EGR valves will grow by 60% up until 2018, for EGR coolers and charge-air coolers by 50 %, and will double for turbochargers over the same period. An eye should also be kept on the development in demand for controlled oil pumps since these are being installed in an increasing number of vehicles. Apart from new engine technologies, another important trend that MAHLE is expecting is a constant growth for commercial vehicles. The economic crisis gave many a commercial vehicle specialist something of a headache, but there have recently been some signs of a return to the fundamental natural growth trend that is to be expected in any case. If the transport mix of commercial vehicles, rail transport, inland waterways and other means of transport such as pipelines remains unchanged in the long term, more than three quarters of continental freight traffic will rest on the strong shoulders of commercial vehicles. MAHLE Aftermarket will continue to expand this segment dynamically in the future. Our focus will be trained on the indispensable combustion engine and its peripherals. Our complete range of engine parts and filters for commercial vehicles will be supplemented at the Automechanika 2010 by further interesting products to make an engineer’s heart skip a beat. Our brands MAHLE Original, Perfect Circle, Knecht and Clevite will then stand for efficiency and performance in aftermarket parts, vehicle fleets and workshops more than ever before. The Automechanika 2010 in Frankfurt will be an important milestone for the future of the spare parts industry. The uncertainty in many markets – in particular the ups and downs of the past two years – calls for a strong partner. MAHLE remains your reliable partner in all subjects relevant for the future. Whether technology, assortment, distribution or information. We take up the challenges and offer you our support with a motivated and efficient team for all global markets. Take us up on our offer and meet us at the Automechanika 2010 in Frankfurt. We are looking forward to your visit. The MAHLE predictions of how demand on the aftermarket will develop also show how important these trends are for the future Yours, Arnd Franz AFTERMARKET n e w s 2 INDUSTRY NEWS TURBOCHARGER AS SALES FACTOR Exhaust gas charging - and thus a turbocharger - is usually the medium of choice if power and torque are needed fast when designing engines. In the meantime, not only are nearly all diesel engines that come off the assembly lines in Europe, North America and Japan fitted with turbochargers, an increasing number of modern downsizing petrol engines also need a turbocharger to achieve the necessary high power density. HIGH EXCHANGE POTENTIAL A turbocharger is designed and built to match the service life of a vehicle – foreign bodies, dirty oil, a faulty oil supply or excessively high exhaust gas temperatures, however, are frequent causes of damage that then necessitate its replacement. On account of the increasing share of turbocharged engines, experts are therefore forecasting a huge growth in turnover on the European aftermarket: The volume of repairs to vehicles between 5 and 8 years old will increase by around a third over the next 5 years and twice as many turbochargers will be replaced in vehicles that are 9 or more years old by 2015. ONLY AT MAHLE: EXACT FITTING MOUNTING KITS – FOR MORE REPAIR SAFETY In order to guarantee professional and safe installation, MAHLE offers an individual mounting kit for every exhaust gas turbocharger. The kit contains all the parts specified by the OEM such as seals, gaskets, nuts, stud bolts as well as oil for the first-filling of the turbocharger. This makes the repair even safer – guaranteed: because if you use the matching MAHLE mounting kit including MAHLE oil and air filters the manufacturer’s warranty for each MAHLE original turbocharger is extended from 12 to 24 months. In the car sector, between 3 and 5 % of existing turbochargers are due for replacement each year depending on the age of the vehicle. In the heavyduty sector, in other words commercial vehicles with an annual mileage of 150,000–200,000 km as well as agricultural and construction machinery, between 5 and 10 % of turbochargers fail each year. Since such a failure during normal operation often entails high consequential costs, many operators of commercial vehicles have now taken to replacing the turbocharger routinely during maintenance work. There is thus a huge demand for high-quality turbochargers, particularly for commercial vehicles as well as agricultural and construction machinery. And MAHLE, the specialist for components in the engine and its peripherals, is one of the few manufacturers that can offer just such turbochargers on the free aftermarket. MAHLE TURBOCHARGER RANGE: FROM BIG TO SMALL Following the premiere in spring 2010 at the Bauma in Munich, the MAHLE Original turbocharger range has been constantly expanded and met with great international approval – for example at this year’s Automechanika Middle East in Dubai and the Equip Auto Algeria in Algiers. Further applications are currently being presented at the Automechanika in Frankfurt. At the time of printing MAHLE can offer a total of 14 turbochargers for agricultural and construction machinery as well as 10 for commercial vehicles. More will follow shortly. Only from MAHLE: a matching mounting kit is available for every MAHLE Original turbocharger. THE MAHLE TURBOCHARGER: ULTRA-MODERN TECHNOLOGY FOR THE AFTERMARKET MAHLE turbochargers are manufactured according to strict standards on highprecision plants using innovative materials, technologies and methods. The turbochargers in older generations of vehicles also profit from the permanent innovation process in the form of ultra-modern design methods and measuring technologies, the result of many years of experience in the development and production of high-strength turbocharger components for OEM’s. This means that all MAHLE original turbochargers – irrespective of the year in which the relevant engine applications were built – are always state-of-the-art. AFTERMARKET n e w s 3 MAHLE