aftermarket news 1/2012

A F T E R M A R K E TM A G A Z I N E F O R T R A D E , W O R K S H O P , A N D E N G I N E R E P A I R w

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Read more on pages 3 and 10/11.

Fresh airFor your saleshow you can proFit From the experts’ knowledge—and how mahle aFtermarket provides you access to Behr hvac service units.

O v e r v i e w

EdiToRiAl 2 Arnd Franz, Head of the

MAHLE Aftermarket division indusTRy nEws 3 About coolants, HVAC service,

and optimal repair shop equip-ment

MAHlE insidE 4 Power ex works—recent

vehicles with MAHLE products

HigHligHTs 6 Outstanding! What original

equipment customers think of MAHLE

TREnds 7 Outlook for current MAHLE

product innovations

nEw on THE MARKET 8 Engine components and filters

THEoRy & pRAcTicE 10 The HVAC module: design and

function 12 Water separation—life insur-

ance for the injection system

cusToMER poRTRAiT 14 Interview with Luca Zacchetti,

Chairman of the Italian Rhiag Group

on locATion 15 MAHLE Schorndorf logistics

centre: fully automatic piston ring packaging

MARKET 16 New Internet presence:

www.mahle-aftermarket.com

This edition of mahle Aftermarket news is characterised by cooperative partnership. The cooperation between MAHLe and Behr, who together are bringing a breath of fresh air to the HvAC sector, is one specific example of this. Another is our collabora-tion with original equipment customers: here we take a look at the new challenges that sustainable individual mobility raises every day, and present products that are currently being pre-pared for series production by our development departments. we also illuminate the requirements and the recognition that ve-hicle manufacturers have bestowed on our efforts.

The interests of our trade and repair shop customers are at least as important, of course. we recently spoke about this topic with Luca Zacchetti, the chairman of the italian whole-saler rhiag. in order to facilitate your day-to-day business, we explain how an HvAC module actually works—and how we contribute to efficient water separation. Finally, we unveil our new internet presence, which is now more closely tailored to your needs. But before you click on www.mahle-aftermarket.com, we wish you a pleasant read of the printed edition of mahle Aftermarket news.

1/2012

xxeditorial

Dear readers,

Arnd Franz, Head of the MAHLE Aftermarket division.

The rapid changes in the technology of individual mobility, especially in power train technology, continue to challenge the automotive industry and its sup-pliers to greater efforts. For many years, MAHLE has been committed to technological progress and has been intensively involved in the current trends from the beginning. With the MAHLE plastics technology, we have allowed for significant weight savings in the charge air line and oil circuit. The latest alloys, production methods, and innovative design shapes for engine compo-nents have contributed to today’s highly efficient combustion cycles. The use of additional technologies, such as pumps and turbochargers, on and around the engine has greatly reduced emissions and met the tough requirements that the law has set.

At the IAA in Frankfurt, MAHLE and Behr presented a series of additional sig-nificant contributions that will shape the future of the automobile. By 2020, purely battery-powered electric vehicles will still represent only a low single-digit percentage of annual vehicle production. Hybrid power trains, however, will cover a much broader range compared to today’s levels, and the compo-nents of the combustion engine—whether as part of a hybrid concept or not—will need to withstand much greater thermal and mechanical loads. MAHLE and Behr have addressed these needs with a whole line-up of new products and technologies.

The MAHLE Range Extender is a two-cylinder in-line engine that charges the battery of a primarily electrically powered vehicle when needed, which may occur after a specific cruising range has been reached, or when high current draw is required under maximum load. The MAHLE solution provides 15 and 30 kW at its two main operating points and is laid out for many vehicle plat-forms, with compact package dimensions of 146 x 327 x 481 mm and a weight of just 70 kg. The battery can be much smaller and less expensive

through the use of the Range Extender. The cruising range of the power train can be increased to an acceptable level at the same time.

MAHLE is meeting the increased requirements of future passenger car diesel engines with the development of a new generation of pistons. Our decades of experience with both steel pistons for commercial vehicles and passenger car diesel pistons have been incorporated in this project. The main advantages are increased strength and the reduction in friction that results from reduced thermal expansion. This, in turn, allows the use of longer connecting rods, which exhibit less deflection and thus lower lateral forces—additionally reducing the frictional loss. MAHLE presented new friction reduction programs for other engine com-ponents as well: improved designs and new coating processes for rings and bearings have markedly improved friction loss, thus contributing significantly to further reductions in CO2 in the combustion engine.

Indirect charge air cooling integrated in the intake pipe, as developed in cooperation with Behr, is an excellent example of the technological potential that this partnership between MAHLE and Behr has to offer. Its position in close proximity to the engine provides advantages both in terms of space required and the lower pressure drop within the charge air line. The greater thermal inertia of the system also keeps cooler air available for a longer time.

Charge air cooling complements the turbocharging technology of Bosch Mahle Turbo Systems. In its first year of large-scale production, the joint venture between Bosch and MAHLE is recording supply contracts for over a million turbochargers annually, which includes both wastegate turbocharg-ers and those with variable turbine geometry, turbochargers for both diesel and gasoline engines, and for both passenger and commercial vehicles. Bosch Mahle Turbo Systems has set the bar very high with regard to effi-ciency, service life, and acoustics.

