Do you know the difference between the quality of MAHLE products for the original equipment market and a MAHLE product for the aftermarket? The answer is nothing. The aftermarket offers a complete program of pistons, cylinder liners, valves, gaskets, bearings, piston ring sets, filters and turbochargers in original equipment quality. Regarding reliability, flexibility and meeting deadlines – original equipment customers and aftermarket partners receive the same treatment. As engines become more and more complicated, MAHLE Aftermarket Inc. offers aftermarket partners entire system solutions for an equally complex business environment.
They have a long tradition in the filter industry. MAHLE – historically a developer of engine components –recognized early how important optimally functioning filters are for the circulation of engine air and fluids. After all, efficient combustion requires good filtration – regardless of whether oil, fuel or intake air has to be cleaned. And because people stay healthy only when they breathe clean air, cabin air filters are another important part of their program.
Clean air intake is one of the most important conditions for optimal engine power, high torque, low fuel consumption and minimized pollutant emissions. With MAHLE air filters, up to 99.9 percent of dust, soot and tire wear particles are filtered out. At the same time, an optimal air/fuel mixture is assured. The high particle uptake capacity ensures long service life under extreme conditions such as heat, cold or chemical contaminants. Their quality filters prevent premature wear of valves, cylinder working surfaces, piston rings, bearings and other engine components. To ensure optimum filter performance, all filters should be replaced within the service intervals stipulated by the car manufacturers.
MAHLE oil filters reliably prevent contaminants from entering the lubrication system and maintain oil quality as well as the performance and efficiency of the engine. Thanks to stable pleat geometry, cold start stability is assured. Load peaks up to 20 bar are compensated due to the high pressure resistance of the housing. A pressure relief valve guarantees the oil supply under all conditions – for viscous oil encountered during cold starts or at low temperatures, for extremely contaminated filter elements, or when the replacement intervals have been exceeded. A non-return flow valve prevents the draining of the filter when the engine is switched off and ensures adequate oil supply when the engine is started. High-grade sealing materials and custom-fit connecting pieces assure reliable separation of contaminated and filtered oil.
However, an important consideration for optimum functioning of oil filters is that filters are replaced within the maintenance intervals stipulated by the automobile manufacturers.
Modern fuel injection systems require an extremely clean, homogeneous and free-flowing fuel supply. However, contaminants can get into the fuel during the production and transport process and need to be filtered out. MAHLE fuel filters reliably remove contaminants. Thanks to high-quality filter media, the fuel system is protected from the smallest contaminants and therefore from corrosion damage. This protects the engine and assures efficient operation of the vehicle. The required constant fuel supply is achieved with pressure regulation and recirculation of the surplus fuel from the injection pump to the tank.
Pulsation damping compensates for the pressure fluctuations caused by the fuel pump. Their fuel filters comply with the correspondingly high safety standards of the automobile manufacturers and ensure secure sealing even in the event of accidents.
However, an important consideration for optimum functioning of fuel filters is that filters are replaced within the maintenance intervals stipulated by the automobile manufacturers.
Cabin air filters are very efficient: During only one hour of driving, an air volume of up to 100,000 liters is circulated through the vehicle interior. All the more reason to change cabin air filter elements regularly. MAHLE recommends changing the cabin air filter every 15,000 km or a minimum of at least once per year. If the cabin air filter fails or is clogged, the pollutant concentration in the interior of the vehicle can increase to six times of that of the outside air. MAHLE cabin air filters reliably supply the driver and passengers with clean air to breathe, which safeguards their health, well-being and ability of the driver to concentrate even in the event of smog or high pollen count. They also reduce the load on the blower, protect heating and air conditioning from contamination, improve air circulation and prevent dangerous fogging of the windows. In addition, the inside of the windows and fittings remain cleaner for longer.
The pleat geometry of MAHLE cabin air filter elements is designed to provide a long service life. The low flow resistance minimizes the load on the blowers. Thanks to the accurate fit of the filter elements in the housings, bypass air is prevented.
MAHLE cabin air filters produce no harmful emissions, as solvent-free methods, such as ultrasound welding technology, are used for their production.
Technicians are increasing their demand for the ability to replace the OE part with a part that looks, feels, and performs as good or better than the original. This is known as OE Form, Fit, and Function ... And MAHLE Original® gaskets lead the way. 99% of gaskets sold in a MAHLE Original box meet this standard - far more than any competitor.
Following the MAHLE acquisition of Dana’s engine parts division in 2007 and the creation of MAHLE Aftermarket Inc., MAHLE invested major resources that had been lacking for years in an effort to grow coverage. The MAHLE investment in gasket tooling enabled the expansion to the industry coverage leader it is today. With 10,000 part numbers covering nearly 900,000 applications, no other gasket supplier is even close.