INSIDE Picture credits: see imprint In focus: the VW Transporter T5. Power E X W O R K S THE VW TRANSPORTER T5: THE 5TH GENERATION OF A BRILLIANT IDEA. It all began in the 1950s with decommissioned Beetle test chassis which were fitted with planks and misused in the Volkswagen works as internal transport vehicles – and a Dutch VW importer who saw the potential for a new type of vehicle in these “panel cars”: the VW Transporter. Whereas the first generation models were the workhorses and tradesman vehicles of the post-war period, the successors developed via the “Hippy Van” of the 19070s to become today’s lifestyle vehicle for everyone who needs a lot of space either professionally or privately, on or off the road. COMMERCIAL VEHICLE WITH A FLAIR FOR TRENDS Over one million of the 5th generation of the VW Transporter that was launched in 2003 has come off the assembly line: more than 70 % of the vehicles on the T5 platform are ordered as vans, estate cars, flatbed trucks or a chassis, the remainder being split between the Caravelle and Multivan models. The modular system and huge variety of configurations and equipment means that the T5 is now available in over 460 different versions. In the spring of this year VW gave its successful model a general overhaul, with not just the new VW brand look including transparent, tapering twin headlamps and a distinctly straight radiator grille but also and above some new inner values. HIGH-TECH IN THE PASSENGER AND ENGINE COMPARTMENT There are some convincing new safety features in the passenger compartment – helping, for example, to make lane changes safer and ensuring an optimum illumination of corners, whereas a rear view camera ensures a better view when reversing and parking. 4-cylinder Common-Rail-TDI engines that have been specially modified for the T5 with a compact 2.0 l displacement, direct injection and turbocharging produce the tractive power. The highest power engine: a two-stage so-called Twin-Turbo with 132 kW (180 PS). All of the models are fitted with particulate filters to meet the Euro 5 standard. MAHLE’s contribution to high-torque driving fun: pistons, piston rings and piston pins, conrods, valves, air filters, oil filter modules and fuel filters. MAHLE ENGINE COMPONENTS AND MAHLE FILTERS ARE USED IN VEHICLES AND ENGINES OF THE FOLLOWING BRANDS: Alfa Romeo, Audi, BMW, Case, Caterpillar, Chevrolet, Citroën, Cummins, Dacia, DAF, Deutz, Ducati, Ferrari, Fiat, Ford, GM, Harley Davidson, Honda, Hyundai, Isuzu, Iveco, Jaguar, John Deere, Kia, Komatsu, Lancia, Land Rover, Mack Trucks, Magna Steyr, MAN, Maserati, Mazda, Mercedes-Benz, Mitsubishi, MWM International, New Holland, Nissan, Opel, Perkins, Peugeot, Porsche, Renault, Renault Trucks, Saab, Scania, Seat, Škoda, Smart, Steyr, Stihl, Subaru, Suzuki, Toyota, Vauxhall, VW, Volvo, Yamaha. AFTERMARKET n e w s 4 MAHLE INSIDE 1 2 4 3 5 6 7 Picture credits: see imprint 1 RENAULT FLUENCE The new 4-door model is a convincing, classical family car. Drivers can choose from 4 small but powerful engines: 2 16V petrol engines with 1.6 l and 2.0 l displacement and 81 or 103 kW (110 or 140 bhp) as well as 2 diesel models with 1.5 l displacement and 66 or 81 kW (90 or 110 bhp), all of which satisfy the Euro 5 standard – thanks also to MAHLE fuel filters, air filters, air ducts, valves, valve seat inserts, piston rings and bearings. 2 NISSAN 370Z ROADSTER Nissan has now opened up its recently launched sports coupé from the Z series for roadster fans – and the traditional fabric roof disappears electrohydraulically beneath a cover painted the same colour as the car in only 20 seconds. A 241 kW (328 bhp) 6-cylinder petrol engine is at work under the sleek and elegant bonnet that breaks the 100 kmh mark in only 5.4 s – the average consumption has been cut by 9–12 % compared to its predecessor. The powerhouse with a 3.7 l displacement is assisted by MAHLE oil filters, oil coolers, air filters, air ducts and activated carbon canister modules. 3 AUDI A1 The new Audi A1 stands for consistent downsizing, in terms of both the vehicle dimensions and engine concept. The TFSI petrol engines have a displacement of only 1.2 l and 1.4 l and an output of 63 and 90 kW (86 and 122 bhp) – but thanks to the exhaust gas turbocharger produce torque similar to those of 1.6 or 2.0 l engines, namely a hefty 160 Nm at 1,500 to 3,500 rpm and 200 Nm at 1,500 to 4,000 rpm. Two extremely thrifty 1.6 l turbodiesel models with 66 and 77 kW (90 and 105 bhp) round off the range of modern engines. Along for the ride: MAHLE pistons, piston pins, conrods, valves, oil filter modules, air intake modules and air filters. 4 DACIA DUSTER Gérard Detourbet, the man at Dacia responsible for the model range, has a very clear claim for the new Duster: “The best price-space ratio.” In the fashionable segment of compact SUVs it is by far the cheapest – and in emerging nations it acts as a sturdy 4-wheel, all-purpose car for the local middle class. The range starts with a 1.6 l front-wheel drive model with 77 kW (105 bhp); 4-wheel drive is available as an optional extra. Whatever the choice, MAHLE fuel filters, air filters, air ducts, valves, valve seat inserts, piston rings and bearings are always on board. 5 BMW X6 HYBRID The new BMW X6 Hybrid has 3 engines: the celebrity SUV runs on batteries with 2 electric engines up to 60 kmh – after which the V8-Turbo petrol engine with 300 kW (407 bhp) is needed. After all, the 2.5 t kerb weight has to be moved in style. The performance figures are quite impressive: from 0 to 100 kmh in 5.6 s – and a top speed of 250 kmh. The 4.4 l engine is supported by MAHLE air intake modules, air filters, air ducts, oil mist separators, oil filter modules, activated carbon canister modules, conrods, pistons and piston pins. 6 OPEL MERIVA Opel, in its own words, wants to become the “Flexibility champion” with the new Meriva. This is backed up by the innovative door concept with rear door hinges on the C-pillars so that these can be opened independent of the front doors. Or the rail system that replaces a rigid centre console. Under the bonnet you will find MAHLE pistons, piston rings and piston pins, conrods, bearings, camshafts, valves, valve guides, valve seat inserts, supplemented by air intake modules, air filters and carbon canister modules. 