With a whole line-up of technical concepts across a variety of products, MAHLE demonstrated at the 64th IAA that the combustion engine still has great potential in every aspect—as well as the ability of the company to play a leading role in the competition of innovations, both for the conventional combustion engine that will continue to dominate, and for hybrid concepts and electric powertrains.

It is this innovative strength that will also be put to use for the benefit of our customers in the aftermarket, with continued brisk expansion of our product range, market-oriented vehicle coverage, excellent availability, and professional sales support measures.

Close cooperation with our partners along this path continues to be of great importance to us. Count on our commitment.

Sincerely,

Arnd Franz

mahle will take a lead role in the competition oF innovations.

n e w sA F T E R M A R K E T 2

industry news


changeClimate

what you should know aBout Both coolants, how the requirements For hvac service are going to change—and how mahle aFtermarket provides you with access to the latest generation oF Behr hvac service units.

the current situation: two coolants in every repair shopThe greenhouse potential of a material is indicated by its GWP value (Global Warming Potential). The lower the value, the better for the environment. For coolants, the EU directive has defined a maximum value of 150 for newly harmonised passenger cars as of 1 January 2011. After 1 January 2017, the traditional coolant R-134a, with a GWP of 1,430, will no longer be permitted in any newly registered vehicle models. The future alternative has been defined as HFO-1234yf. Its GWP is only 4. The air conditioning systems in the existing vehicle population, however, do not need to be retrofitted. For repair shops, this means: you will need to need to retain service equipment for R-134a until all vehicles that use the old technology have disappeared from the market. This could easily be another 20 to 30 years.

the challenge: strict saFety requirementsWhile the new coolant requires only minimal manufacturing changes to the A/C circuit, both repair shops and service equipment manufacturers are faced with an additional challenge: HFO-1234yf is classified as highly flam-mable. HVAC service units are therefore subject to stricter safety standards. The Behr ACxpert 2000yf has therefore been tested and certified by an independent technical testing agency and institution.

The new Behr HVAC service unit for HFO-1234yf, the Behr ACxpert 2000yf, is based on a safety concept prescribed by the VDA “Service” working group. Some vehicle manufacturers have approved it for use in their own repair shops only if the entire equipment concept has been successfully tested by specialised insti-tutes. Part of this safety concept is the gas analyser that is integrated in the unit.

It ensures that only HFO-1234yf coolant is present and is extracted. Otherwise the coolant must be extracted separately and disposed of—it may not be put into the coolant bottle for recycling. In addition, special service fittings are designed for HFO-1234yf, preventing R-134a from being accidentally extracted even before the HVAC service is started.

the saFer solution: two separate service unitsCompliance with this strict safety concept is one reason why Behr Service offers a dedicated technological solution for each coolant. The HFO-1234yf unit is also fundamentally different from an R-134a unit, due to its required explosion-proof zones and specially designed components. In this context, an HVAC specialist would also advise against combining both technologies in one unit, or using upgrade solutions.

why hvac service units From hvac experts?HVAC service units from Behr Service are not only attractively designed, they also excel with their high-quality components. The Behr ACxpert 2000yf for HFO-1234yf comes in a solid metal housing. The ergonomically designed user interface and logical menu layouts are simple to navigate, and intuitive symbols make them easy to work with. Both units also have class 1 pressure gages that can be read from a distance. The current operating status is indicated by an easily visible indicator light, and an integrated printer provides a record. Special service adapters designed for each connection and an integrated flushing function (for the use of an external flushing unit) round out the two repair shop machine concepts for HFO-1234yf and R-134a. Effective imme-diately, repair shop equipment for Behr Service HVAC checks is available through MAHLE Aftermarket.

Behr acxpert 2000yF—For hFo-1234yF Coolant extraction Coolant recycling Automatic separation of coolant and oil Automatic refill of oil and coolant Vacuum and pressure tests to check leak tightness Integrated flushing function (with external flushing unit) Integrated safety concept Integrated coolant analysis

Just in time For the 2012 air conditioning season, mahle aFtermarket is launching the new Behr acxpert Family oF hvac service units, developed By the mahle partner and hvac pros at Behr service, who are working in close cooperation with the maJor vehicle manuFacturers.

Behr acxpert 1000a—For r-134a Coolant extraction Coolant recycling Automatic separation of coolant and oil Automatic refill of oil and coolant Vacuum and pressure tests to check leak tightness Integrated flushing function with external flushing unit

In focus: Ford B-MAx.

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.

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Ford B-MAX: entering A new diMensionThe B-MAX was one of the highlights that Ford presented at the IAA 2011. It is the successor to the Fusion, also known as the “high-roof Fiesta,” the last model from the old Fiesta series. Some of its technology is still to be found in the B-MAX, but the engines and body have been completely renovated.

Very generous: the interior spAceThe innovative 4-door body concept really catches the eye. It does away with the classic B-pillar, giving the rear-seat passengers sliding doors that open up to provide 1.5 m wide access to the rear compartment on both sides. The feeling of spaciousness is underlined by a generous glass panorama roof. The B-MAX also has more cargo space than its predecessor. The front passenger seat and rear bench fold down to create a 2.35 m long loading area.