The MAHLE Aftermarket commitment to making Technicians’ lives easier is prevalent in the most thorough bills of materials in the industry. Every component a technician needs to complete a repair, from the biggest head gasket to the smallest o-ring, it can be found in a MAHLE Original® gasket set. This eliminates costly delays and returns while raising customer satisfaction leading to more money.
The MAHLE Aftermarket gasket team pioneered innovative packaging years ago, and it carries on throughout the MAHLE Original® gasket line. MAHLE is the only gasket supplier that designed a package enabling a counterperson or technician to either see the actual gaskets inside, or if it is a bigger set packed in a box, every one carries the image of the contents instead of simply a bill of materials like other brands.
With the best coverage on the planet, the MAHLE Original gasket product offering covers over one million applications worldwide and approximately 200 million vehicle registrations for engines 1990 and newer. This exceptional selection is backed by a full range of technical information, support and training. What comes in the package and what stands behind it is real value that technicians appreciate.
Regardless of what application you are trying to seal, you can count on MAHLE Aftermarket doing the research and testing to provide the optimum material and technology for that specific application - this systems sealing approach requires a variety of materials. No other gasket distributor offers the Application Engineered approach to sealing an engine. A variety of different gasket materials insure an engine gets the optimal seal. All gaskets are not created equal - MAHLE Original® gaskets prove it every day.
MAHLE Aftermarket has one of the most complete gasket product lines available anywhere. Total coverage for medium and heavy duty truck, commercial marine and industrial applications results in a truly world class source for gaskets. From the simplest composition shapes to advanced multi-layer steel designs, engine gaskets have to be tough. Drastic temperature extremes, high internal pressures, coolants and lubricants of every description... gaskets must handle them all. MAHLE Original gaskets meet these demanding conditions with unsurpassed standards of innovation and quality.
MAHLE Aftermarket offers MAHLE Original gasket sets for in-frame, consolidated full sets and many more. When you want gaskets that address the needs of the heavy duty market, look no further than MAHLE Original heavy duty gaskets.
The development and production of pistons and engine components is part of the traditional core business of MAHLE. This competence is also supplied to the Aftermarket – under the brand names MAHLE Original and Clevite.
Whether Diesel or gasoline engines, passenger cars or commercial vehicles, small or stationary engines – MAHLE Clevite can help. MAHLE comprehensive range includes everything needed for repair and maintenance, such as fully finished pistons and assemblies in standard and oversize, cylinder liners for all internal combustion engines, complete piston ring sets, bearings and valves.
MAHLE line of Clevite® heavy duty engine bearings includes rod, main, and cam bearings. All but their cam bearings are made with the legendary Clevite® TriMetal™ CL-112 material. Clevite® cam bearings are precision bored to eliminate the need for machining after installation. This exclusive bearing design features a steel backing for support, a cast-copper lead alloy center for strength and durability, nickel dam for chemical stability, and an electroplated white metal babbitt overlay for slipperiness, conformability and embedability. The intermediate cast-copper lead layer creates and interlocked columnar structure capable of withstanding much heavier pulsating loads than any other bearing design.
Clevite® TriMetal™ engine bearings have been tested and given a 12,000 psi rating, the highest in the industry. They are more resistant to corrosion and out-perform traditional bearings by 20 percent or more. That makes Clevite's TriMetal material the strongest currently available in the industry.
Only MAHLE Original can say that it is the largest manufacturer of piston rings in the world today. This stability leads to a tremendous research and development foundation, which guarantees that MAHLE Original is the highest performing ring in both light vehicle and performance applications.
MAHLE Original® piston rings lead the way in ring technology and innovation for the Aftermarket – after all, MAHLE is the largest manufacturer of piston rings in the world. MAHLE Original rings are at the forefront of light vehicle piston ring technology. Extensive OE connections mean that MAHLE Original rings have the technological edge.
MAHLE manufactures high-quality valves for internal combustion engines at several production sites worldwide. Their program includes valves of diverse designs and types with stem diameters from 5 to 12 mm as well as valve lengths from 80 to 210 mm for passenger cars and commercial vehicles. Thanks to the expert technical know-how, the high productivity and the outstanding quality of these products, MAHLE is one of the world's leading valve manufacturers today.
MAHLE employ state-of-the-art production technology as part of their large-volume production to ensure their quality standards. For example, MAHLE use plasma powder methods in the production of forgings or high-speed grinding methods for mechanical finishing. In order to make valves resistant to the high loads, their valves have reinforced seats, are hardened, chrome-plated or nitrided as needed. A wide range of materials is available for every application. For special applications with extreme demands, sodium-filled hollow valves are available to reduce thermal loads.
Not many components in engines are under as much load and tribological stress as valves and their associated parts. Tribology is the science of friction, lubrication and wear of bodies in relative motion. The greatest challenge is to determine the design of the valves. MAHLE valves are designed for a wide variety of operating conditions in order to withstand extreme mechanical, chemical and thermal loads and to assure optimum heat dissipation. At temperatures up to 1472ºF, the red-hot exhaust valves strike the valve seats more than 70 times per second and must withstand the hot and corrosive exhaust gases that flow around them. At every valve lift, enormous acceleration forces and retractive forces occur due to the strong valve springs.