7 PEUGEOT BIPPER TEPEE A useful volume of 2.5 m3 with a compact overall size, a very comfortable ride thanks to urban manoeuvrability, a modern design and low operating costs are the key sales arguments at Peugeot for the Bipper – particularly now that the microvan has been given a much more temperamental engine: a chain driven multijet 16-valve with 190 Nm. MAHLE’s contribution to accelerating transport: pistons, piston rings and piston pins, bearings, camshafts and oil filter modules. AFTERMARKET n e w s 5 HIGHLIGHTS TURBO ON THE test bench Vehicle and engine manufacturers are increasingly turning to improving exhaust gas turbocharging so as to comply with the future requirements of exhaust gas standards and emission values as well as fleet consumption. MAHLE is also heavily involved in this sector. Special test facilities are needed, including so-called hot gas test benches, to test the highly sensitive components both during and after the development phase. MAHLE operates 2 of these at its Stuttgart site. As a development partner for the automotive industry and expert for engine parts and components in and on combustion engines, MAHLE is involved in the development of new engine concepts from the very beginning and performs extensive test series on numerous types of combustion engines – in some cases as a service paid for by car manufacturers. The Stuttgart site alone has 32 flexible engine test benches for car, commercial vehicle and small engines, some of which are special test benches for friction testing, for example, a cold cell and an anechoic test chamber for acoustic tests. There are also 2 hot gas test benches in operation where the turbochargers are first tested as components before being run with the engine on the engine test benches. But what exactly happens on a hot gas test bench? Dr. Reiner Künzel, head of MAHLE engine tests, provides an overview of the extensive test series. “These can first be divided up into 3 areas: thermodynamic design, endurance testing and safety tests.” THE THERMODYNAMIC TESTS The main job of these tests is to achieve the optimum efficiency of compressor and turbine and to adapt the turbocharger to the engine’s full load curve. The structural design of the compressor and turbine wheel are tested, amongst others. The compressor wheel is normally made of an aluminium alloy and has to prove its dimensional stability – at the temperatures and speeds defined in the specifications. The turbine wheel, usually made of a steel alloy, works in the hot exhaust gas flow and should therefore withstand temperatures of up to around 1,050°C depending on the application. Thermodynamic tests also include tests of the flow rate where the volume of exhaust gas and fresh air handled by the turbocharger is compared to the set operating map. ENDURANCE TESTS The mechanical developments have to prove themselves in endurance tests – in other words the component strength of the turbocharger and its resistance to wear. To this end, a turbocharger may also be subjected to a thermal shock AFTERMARKET n e w s 6 test that accelerates the ageing process of the material and components – high-speed wear, so to speak. SAFETY TESTS Oil can escape from a damaged compressor or turbine casing that may then be ignited by the hot temperatures of the exhaust manifold in a matter of seconds, thus triggering an engine fire. This means that the overspeed test first has to be passed to answer the question: “At what speed do the compressor and turbine wheel break?” In a second series of tests, the containment test, the wheels are then deliberately weakened to make them break – and then smash against the casing wall with a high energy. In this way it is possible to determine the structural strength of the casing. Only when the turbocharger has passed the tough, but relatively static load tests on the hot gas test bench is it ready for the series of dynamic tests on the engine test bench which emulate the later operating conditions in the car – after all, the turbocharger has to cope with the vibrations and temperatures on the engine too. Only then is it possible to say whether the turbocharger and engine actually work together. Or, as Reiner Künzel puts it: “They have to breathe together.” IMPORTANT: THE ADJUSTMENT OF THE ENGINE AND TURBOCHARGER The operating map application is needed before any exact harmonisation of the engine and turbocharger is possible – in other words, the engine data saved in the control unit is adapted to the parts and components. Thermodynamic adjustments and endurance tests are then carried out (at full load and in combination with cold-hot tests). So-called approval runs are then performed according to specific requirements such as exhaust gas and consumption values or the fracture strength of the casing. If all of these tests are passed, the turbocharger continues on to the field tests, in other words trial runs in the vehicle. Only then is the new type of turbocharger ready for the SoP, or “Start of Production“. EVENTS The MAHLE motor shows: assembling and dismantling an original cylinder head including peripheral components – on the hour, every hour at the Automechanika. First show: Friday at 2 p.m., last show: Sunday at 4 p.m. MAHLE– WHEREVER THERE IS PROGRESS AUTOMECHANIKA 2010: AN INVITATION TO ANYONE INTERESTED IN THEIR FUTURE. The responsible way to handle resources. The reduction of energy consumption and pollutant emissions. The optimisation of efficiency. Improving efficiency. Striving for sustainability. – the automotive future is full of challenges. As a specialist for the combustion engine and its components, MAHLE is instrumental in promoting the development of green, and therefore future-proof drive components and develops convincing and practical solutions to guarantee tomorrow’s mobility. You can gain an insight into what MAHLE engineers and technicians are currently up to and an outlook on how you