Most unoBtrusiVe: the new three-cylinderThe B-MAX also debuts a particularly consumer-friendly and low-emission direct injection turbocharged gasoline engine with variable valve control. The three-cylinder downsizing unit, with 1.0 L displacement, provides the power output of a conventional 1.6 L engine but emits less than 120 g/km of CO2.

MAHLE contributes to greater efficiency throughout the entire engine: pistons, piston rings and pins, bearings, bushings, camshafts, valve guides, valve seat inserts, air intake modules, air filters, and oil filter modules.

mahle inside


mahle inside


1 FiAt pAndAA model of success for over 30 years, now in its 3rd generation: the Fiat Panda. It’s a bit bigger (11 cm longer, 5 cm wider, 1 cm taller) and is much more rounded than its predecessor. Internally, its cutting-edge engines contain pistons and piston rings, oil filter modules, oil mist separators, valve guides, and valve seat inserts from MAHLE. The two new gasoline engines with “TwinAir technology” are particularly efficient on the road—a newly developed holistic concept by Fiat that for the first time combines electrohydraulic valve control with a two-cylinder downsizing turbocharged engine.

2 Mercedes-Benz ActrosExcellent driving comfort, paired with uncompromising safety, reliability, per-formance, and economic efficiency: the Actros leads the way in international long-haul trucking. Mercedes-Benz has redesigned the King of the Road with many new technological innovations, including engines that reduce fuel con-sumption. The power plants, available in four performance levels from 310 kW (422 HP) to 375 kW (510 HP) are paired with a standard automatic shift sys-tem for outstandingly economical driving enjoyment. The power plants con-tain: cylinder liners, piston pins, connecting rods, valve seat inserts, fuel filter modules, and oil filter modules from MAHLE.

3 BMw M5Munich goes on the offensive—with the new BMW M5. Other than the newly designed front end with generous air scoops for the radiator, it is not obvious at first glance what this sedan hides inside. The 4.4 L V8 engine puts out 412 kW (560 HP) and is turbocharged by two turbochargers. In brief: top speed of 250 km/h, from 0 to 100 km/h in 4.4 s. MAHLE products also make their contribution to its driving pleasure: air intake modules, air filters, air guid-ance systems, oil mist separators, oil filters, oil pumps, valves, pistons, piston rings, and piston pins.

4 cheVrolet cAMAro coupéIf this were not an American model, one could almost call it a coupe for the common man, as the new Chevrolet Camaro Coupe is one of the most afford-able sports cars with a V8 engine. It puts out a hefty 318 kW (432 HP) with a stick shift, and 298 kW (405 HP) in the automatic version. The 5th generation of this Chevrolet, which might even impress right-lane drivers with its rakish design, takes it from 0 to 100 km/h in 5.2 s, while a governor limits the top speed to 250 km/h. The American legend of the muscle car uses pistons, piston rings and pins, connecting rods, air filters, and air guidance systems from MAHLE.

5 opel AstrA gtc“Man’s new Baby”: with 5 whimsically humorous episodes about pregnant men who joyfully await the Astra GTC, Opel is launching a model via the Inter-net for the first time, striking a new path in target marketing. The GTC also has a number of automotive technology innovations worth waiting for: highly efficient engines, for example, from a 1.4 L gasoline version with 74 kW (100 HP) to the 1.6 L turbo package with 132 kW (180 HP). MAHLE contrib-utes pistons, piston rings and pins, connecting rods, bearings, bushings, camshafts, valves, and oil mist separators to this advanced engine technology.

6 Audi Q3With the Q3, Audi has put an “urban offroader” on the street. Its appearance reflects this theme—a powerful body with a dominant single frame, combined with the elegant roofline of a coupe. Extremely efficient TFSI power plants under the hood combine the advantages of an FSI engine and exhaust gas turbocharging; in addition, two modern TDI diesel versions are available. MAHLE’s contribution: oil filter modules, valves, connecting rods, pistons, piston rings and pins.

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Continuously recognised by leading automobile manufacturers and famous institutions in this sector: the innovative strength and product quality of MAHLE.

xhighlights

how the automotive industry sees mahle—and what this means For the aFtermarket.

Associations and other institutions regularly issue significant awards as well. The Society of Plastic Engineers (SPE), for example: it recently recognised MAHLE Filtersysteme GmbH with a first prize in the category “Parts & Com-ponents—Power Train” for the BMW all-plastic oil filter family, which combines an innovative modular design with a unique integration of various functions. Then there is the coveted PACE award, which is awarded annually by the American trade magazine Automotive News, together with the consulting firm Ernst & Young. It is considered the “Oscar of the supplier industry.” In the “Product” category, the prize recognises outstanding innovations in the auto-motive market, such as the electrical turbocharger wastegate actuator from MAHLE, for example: its fast and precise actuating element engages the bypass valve in the exhaust flow independently of the pressures in the system, allowing significant fuel savings.

What all of these awards have in common is that they honour the impetus that MAHLE continually provides to the automotive industry. Innovations that are being developed and implemented today for original equipment—and that will become sales factors in trade and repair shops tomorrow and the day after. Innovations are also a positive image factor, of course. Above all, however, they help to secure the future of mobility—and therefore of us all.

excellent! How innovative is a company? What is its approach to product quality? How smoothly do series production launches proceed? And what is the cooperation like? These are just a few of the many questions that the international automo-tive industry asks, year after year, as it inspects every aspect of its suppliers. The automotive industry issues annual “report cards,” even to such well-known manufacturers as MAHLE—and awards coveted prizes to its best partners.