Together with valve seat inserts and valve guides, valves form a closed system, which has to withstand extreme loads and stresses. Therefore, MAHLE not only have valves in program, but also their tribological partners, valve seat inserts and valve guides. The combined development of these products in one system allows us the advantage of optimizing wear characteristics and minimizing component costs.
MAHLE Clevite offers a wide range of sleeves for both wet and dry applications and in most cases, provides the appropriate o-ring kits included in the box. The MAHLE Clevite policy is to meet or exceed OE specs for material construction and hardness on sleeves. MAHLE Clevite also offers a wide variety of cast iron repair sleeves for general machine shop use.
Clevite® assemblies are ready for installation and have a finish-machined or rough-turned cylinder bore depending on the type of engine.
In cases where subdivided dimensions groups (e.g. color coding or letters) are specified by the engine manufacturer, this system is maintained by means of corresponding markings for Clevite assemblies. For more information, please see the installation tips below.
For foreign nameplate applications, MAHLE offer the same OE quality heavy duty engine parts in the MAHLE Original brand.
"More Than Just Parts in a Box"
When many suppliers say they offer engine kits, all they're doing is packing parts in a box. But at MAHLE made a commitment to offer a full line of engine kits, they also made a commitment to support the kits the MAHLE support every part they've ever sold. When you buy an engine kit from MAHLE Aftermarket, you're not just buying parts in a box. You're buying a philosophy of service that extends to every division of MAHLE.
Before MAHLE will even consider putting a part in their kits, it must meet their stringent guidelines. It must live up to the MAHLE name. That's why you'll find the names you trust in every kit – Clevite® engine parts and MAHLE® gaskets. You don’t have had to settle for engine kits that are not backed by the kind of service, or packed with the quality parts you can only get from MAHLE Aftermarket. But with their full line of quality engine kits at competitive prices, you'll never have to "settle" again.
Whether it is a Master Kit, or a Cam and Lifter Kit, rest assured that the same quality you expect from the MAHLE Clevite family of internal engine parts will be delivered in one convenient box ready to build an engine.
MAHLE Original® Engine Parts – MAHLE Original branded timing components, oil pumps, pistons, and lifters all offer the highest quality in the industry available in an engine kit.
Clevite® Engine Bearings - Every engine kit contains Clevite engine bearings. The number one name in replacement engine bearings, Clevite offers premium strength, low friction, embedability and conformability. Look at competitive kits to make sure you know what’s inside the box before making that kit purchase!
Victor Reinz® Gaskets - Clevite engine kits offer 95-3000 Series kit gasket sets. These sets are constructed with premium components using Nitroseal™ head gaskets where available. 95-3000 sets have the same quality components as a regular Victor Reinz set only the bill of materials for the set has been modified to suit an engine rebuilder.
MAHLE Original® Piston Rings - The engine rebuilders' choice for piston rings is MAHLE Original, and these are the rings included in every MAHLE Clevite engine kit. MAHLE Original’s tremendous OE presence transfers to excellence in the replacement market.
For foreign nameplate applications, MAHLE offer the same OE quality heavy duty engine parts in the MAHLE Original brand.
MAHLE Original® engine parts are the one source for superiority regarding internal engine parts. For lifters, oil pumps and timing components, MAHLE Original is the one name that can be trusted as the best.
Clevite® heavy duty engine parts include a wide selection of parts to address the Transportation, Construction, Marine, Agricultural and Power Generation markets. Unsurpassed quality, competitive pricing, excellent availability, comprehensive warranty and unparalleled service have been combined to create the number one source for your Heavy Duty Engine Parts needs.
Exhaust-gas turbochargers are a key technology to enhance performance, reduce fuel consumption, and lower exhaust emissions. When fitted to direct-injection diesel engines, they reduce fuel consumption by up to 25 percent compared with similar gasoline engine with duct injection. For this reason, they have taken over almost the entire market segment. The trend with gasoline engines is toward downsizing, that is to say, a reduction in cubic capacity for the same power output. This is achievable by turbocharging, since the high power-to-capacity ratio of these engines requires an increase in the air mass supplied to the engine. This is only attainable by supercharging. Inevitably, the number of turbocharged gasoline engines will undergo a significant rise worldwide.
Experts estimate that in 10 years time, there will be about 160 million cars and roughly 16 million trucks (>3.5 metric tons) running on this key technology, and the tendency will continue to rise. As a result, the turbocharger segment represents one of the largest growth markets in the automotive industry worldwide.
To operate efficiently while minimizing wear and emissions, a combustion engine requires the temperature to remain as constant as possible. Thermostats are used exactly for that purpose, as they regulate the engine temperature with coolant.