can profit from this, both directly and indirectly, at the Automechanika 2010 in Frankfurt: in Hall 5.0, Stand B 46. The leading international trade fair for the automotive industry, which opens its doors every two years, is being held between 14 and 19 September at the Frankfurt Exhibition Centre. If one takes a look at the list of exhibitors and the space they have booked, one is tempted to say: yes, the end of the crisis is in sight. Yes, the industry has once again plucked up courage. And yes, the time for complaining has passed: it’s now time to roll up our sleeves again and get to work on tomorrow’s mobility. The fair organiser has consistently turned the industry’s increased demand for information into the communication of knowledge – and is offering a special aftermarket forum with some interesting seminars, podium discussions and lectures. Outstanding new developments in the industry will once again be honoured with the coveted Innovation Award. And there will also be a new edition of the “Green Directory” visitor’s guide that refers the trade visitors to particularly environmentally friendly products. Furthermore, the organisers have initiated a crowd-pulling rally for old-timers, classic cars, youngtimers and special models on the weekend of the trade fair during which awards will be handed over to the best participating cars. And what can you expect directly on the MAHLE booth? Obviously, we don’t want to give away too much. But you can reckon with some special attractions (such as the motor shows, where you can take a peek over the shoulder of our engineers during their hourly live demonstration of how to dismantle and assemble an engine). And we have prepared something really exciting for you: a glimpse of our common future. Ultimately it’s all about what the market of tomorrow will be like. In other words, which products will be important for your sales. Or how we can help make you fit for tomorrow’s mobility. A visit to Frankfurt is well worth the effort. We are looking forward to seeing you there. AFTERMARKET n e w s 7 NEW ON THE MARKET TURBOCHARGERS For commercial vehicles: MAN Diesel 11.97 l, 298 kW, engine D2866LF14/F16, model year 1993-2003 Characteristic features: Separately ordered mounting kit 228 TA 14666 000 Part no.: 228 TC 14666 000 AIR FILTER ELEMENT LX 2633 TURBOCHARGERS For passenger cars: Characteristic features: For commercial vehicles: MAN Diesel 11.97 l, 298 kW, engine D2866LF, model year 1999–2005 Characteristic features: Separately ordered mounting kit 228 TA 14481 000 Part no.: 228 TC 14481 000 Part no.: Ford Fiesta IV and VI, Mazda 2 from model year 2008 Special shape: bevelled along one side and with stabilising glue bead against block forming 70386381 (MAHLE) and 70386380 (Knecht) TURBOCHARGERS BEARING For commercial vehicles: Volvo B7F, FL7-, FL290, BUS 5000/7000/8700, FE240, FE280, FE320 (D7A/B/C/E) from model year 1998 Characteristic features : Full program for Volvo: conrod bearing, main bearing, thrust washer Part no.: 038 PS 20732 000, 038 HS 20091 000, 038 AS 20093 000 (each MAHLE and Perfect Circle) OIL FILTER CARTRIDGE OX 366 D ECO For passenger cars: Characteristic features: Part no.: AFTERMARKET n e w s Porsche Boxster and Cayman 2.9, 3.4 from model year 02/2009 Fleece end plate and internal plastic support frame 70384107 (MAHLE) and 70384105 (Knecht) 8 For commercial vehicles: MAN Diesel 11.97 l, 301 kW, engine D2866LF31 (4V), model year 1998–2009 Characteristic features: Separately ordered mounting kit 228 TA 17921 000 Part no.: 228 TC 17921 000 NEW ON THE MARKET Y O U C A N F I N D D E TA I L E D I N F O R M AT I O N A B O U T N E W P R O D U C T S I N T H E O N L I N E C ATA L O G U E S AT W W W. M A H L E - A F T E R M A R K E T. C O M , W H I C H A R E U P D AT E D C O N T I N U O U S LY. CABIN AIR FILTER ELEMENT LA 412/LAK 412 For passenger cars: Characteristic features: Part no.: Citroën Jumpy II, Peugeot Expert II Available as particulate filter (LA) or also with activated carbon (LAK) LA 412: 70374182 (MAHLE) and 70374181 (Knecht) LAK 412: 70373063 (MAHLE) and 70373062 (Knecht) PISTONS For passenger cars: Part no.: ASSEMBLY Citroën Berlingo, C15, Dispatch, Jumpy, Xsara (DW8), Peugeot 206, Expert, 306, Partner, Ranch (DW8) 040 01 00 (MAHLE) and 59 80278 0 (Perfect Circle) For commercial vehicles: DAF 85 340, 95 340, 95 430, 95 480 (XF250 M, XF280 M, XF315 M, XF355 M Euro 2) from model year 1997 Characteristic features: Pistons: ring carrier, corresponding liner 213WT03 Part no.: 213 70 90 (MAHLE) and 76 13041 1 (Perfect Circle) OIL SPIN-ON FILTER OC 604 For trucks: Part no.: DAF Series LF45, LF55, CF65 70511537 (MAHLE) and 70511536 (Knecht) PISTON RING SET For passenger cars: VALVES For commercial vehicles: Scania T112E, L111, LS111, L141S, R142 (DN11.01, DS11.01, DSC11 DS14) from model year 1975 Characteristic features: Valve seat reinforced with Stellit Part no.: Inlet: 061 VE 30986 000, outlet: 061 VA 30987 000 (each MAHLE and Perfect Circle) Characteristic features: Part no.: Honda Acura, Balad, Civic, Concerto, Domani (D15 B1, D15 B6) from model year 1987 1st ring chromium-phosphate coated 631 59 N0 (MAHLE) and 47 90686 0 (Perfect Circle) AFTERMARKET n e w s 9 PISTONS & CO. WHAT’S IMPORTANT WHEN REPLACING A TURBOCHARGER A turbocharger is designed and built to match the service life of the engine. However, the high-tech components in the exhaust gas system are exposed to several risk factors which could lead to their failure: for example from foreign bodies that penetrate the turbine, dirty oil, a faulty oil supply or excessively high exhaust gas temperatures. This makes the mechanic’s know-how all that more important. There follow some practical tips and tricks for an effective replacement. IMPORTANT: ANALYSIS A precondition for a successful repair is that the cause of the failure has been identified and eliminated – otherwise there is a risk that the new turbocharger will fail again after a short time. INDISPENSABLE: CLEANLINESS Even the smallest of foreign bodies acts like a projectile at the enormously high speeds of the turbine and compressor wheels. The