One of the these accolades is the World Excellence Award, which Ford awards to its best international supplier for excellent performance in qual-ity, technology, cost efficiency, and on-time delivery. MAHLE Engine Com-ponents Inc. in Morristown, USA, recently received the Gold level of this coveted award—as one of only 15 companies worldwide. The prizes awarded by Toyota are also highly regarded in the industry, particularly the Superior Quality Performance Award. It is given to those suppliers that make significant contributions to the improvement of quality—and the MAHLE Group was recently once again among the awardees. Technical savings are also recognised—in this regard, the MAHLE Group received the Supplier Award of the PSA Group in the category of cost management: MAHLE engineers were able to eliminate the piston cooling channel on one part of the DV6 engines.


resource conservation, increasing eFFiciency, minimising pollutants—individual moBility continuously poses new questions. the answers are Being generated in the mahle research and development centres.

the future?where are we heading in

the Future oF the electric powertrAin: greAter cruising rAngeBattery capacity is one of the main problems with the electric car. The solution: the range extender principle. It places a small combustion engine next to the electric motor and engages it when needed, charging the battery with a genera-tor. MAHLE Powertrain has a developed a Range Extender gasoline engine that features extremely compact outer dimen-sions (416 x 327 x 481 mm) and weighs less than 70 kg: with 2 cylinders, 0.9 L displacement, 30 kW rated power, and an integrated generator. The generator supports a 55 kW per-manent synchronous motor with a 15 kWh lithium ion battery in electric vehicles. The result: compared to the conventional reference vehicle, CO2 emissions are significantly reduced for all driving cycles and charging strategies.

the Future oF the gAsoline engine: 3 cylindersWith the second generation of the downsizing demonstrator, MAHLE has highlighted the potential savings that can be unlocked in the combustion engine. The three-cylinder engine developed by MAHLE Powertrain (120 kW, maximum torque 286 Nm) was installed in a street-ready mid-range vehicle, where it replaced a naturally aspirated engine nearly double its size. The result: excellent driving performance, great practical-ity for everyday use, low fuel consumption, and low emissions values. A series of various tests and test drives with industry professionals have provided MAHLE with the confirmation.

the Future oF chArge Air cooling: indirect And integrAtedModern turbochargers require the effective cooling of charge air. MAHLE and Behr have developed an integrated, indirect charge air cooler that exhibits 20% less pressure loss, which benefits the density recovery and volumetric efficiency for each cylinder. The increase in thermal inertia provides the engine with cooler air for a significantly longer period, which positively effects the respon-siveness and engine output. Integration in the intake pipe elimi-nates the charge air lines, reduces the charge air route by about 80%, and achieves the best possible leak tightness of the system, adding to the advantages of indirect charge air cooling.

the Future oF the cAMshAFt: VAriABleWide under full load at high speeds, narrow at lower speeds—this

defines the ideal state of the exhaust cams. The solution from MAHLE: the CamInCam® camshaft. It consists of two nested shafts, exercises variable control of the exhaust valve, and pro-vides clear advantages in the torque curve, power output, fuel consumption, and emissions.

the Future oF the oil puMp: BidynAMicThe controlled pendulum-slider oil pump patented by MAHLE has already been tried and tested in millions of combustion engines. Now it has been further developed into a bidynamic pressure pump that can be used in automatic transmissions, among other applications—or in hybrid drives, where it feeds two separate oil circuits.

the Future oF the piston: steelThe TopWeld® piston consists of two welded steel elements with an integrated cooling channel. The material properties allow the piston height to be reduced by about 30%, which saves instal-lation space or minimises lateral forces. Its lower thermal expan-sion, in comparison to aluminium pistons, results in fuel savings of up to 5%.

the Future oF piston rings: optiMised Friction coeFFicientsThe friction losses in the engine present a considerable potential for savings. In order to optimise the friction coefficient of piston rings, the ring stress has been lowered, the ring width reduced, the surface profile improved, and coatings applied to the surface. The result: reduction in fuel consumption by up to 2%.

the Future oF the BeAring: coAtedVehicles with stop-start systems or hybrid drives rack up considerably higher numbers of starting cycles. This places additional loads on the bearing points in the engine. The solu-tion from MAHLE: polymer coatings with high wear resistance, temperature resistance, and chemical resistance.

the Future oF the ureA Filter: Fully syntheticAmmonia is used in the exhaust lines of modern diesel engines to convert nitrogen oxides into nitrogen and water. To prepare the urea, MAHLE has developed a special filter media made of fully synthetic material that is characterised by extreme tem-perature resistance.

MAHLE Range Extender.

MAHLE Behr intake module with integrated indirect charge air cooling.

MAHLE CamInCam® camshaft.

xtrends


PistonFor passenger carsCharacteristic features

Part no.

