MAHLE Jobs & Career | Jobs & Career at MAHLE

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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
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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
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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
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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
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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.
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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
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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
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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
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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)
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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.
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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.
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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.
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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.
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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.
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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
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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
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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