air filter therefore has to be replaced in every case. Just as important is the careful cleaning of the entire intake and fresh air system to and from the charge air cooler including the removal of all foreign bodies from the exhaust pipe. AFTERMARKET n e w s 10 A MUST: LUBRICATION The rotor shaft bearing needs engine oil. TIP: pour a little engine oil into the oil inlet bore before installing the new turbocharger, place a clean cloth over this – and then distribute the oil in the bearings with a short blast from a compressed air gun (see illustrations). After installing the turbocharger and before connecting the oil supply, pour some more engine oil into the oil inlet bore. A small syringe with engine oil is enclosed with the MAHLE turbocharger sets of seals to make this work easier. PISTONS & CO. WHAT GOES IN, MUST COME OUT The turbocharger needs engine oil for lubrication and cooling and this is supplied by the oil pump in the engine. The oil is returned to the circuit via the oil return pipe. The complete oil return pipe and connection to the crankcase must be laid without any kinks and must be free from deposits so that the oil is transported smoothly. If the return flow is disturbed this leads to blockages and the turbocharger loses oil through the turbine and compressor wheels. Imminent consequences include major engine damage. TIP: a new oil return pipe is just as sensible an investment as a new charge air cooler. ANOTHER TIP: there should be no excess pressure in the crankcase. If the crankcase vent is dirty an excess pressure builds up that hinders the return flow of oil in the turbocharger. The turbocharger starts to lose oil through the turbine and compressor wheels as soon as an excess pressure of only a few millibars is measured at the dipstick tube with a manometer. ALL TIGHT? All connections on the turbocharger must be tight so that oil, air, exhaust gases and, depending on the type, cooling water can be passed through the turbocharger cleanly, safely and without losses. Each MAHLE turbocharger has a matching mounting kit – consisting of seals as well as exactly fitting builton parts (for example stud bolts, nuts, etc.). Important: only ever use these original sets of gaskets. And never use the old gaskets again – they are often deformed or porous and therefore cannot guarantee the necessary seal. Sealing compound or liquid sealers are also forbidden on the turbocharger. Sealing compound may reduce the cross-section of the bores – and parts of the sealing compound may become loose and block the supply of oil. The consequence: major damage to the turbocharger. Pour in a little engine oil before installation to lubricate the rotor shaft bearing. Then place a clean cloth over the oil inlet bore … COVER LOST? The oil supply and return lines often run very close to the turbocharger. Car manufacturers thus protect the oils pipes with shielding. This should also be checked when replacing the turbocharger: is it still in place and undamaged? NEW TURBOCHARGER – NEW OIL A new turbocharger should always be given new oil – and a new oil filter. This ensures that any foreign bodies in the oil system are eliminated and cannot damage the new turbocharger. (After all, the old turbocharger is faulty – which may be due to infiltrated foreign bodies or particles.) TIP: “If a little is good, then more is better” does not hold true for the oil level! Because if the oil level in the engine is too high this leads to disturbances of the compression ratio in the engine. This forces engine oil into the turbine and compressor of the turbocharger where it collects in the charge air cooler. If this oil is sucked in and burnt again by the engine this could lead to major engine damage. MAN THE PUMPS Once the turbocharger has been fitted, the oil and possibly water lines connected and the air and exhaust gas line connected to the turbocharger, the oil can be changed and the cooling system vented. Ignition must be prevented when the engine is started – for example by removing the fuel pump’s fuse or relay. Then turn the engine with the starter until oil pressure has been built up. If the engine is being started for the first time we recommend that you leave the engine idling for 2 minutes before opening the throttle to ensure the supply of oil. A SCREW LOOSE? You then have to check whether all screws and connections are tight and that there are no leaks. TIP: check the tight fit of all screws again after running for approx. 20 hours or 1,000 km. LONG-DISTANCE RUNNER Every engine profits from being run for a longer period of time. A turbocharged engine takes poorly to short trips because after a cold start the unburnt fuel and condensation water collects in the engine oil. This worsens the tribological properties of the oil and reduces the carrying capacity of the lube oil film. These unwanted companions only disappear at oil temperatures over 80 °C. If the oil … and distribute the oil in the bearings with a shot of compressed air. temperature stays below this level for a longer period of time, as is the case with short trips, this constitutes a risk for the turbocharger: the bearings of the crankshaft and camshaft and rotor shaft in the turbocharger become worn. At low outside temperatures the emulsion of engine oil and condensation water in the oil return pipe of the turbocharger and in the crankcase vent can also freeze leading to disturbed engine compression ratios. BIODIESEL? A HIGHER RISK FOR ENGINE OIL AND TURBOCHARGER Vegetable oils do not evaporate – and unburnt vegetable oils collect in the engine oil. This becomes viscous as of a certain concentration and the lubrication system collapses soon afterwards. This means much shorter intervals between oil changes if vegetable oils are used as a fuel. Customer care: good to know And finally, a few tips from experts that you can pass on to your turbo customers – because satisfied drivers keep coming back. Idling prophylaxis: let the engine run at idling speed for around 30 seconds before setting off to ensure the supply of oil to the turbocharger – and 30 seconds idling after a fast trip on