VW T5 and Touareg (engine: BPC + BPD, model year 01/2006–05/2010)With ring carrier, cooling channel, relief for cooling oil injection nozzle, graphite coating, profiled piston pin, and pin bore bushingCylinder 1/2: 028 20 00 (MAHLE Original) or 56 14408 0 (Perfect Circle)Cylinder 3/4/5: 028 21 00 (MAHLE Original) or 56 14418 0 (Perfect Circle)

BearingsFor passenger carsCharacteristic features Part no.

Audi A3, A4, Škoda Octavia, Seat Leon, VW Passat, Jetta, Golf Plus (engine: CCSA, ALZ, ANA, ARM, etc., from model 05/2000 onward)Connecting rod bearing set, main bearing set, and thrust washer bearing set available029 HS 20864 000/025/050, 029 PS 20896 000/025/050, 029 AS 20866 000 (both MAHLE Original and Perfect Circle)

turBochargerFor passenger carsPart no.

VW Group, Audi A3, Golf IV, Bora, Škoda Octavia (engine: 1.9 TDI, engine code ALH, AHF, AJM)030 TC 15116 000 (MAHLE Original)

inline fuel filter Kl 485/15 DFor passenger carsCharacteristic features Part no.

Renault Mégane III CC all dieselIncludes O-rings for bar heater (3) and water level sensor (1)70539065 (MAHLE Original) or 70539064 (Knecht)

caBin air filter insert la 624For passenger carsCharacteristic features Part no.

Chevrolet Matiz, SparkInjection-moulded filter, bendable for assembly

70537698 (MAHLE Original) or 70537699 (Knecht)

new on the market

A F T E R M A R K E T 8n e w s

Piston ring setFor commercial vehicles

Part no.

Perkins and Massey-Ferguson MF5435, MF5445, MF5455, MF6445, MF6455 (engine: 1104C-E44T, from model 09/2003 onward)043 93 N0 (MAHLE Original) or 47 90713 0 (Perfect Circle)

ValVesFor passenger carsCharacteristic features

Part no.

Mercedes-Benz A150/170/190/200/210, B150/200, Vaneo (engine: M166/M266)Intake valve: monometallic, nitridedExhaust valve: bimetallic, nitrided and reinforced around the seatIntake: 001 VE 30984 000 Exhaust: 001 VA 30985 000 (both MAHLE Original and Perfect Circle)

oil filter insert oX 389/1 D ecoFor vans Characteristic features Part no.

Opel Movano-B 2.3 CDTI, Renault Master IV 2.3 DCINonwoven end disc and plastic inner frame70531332 (MAHLE Original) or 70531331 (Knecht)

air filter insert lX 1841/1For motorcyclesCharacteristic features Part no.

BMW S 1000 RRWith 4.795 cm2 filter surface area

70523686 (MAHLE Original) or 70523685 (Knecht)

turBochargerFor commercial vehiclesPart no.

Caterpillar (engine: F-302)127 TC 15298 000 (MAHLE Original)

YOu CAn Find deTAiLed inFOrMATiOn ABOuT new PrOduCTs in THe OnLine CATA-LOgues AT www.MAhle-AFterMArket.coM, wHiCH Are uPdATed COnTinuOusLY

new on the market


climateIN OPERATION

anyone who does maintenance and repair work on automotive hvac systems has an abundance of questions. we hope we were able to answer yours about the new coolant hFo-1234yf (and its implications for hvac service) on page 3. at this point, however, the subject is more fundamental—how exactly an hvac module actually works.

hvac module typologyToday there are a number of different types of HVAC systems on the market, which can be divided into three main groups by their function and design.

manual hvac systems The temperature, air distribution, and blower speed are set by hand. The air

conditioning compressor is either on or off, and the temperature in the pas-senger compartment is controlled by adding heat from the heater.

temperature-controlled hvac systems The temperature is set and then held constant. The air distribution and blower

speed can be controlled manually. The air conditioning compressor is cycled (switched on and off) by the control unit as needed.

Fully automatic hvac systems/climate control systems The selected temperature for the vehicle interior is held constant. To this

end, a number of sensors continuously measure the temperature and at times the air quality as well—both at various locations in the vehicle interior and outside the vehicle—and provide feedback to the control unit. Its elec-tronics control the temperature, air flow, and blower speed as needed for optimal performance.

more than a comFort FactorWe are most comfortable at about 22°C and 50% relative humidity, which allows us to concentrate on our work and display optimal reaction behav-iour. When the ambient temperature and humidity rise, the body is exposed to formidable loads: already at 27°C, the pulse and body temperature rise, resulting in lowered concentration, increased tiredness, or even aggression. A further rise in temperature by another 10°C increases the risk of accidents by 20%, according to studies, because the driver feels the same under these climatic conditions as if he had a blood alcohol level of 0.05%. The avail-ability of a system that allows the driver to control the climatic conditions in his immediate surroundings to his liking is therefore more than just a comfort factor: it is one of the active safety systems of the vehicle.

theory & practice


hvac modules do not like waterCoolants are hygroscopic, that is, they attract water. Water can enter the coolant circuit through leaks in the cooling system. Because liquids cannot be com-pressed, they would destroy the compressor. The reservoir for the coolant thus also serves as an equalising tank: the drier cartridge draws moisture out of the system by adsorption. The drier is additionally designed as a filter.