the motorway cools the turbocharger. Short trip compensation: drivers whose journeys are mainly short trips should take a longer trip at least once a week to give the engine oil the chance to regenerate. Heater output optimisation: to help get the engine up to working temperature faster in winter you should wait for 3 minutes before switching the heater on – it will then heat up quicker too. AFTERMARKET n e w s 11 FILTERS – THE PURE TRUTH A BIT ROUGH A CABIN AIR FILTER HAS A LOT OF WORK. AND IT SOMETIMES NEEDS A LITTLE HELP: FROM A COARSE OR PRE-FILTER. Car manufacturers have been using cabin air filters for many years now to make sure that the passengers get enough clean air to breathe. Whether passenger cars, trucks, buses or agricultural and construction machinery: almost every vehicle today has a “cleaner” – either as a simple particulate filter or combination filter with activated carbon layer. Particulate filters filter solids out of the air we breathe and protect us against fine particulate, pollen, industrial dusts and other microscopic, respirable particles. Activated carbon filters also absorb smells and toxic gases such as nitrogen oxides, petrol vapours or fertilizers and break down up to 99 % of ozone. AFTERMARKET n e w s 12 FILTERS – THE PURE TRUTH Additional coarse filters are often used in vehicles with a long service life that are operated in heavily polluted areas. This type of filter mat can often be seen in traffic as roof-top structures on buses. Others are fitted in the air intake system before the actual cabin air filter and installed as pre-filters in the heater and air-conditioning casing. These coarse filters are used to ensure the maximum filter service life for the complete filter surface area of the cabin air filter: if a mass of coarse particles hits the fanfold surface of the filter this can lead to a premature clogging of the inlet side of the air filter – even to the dreaded pleat bellows clogging that prevents the passage of any air at all. Upstream coarse filters can reduce one-sided clogging of the surface of the cabin air filter on the inlet side, thus helping to ensure that the entire filter capacity is used before the cabin air filter is changed during routine inspections. CABIN AIR PRE-FILTER (LAP): FOAM OR FLEECE Pre-filters are normally made of polyester foams or fleece mats. The choice of material depends on the specifications of the vehicle manufacturer. FOAMED: A HOMOGENEOUS STRUCTURE Polyester foams consist of a homogeneous block with uniform pores produced by a special thermophysical process, reticulation (see box, bottom right). After cooling the foam is cut into slices and shaped by cutting dies. The filter effect of the reticulated material depends on the pore size PPI (pores per inch, in other words the number of open linear pores per inch = 25.4 mm). The higher the PPI number the smaller the particles that can be filtered. Common foams have between PPI 10 and PPI 80. MAHLE Original and Knecht LAP pre-filters are made using foams with a PPI of 30 since extensive laboratory tests have proven the optimum relationship between service life and coarse particle filtration for this pore size. Polyester foam is resistant to ozone and partly resistant to hydrolysis, it withstands ageing and temperatures up to 90 °C and it is free from plasticizers and CFCs. The material can be recycled and poses no problems for thermal disposal. FLEECE MATS: PROGRESSIVE LAYERS These fleece mats are based on approx. 10 and 20 mm thick polyester fibre mats that are made up of various, progressive layers so that they become denser and denser on the clean air side. This structure combines a maximum filter performance with optimum dust retention properties. 1 Filter mats are classified in filter classes according to DIN EN 779. Filter class Filtration efficiency G2 up to 80 % G3 up to 90 % G4 > 90 % 2 Weights of between 100 g/m² and 200 g/m² are used depending on the requirements. For example, a G2 filter mat with a weight of 100 g/m² will primarily stop coarse particles whereas a G3 filter mat of the same thickness and a weight of 200 g/m² can filter out much finer particles. Polyester fleece is hardly flammable (classification of inflammability F1), resistant to hydrolysis, withstands ageing and temperatures up to 100 °C. The material is free from silicon, plasticizers and CFCs, can be recycled and is suitable for thermal disposal. REPLACING CABIN AIR FILTER MATS (LAP) Since the coarse filters are often located in front of the actual cabin air filters they can usually be replaced with no great effort by the driver. Only a few steps are needed and these are described in detail in the MAHLE fitting instructions (see illustration example). 3 4 LAP filters are either used as pre-filters in addition to particulate filters (LA) or as combi-filters (LAK). Older commercial vehicles only filter the outside air for the driver’s cab through filter mats. MAHLE Original and Knecht cabin air filter mats (LAP) are also available for a number of these commercial vehicles. 5 MAHLE is one of the top suppliers of cabin air filter mats on the free aftermarket. Following a successful market launch the range of products is constantly expanded, with a focus on commercial vehicle applications and older passenger cars as of model year 1980. Popular examples include the Renault Truck Midlum or Volvo 760. Cabin air filter mats will also be available as of October 2010 for commercial vehicles from DAF, MAN, Mercedes, Neoplan, Saab, Webasto or cars such as the Mercedes-Benz S-Class. The future LAP program will appear in the online filter catalogue in autumn. 6 Reticulation – what’s that? 7 Fitting and removing the coarse filter is easy and can usually be carried out by the driver himself. The surface of the cabin air filter can become clogged with coarse dirt particles – right through to pleat bellows clogging (see left) – whereas the lower depths of the pleats remain relatively clean (see right). A pre-filter protects against this premature wear (LAP). Reticulation is the term used to describe the subsequent removal of foam membranes in a pressure vessel charged with gas. This process produces a uniform, open pore lattice structure with a minimum flow resistance for gases and fluids. AFTERMARKET n e w s 13 CUSTOMER PORTRAIT MAHLE Aftermarket news: The roots of the cooperation with MAHLE stretch back to the 1970s … Roland Dilmetz: So that the dialogue is particularly intensive and constructive. We have also regularly helped MAHLE solve problems of a mutual interest in the past. In this respect both we and our customers are very satisfied with MAHLE. MAHLE Aftermarket news: So ATR acts like a mediator on the market – between vehicle manufacturers and workshops. How do workshops profit from this? TRADE AND CHANGE Behind ATR are the 3 German wholesalers Matthies, Stahlgruber and WM AG as well as further partners from abroad. All of them together make up ATR International AG, one of the biggest cooperations in the automotive parts sector both within and outside Europe – it made a turnover of around 3.7 billion euros in 2009. MAHLE Aftermarket news spoke to Roland Dilmetz, a member of the ATR management board, about the market opportunities and risks. MAHLE Aftermarket news: As the CEO of ATR International AG you currently have the best insight into the situation of automotive parts dealers and workshops. How do things stand after the financial crisis and scrapping premium? Roland Dilmetz, CEO of ATR International AG, knows the automotive parts market like hardly any other. Roland Dilmetz: Our dealers and workshops are profiting from the crisis at the moment. The shift in the volume of service and repair work from contractual to independent workshops more than compensated the losses through the both ecologically and economically absurd scrapping premium. At the same time we are currently noticing a recovery of the eastern European market – and thus a sensitisation for market and economic aspects. One example is stock keeping, where only a few years ago the warehouses of the eastern European companies were full to the brim and tied up a huge amount of capital; in the meantime an optimisation of stocks has taken place. This sort of process naturally calls for efficient wholesale partners and parts manufacturers who have to ensure the flow of goods. MAHLE Aftermarket news: ATR cooperates with a total of 104 partners in industry. 32 of these, including MAHLE, have an IPAS status. What’s so special about this? ATR International offers its workshop and specialist trade customers access to various concepts that can be tailored to their specific needs with individual modules and elements – in Germany, for example, the AC Auto Check workshop system. AFTERMARKET n e w s 14 Roland Dilmetz: The 32 “International Preferred ATR Suppliers” (IPAS) are those with whom we make around 70 % of turnover in the corresponding merchandise groups. This makes the IPAS by far our strongest supplier partners in Europe. This rating is an indication for workshops of a particularly reliable automotive parts manufacturer. Because it goes without saying that special quality and performance criteria have to be met to achieve the IPAS status. Roland Dilmetz: We can offer around 50 different service modules within our 3 workshop and specialist store concepts in Germany – right through to workshop equipment or the construction of new business premises. We are also active in other European countries and beyond. If our cooperation partners there already have their own workshop systems we provide support for their expansion. After all, the market is changing constantly – and we have to change with it. MAHLE Aftermarket news: Another topic that is dominating the industry throughout Europe is the reorganisation of the block exemption regulation (GVO) … Roland Dilmetz: The resolution of the vertical or “umbrella” block exemption by the EU Commission on 20.04.2010 is an important step that both benefits drivers and helps secure the future of the independent repair and service market. A specific regulation for the aftermarket will also be passed in future, the so-called “Aftermarket-GVO.” The ATR involvement in the “Right to Repair” campaign, which is also supported by MAHLE, is along the same lines. However, we have noticed a tremendous lack of information amongst drivers when it comes to the topic of the free choice of workshop. Most of them are unaware that they can still have their cars serviced in an independent workshop during the warranty period. MAHLE Aftermarket news: ATR has also developed from a simple purchasing cooperation into a militant all-round service provider for the independent service and repair market … Roland Dilmetz: Workshops and specialist trades need one thing above all others apart from top quality goods at the right time and in the right place: information. Our top priority thus has to be to ensure the flow of information from the manufacturer to the workshop. But if a workshop wants to not just survive but also have lasting success in a constantly changing market it has to offer not only professional training and work, it has to present itself as a professional too – through a signal system, work wear, marketing and much more. MAHLE Aftermarket news: Can a workshop afford not to be a member of a workshop concept in this day and age? Roland Dilmetz: I am certain that there are still good workshops out there which are very successful without a workshop system. But these workshops have to put in an enormous amount of effort. After all, they have to provide those modules and elements offered by a cooperation on their own – and this means a much higher financial burden too. MAHLE Aftermarket news: Mr. Dilmetz, we would like to thank you for the interview and wish you, ATR and its customers every success. ON LOCATION AIMING HIGH THE NEW MAHLE LOGISTICS CENTRE IN ST. MICHAEL, AUSTRIA, ENSURES ON-TIME SUPPLIES OF MAHLE ORIGINAL AND KNECHT FILTERS TO THE EUROPEAN AFTERMARKET. The constantly changing number of European vehicles necessitates a constant expansion of the range of filters. This goes hand in hand with a permanent optimisation of trade stocks, making the logistics services