the coolant: changing states The coolant circulating in the cooling circuit utilises two known phenomena: condensation and evaporation. During compression of the gaseous coolant, heat is generated and brings the coolant temperature up to about 100°C. When it travels into the condenser, which is cooled by the passing wind, the coolant gas is cooled rapidly and transitions from the gaseous to the liquid state. An expansion or throttle valve controls and regulates the amount of coolant that flows into the compressor and evaporates there due to the lower pressure level. Heat is required for the transition from liquid to gas, and it is extracted from the air that the blower moves across the evaporator. The air that is thus cooled then flows into the passenger compartment.

maintenance is mandatoryDue to the hygroscopic property of the coolant and normal compressor wear, HVAC modules require regular maintenance. This is a vital step—after all, collateral damage or even poor health may be the consequence if maintenance is neglected.

well oiledIn order to protect the HVAC components against corrosion, the coolant in the circuit has a special oil added to it, which lubricates the compressor and binds particles and wear debris. During HVAC service, which must be performed regularly in accordance with the maintenance plan, the coolant and oil are extracted: the coolant is cleaned, dried, and topped off, if necessary; the oil is separated and replaced completely.

leak inspectorIt is recommended that a liquid UV indicator be added to the coolant in the course of HVAC service. In case of leakage, the leak point can be determined at the repair shop using black light. Because the circuit often cannot be refilled in case of failure, so that the indicator can no longer be fed, this method prevents costly piece-by-piece replacement—an advantage that can be easily commu-nicated to the customer.

good healthThe damp, dark environment of the evaporator allows fungi, bacteria, and micro-organisms to reproduce easily and unhindered. These pathogens then enter the interior compartment through the ventilation system, where they can cause water-ing eyes, colds, allergies, and serious illnesses for passengers. During regular HVAC service, the cabin air filter must therefore be replaced and the ventilation system disinfected.

tasks oF the individual cooling components

1 compressor: compresses and heatsThe compressor, generally an auxiliary system driven by the engine, draws in gaseous coolant and compresses it. The coolant, which is heated in the process, is then forced onward to the condenser.

2 condenser: cools and liquefiesThe condenser, generally positioned upstream of the radiator, has wind from the vehicle’s motion streaming through it. The coolant, which can flow in at up to 100°C, is quickly cooled in the interior and becomes liquid.

3 throttle/expansion valve: expands and cools furtherThe liquid coolant is transported further in the direction of the evaporator, through either an expansion valve or a fixed throttle, depending on the manu-facturer. The expansion causes the coolant to evaporate into a gas. Because the pressure of the coolant drops rapidly as it transitions into the evaporator, it cools off significantly.

4 evaporator: cools and converts The evaporator is installed in the passenger compartment, upstream of the blower. When coolant flows into it, the evaporator cools off. The conversion from liquid to gaseous form causes the evaporator to draw heat from the air flowing through it, thereby cooling the passenger compartment.

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theory & practice


c Behr GmbH & Co. KG

patented solution From mahle For saFe Filtration and eFFicient water separation.

liFe insuranceFor the Fuel inJection system

Water separation:

theory & practice


xtheory & practice


the world of automobile manufacturing is getting smaller—the world engine (or even the world car) is a clear trend that more and more automobile manufactur-ers are following. For component development, this means that concepts need to work optimally everywhere, even under difficult climatic conditions. For fuel filtration, the requirements are clearly defined: the filter must clean contaminant particles from the fuel and separate the water content in a controlled manner.

Fuel preparation in diesel vehicles is a special challenge, par-ticularly because there is no global standard for diesel fuel, so that its water content varies greatly from region to region. In Europe, the upper limit for the total water content is 200 ppm, or 0.02%, while so-called low-quality fuel countries, such as the USA, can contain much higher levels. The more water the diesel fuel contains, the greater the risk of damage to the injection system, such as rust or locally deficient lubrication—and the greater the importance of effective water separation systems.

Another requirement for reliable water separation is the instal-lation of the fuel filter on the pressure side, that is, downstream of the fuel pump. This has become typical in line with recent technological developments. Standard filters can no longer provide reliable water separation in this regard.

patented: mahle fuel filters kl228/2d, kl490d, and kl490/1d with two-stage water separation When the fuel filter is installed on the pressure side, it has a direct effect on water separation: the large water droplets on the intake side are reduced to such an extent by the injection pressure that the fuel and water form an emulsion.

Emulsification is only one of many factors, however, that affect the process of water separation. It also depends on the vol-ume flow, flow guidance, stability of the emulsion, hydropho-

bicity of the filter layer that separates the water, and additives in the fuel.

The solution: two-stage water separation, which has been developed by MAHLE especially for the pressure-side appli-cation in diesel vehicles. Two separate steps are taken for water separation. The novel ideas incorporated into this filter system have been patented by MAHLE.

step 1: enlarge the water dropletsIn order to convert the emulsion that results from injection back into a two-phase liquid, the microfine water droplets must first be enlarged again. This process, known as coalescence, is performed by the actual filter medium, together with the filtration of contaminant particles out of the fuel. This is a cellulose filter media with a melt-blown overlay on the untreated side, that is, a fully synthetic polyester fibre layer that increases its dirt-holding capacity. The base paper and melt-blown stage optimally merge the many tiny droplets into larger ones, and the pleat-star par-ticulate filter agglomerates even the finest water droplets.

step 2: separate the waterThe second step of the filtering phase takes place in the water separator, which has a hydrophobic fabric with a mesh size of 25 µm that separates the now unstable emulsion, and thus separates the water. Because water is heavier than diesel fuel, the water droplets sink down into the water collection chamber. The lighter diesel fuel flows on towards the filter outlet. Through this process, the injection system is reliably protected against damage due to high water content in diesel fuels.