of automotive parts manufacturers one of the most important factors for product availability. The biggest filter production works in the MAHLE group in St. Michael ob Bleiburg, Austria, has been expanded to cope with this challenge in future: with a hightech, high-bay warehouse that offers space for 38,700 pallets. UNBROKEN LOGISTICS CHAIN After a construction time of only 11 months, the new logistics centre has been in operation as the filter supply centre for European aftermarket needs since February 2010. Its commissioning was preceded by an uncompromising optimisation process, whereby the former external storage areas were shut down and integrated in the new centre. Trucks can now be loaded directly from the high-bay warehouse so that internal transports are now even shorter. The MAHLE aftermarket regional warehouses are also supplied directly from St. Michael – making for more time savings. The unbroken logistics chain that this creates from manufacturing via high-bay warehouse through to dispatch guarantees an optimum flow of materials with an effective stocking of semifinished and finished goods. Peaks in stock movements can also be safely handled thanks to the increased storage capacity – today, tomorrow and in the future: because expansions that may become necessary in the future have already been taken into account in current plans. OPTIMISED SWAPPING IN AND OUT But what is daily work like in the new high-tech warehouse? During goods receipt the container is first checked for contour, forklift slots and weight. The barcodes are then scanned and compared with the data previously determined by the SAP system. The pallet is then transported to one of the 10 stacker cranes which safely stows it away in the compartment specified by the warehouse management system. Shipping out is just as precise: the pallet is removed from the high-bay warehouse and forwarded to production or dispatch via nodal points, the so-called retrieval tables. The lines are arranged so that the forklift truck can remove them in one direction. This highly complex procedure is controlled by specially developed software whereas goods in, production supply and shipping out for dispatch is controlled via SAP. An online interface ensures a permanent data exchange. The system has been consistently planned to meet the needs of MAHLE Aftermarket customers and, for example, is able to compile all pallets on a truck into a consignment, print dispatch labels for specific customers and optimise the packaging material logistics – including its own order reserve or the warehouse management of packaging sets.. THE NEXT STEP: BUILD-TO-ORDER Even more speed and flexibility will be needed to provide an optimum service for aftermarket customers in future. MAHLE is therefore working on a new Build-to-Order system that is based on the order call behaviour in the industry. Instead of storing the filters ready packed and labelled as is the case at present they will be kept in stock unpacked as semi-finished goods and completed through printing and packaging as required. The ambitious goal is to achieve a lead time of 3 working days from the receipt of the order to delivery. This will change the high-bay warehouse from a simple storage warehouse into an integral part of the automatic production process. Just-in-time deliveries will be possible thanks to the connected materials handling technology and a special production buffer store. MAHLE HIGH-BAY WAREHOUSE ST. MICHAEL, AUSTRIA Storage products: All types of MAHLE Original and Knecht brand filters Design: 10-lane, single depth warehouse for large load carriers of various formats Building volume (L x W x H): 117 x 45 x 33 m Pallet slots: 38,700 Pallet dimensions: Width 850–1,200 mm, height 1,000–1,350 mm Pallet turnaround: shipping in max. 180 pallets per hour, shipping out max. 210 pallets per hour Linear transport: 269 m roller conveyors Transverse transport: 341 m chain conveyor Conveying speed: 0.3 m/s to 0.45 m/s AFTERMARKET n e w s 15 MARKET Put your TURBOCHARGER ON THE SHELF! MAHLE Aftermarket news 2/2010 EDITING MAHLE Aftermarket news MAHLE Aftermarket GmbH Pragstraße 26–46 70376 Stuttgart - Germany www.mahle-aftermarket.com RESPONSIBLE FOR THE CONTENTS: Arnd Franz EDITORS: Andrea Arnold, Yves Canaple, Christoph Dutschke, Eckart Fritz, Andreas Kimmerle, Hans-Ulrich Melchert, Peter Riedmayer brochure and latest catalogue, which also contains the turbocharger mounting kits, this also includes a poster showing typical damage to a turbocharger. All of this information is available from your MAHLE sales partner – as are further copies of the turbo check poster, one of which has been enclosed with this edition of MAHLE Aftermarket news. EXTERNAL EDITORS: Ingrid Münzer, Sabine Steinmaier (Bransch & Partner GmbH, Stuttgart) DESIGN AND PRODUCTION:: Bransch & Partner GmbH, Stuttgart PHOTOS: Bransch & Partner GmbH, Stuttgart, MAHLE GmbH, Stuttgart, Blühdorn GmbH, Stuttgart, C. Bittmann/Auto Bild (VW Transporter, p. 4; Nissan 370Z Roadster, p. 5, fig. 2), Werk/Auto Bild (Renault Fluence, p. 5, fig. 1; BMW X6 Hybrid, p. 5, fig. 5), A. Emmerling/Auto Bild (Audi A1, p. 5, fig. 3; Dacia Duster, p. 5, fig. 4), T. Bader/Auto Bild (Opel Meriva, p. 5, fig. 6; Peugeot Bipper Tepee, p. 5, fig. 7) REPRODUCTION: HKS-ARTMEDIA GmbH, Stuttgart PRINTING AND DISTRIBUTION: Raff GmbH, Riederich All rights reserved. Reproduction and publication of any kind, including in electronic media and/or in parts, only with prior express written consent from MAHLE Aftermarket GmbH. For further information and authorised copies, please contact your MAHLE sales partner/agent. AFTERMARKET n e w s 16 Printed in Germany.Ra.08/10 IMPRINT Whether diesel or petrol engine, commercial vehicle or passenger car: numerous vehicles today already have a turbocharger – and the curve shows a steep upward trend. This is why MAHLE is constantly extending its range of turbochargers. MAHLE can provide you with extensive information material to help you when replacing turbochargers: apart from the comprehensive product
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