Two-stage fuel filters are installed in series production by well-known automobile manufacturers and are available in the maintenance and repair market under the MAHLE Original and Knecht brands for vehicles from Chrysler, Jeep, Mercedes-Benz, Mitsubishi, and Smart, among others.

cross section through a heated, two-stage Fuel Filter

Water disposalElectric heating and water detection unit

Fuel inlet

Water separator

Water detection

Water collection chamber

Electric heater

Filter element

Fuel disposal

the Functional principle oF the two-stage diesel Fuel Filter with integrated water separator

Emulsion downstream of the pump Filtered fuel

Particle separation and agglomeration of water droplets

Pure diesel fuel with water droplets

Hydrophobic mesh

Collected water volume

BrieF glossary oF Fuel Filters

agglomerationThe process of collecting or massing together water droplets.

emulsionA finely distributed mixture of two liquids that normally do not mix together, without visible phase separation.

hydrophobicAvoiding or repelling water.

coalescenceThe formation of larger droplets by combining smaller droplets.

xcustomer portrait


MAhle Aftermarket news: Mr Zacchetti, let’s start at the beginning …

Luca Zacchetti: Rhiag was founded in Italy in 1962 and has grown continuously ever since. At the end of the seventies, it went international, starting with Switzerland. In 1995, with the acquisition of the Elit Group, it moved into the Eastern European market. At the turn of the millennium, we expanded our position in the domestic market by buying the Bertolotti company. The latest acquisition to date took place in 2010: the Czech company Auto Kelly CZ and its subsidiary Auto Kelly Slovakia. We are now one of the most important companies in the Italian, Czech, and Slovakian markets, with locations in Switzerland, Hungary, Romania, and the Ukraine.

MAhle Aftermarket news: Those are very different markets indeed.

Luca Zacchetti: Yes, on one hand we are present in well-estab-lished markets, such as Italy and Switzerland, while on the other hand we are also active in Central and Eastern Europe, markets with great growth potential. This international presence is essential in order to be able to continue our growth—a process in which we apply our experience with established markets, such as Italy, in order to gradually carry it over to the growth markets.

MAhle Aftermarket news: Who are your customers—repair shops? Wholesalers? Motorists?

Luca Zacchetti: We supply over 60,000 operations, and the orientation varies by region: in Italy we have local sales partners, in Eastern Europe primarily repair shops, and in Switzerland mainly wholesalers. In Eastern Europe, we also sell directly to private customers through the trade channel of our subsidiary Auto Kelly.

MAhle Aftermarket news: Does this imply different approaches in terms of logistics?

Luca Zacchetti: The sales structures in the various countries are oriented to their particular markets. A common feature of them all, however, is the “pull principle.” This means that our ware-house inventories are determined by customer demand and the resulting flow of orders. An efficient IT system provides continu-

ous information exchange, an ideal stock level, high efficiency, and therefore optimal customer service.

MAhle Aftermarket news: Speaking of service, what are you doing to provide your best to your customers?

Luca Zacchetti: We offer a range of products with a width and depth that covers nearly the entire vehicle fleet in the countries where we are present. This includes chassis frame, body, and engine components, as well as electrical and electronic parts. We are partners to the most important manufacturers. In the filter sector, we have been working with the Knecht brand since the late 1980s, and we have also sold MAHLE Original engine components since 1996. Another milestone of this constructive collaboration was the joint expansion of the product range at the beginning of the new millennium. In 2006, we jointly introduced a software-supported system for inventory management and optimisation that is still in use today—an absolute first in the independent aftermarket.

In the service area, we offer our customers tools to simplify the ordering process, such as electronic catalogues and e-com-merce, as well as a wide range of specialised technical training programs. These are some ways in which we help the inde-pendent aftermarket to provide professional and qualified ser-vice to the end customer.

MAhle Aftermarket news: The Italian vehicle population has an average age of 7 years, one of the youngest in Europe. What does that mean for Rhiag?

Luca Zacchetti: With a young vehicle population, trade channels must be fast, both in the introduction of new products and in the information flow of repair data to the repair shops.

MAhle Aftermarket news: What strategy are you pursuing to secure and expand your market position?

Luca Zacchetti: In established markets, we will continue to rely on organic growth, as we continuously improve our range of goods and services. In countries with strong growth potential, we will surely expand with acquisitions as well. Overall, the after-market remains fragmented and its complexity will only increase. In order to be successful, a company such as ours must be able to offer customised concepts in individual markets.

Luca Zacchetti, CEO of the Rhiag group.

Market-oriented

growthitaly, switzerland, central and eastern europe: this is the operating range of the rhiag group, which specialises in spare part sales for passenger cars as well as commercial and utility vehicles. with 2,500 employees and sales of nearly eur 700 million, the company is one of the leaders in the independent european spare parts market: with 10 main warehouses, 165 local sales centres, 1,000,000 cubic metres of storage space, and 50 million items shipped annually—the logistical capacity of the company is impressive. mahle Aftermarket news spoke with luca Zacchetti, the chairman of the group.

xon location


The folded boxes are bundled into an outer package.

under software control, where they are sealed in special air-tight paper bags. A sticker is applied, which indicates the location of the ring (1st, 2nd, 3rd, 4th, or 5th ring groove, depending on the type of assembly.) In another machine, the ring sets are customised automatically and are packaged in an individual box, together with installation instructions, which then receives a security label and appropriate markings. Finally, the individual boxes are collected into an outer package and marked, and then shipped to wherever they are needed.

what is changing For mahle aFtermarket customers? MAHLE Original piston rings remain exactly the same as ever—with identical quality. The optimisation and relocation of the packaging process, however, means that MAHLE Aftermarket can react more flexibly to your orders. Fun-damental changes have been made to the packaging. Instead of multiple interior pockets, we now ship in individual pockets—in the standard sizes of 125 x 125 x 30 mm and 190 x 190 x 30 mm. The pictogram that indicates the groove is no longer red; now it is printed in black on the label. During the transition period, both piston ring packaging types will be in circulation.

n e w sA F T E R M A R K E T

Since the end of last year, MAHLE Original piston rings for the European sales region have been packaged on two fully automated lines at the MAHLE logistics centre in Schorndorf. The complete system is clocked at one second per ring—and thus has an annual production capacity of 1.8 million ring sets per shift.

A fundamental advantage of location consolidation is evident in the assembly of pistons—that is, mounting the appropriate piston rings on the piston—and the packaging of ring sets. Because both process chains are now performed in Schorndorf, they can access the same individual rings. Stock levels, and therefore parts availability, are significantly optimised. At the same time, flexibil-ity in terms of scheduling can be increased: the shift to a central warehouse significantly reduces access time to the ring sets to be packaged.

how the rings get packagedIndividual rings are taken from the automated small parts storage according to the customer orders, and are sent to the ring packaging machine via a con-veyor transport system. The rings are then fed into a so-called ring magazine

piston ring packaging:

mahleis moving quickly

Piston rings are made available here in line with demands.

The ring pocket gluing machine at work. The ring set is inserted into a folded box.

the packaging process for mahle original ring sets has been automated and shifted to the central warehouse in schorndorf, germany. For the customers of mahle aftermarket, this means new packaging sizes, new interior pockets, new labels—and faster order processing.

new piston ring packaging line at the mahle logistics centre in schorndorF

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MAhle Aftermarket news 1/2012

editing: MAHLe Aftermarket newsMAHLe Aftermarket gmbHPragstraße 26–4670376 stuttgartwww.mahle-aftermarket.com

responsiBle For the contents: Arnd Franzeditors: Andrea Arnold, Yves Canaple, Christoph dutschke, eckart Fritz, Andreas Kimmerle, Hans-ulrich Melchert, Peter riedmayer

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.

eXternAl editors: ingrid Münzer, sabine steinmaier (Bransch & Partner gmbH, stuttgart)design and production: Bransch & Partner gmbH, stuttgartphotos: Bransch & Partner gmbH, stuttgart, MAHLe gmbH, stuttgart, Blühdorn gmbH, stuttgart, Photo factory/ Photo car (Ford B-MAX, p. 4; Mercedes-Benz Actros, p. 5, Fig. 2; Chevrolet Camaro Coupé, p. 5, Fig. 4), A. Avarvarii/Photo car (Fiat Panda, p. 5, Fig. 1), w. gregor-Meier/Photo car (BMw M5, p. 5, Fig. 3), s. Krieger/Photo car (Opel Astra gTC, p. 5, Fig. 5), T. Bader/Photo car (Audi Q3, p. 5, Fig. 6)reproduction: HKs-ArTMediA gmbH, stuttgartprinting and distriBution: raff gmbH, riederich

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The new MAHLE Aftermarket Internet presence has been thoroughly aligned to the needs of its visitors. Special emphasis was placed on intuitive menu navigation and user-friendly design. The new website uses an intelligent rout-ing concept that detects the region of the user and automatically opens the country-specific pages in the language defined in the browser, if it is offered by MAHLE. The expanded functionality provides modern layer navigation that saves the time-consuming navigation of individual menu items. The internal search fea-ture and browsing in the online catalogue are even faster and more reliable:

the existing catalogue publications for filters, engine components, and engine peripherals are combined into one. For the information stored on the new website to also be found by the customers of MAHLE Aftermarket sales partners, extensive measures have been taken with respect to external search engine optimisation. Waiting for the user are new categories and a practice-oriented Download Centre, in which helpful publications, such as the latest turbo-charger damage brochure, can be found. But what else is there to say—go ahead and give it a try: www.mahle-aftermarket.com

now online: the new mahle aFtermarket weBsite.

do you Find inFormation?Howww

the internet has changed many things—including the way we consume information. the demands on the medium that provides us this infor-mation have grown accordingly: facts have to be available efficiently and quickly.

aftermarket news 1/2012

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