MAHLE CR 954 000P RADIATOR ENGINE COOLING. GET THE CORRECT PART FIRST TIME.PLEASE MAKE SURE YOU CHECK THE NOTES SECTION TO THE LEFT OF COMPATIBILITY TABLE. IF IN ANY DOUBT AT ALL PLEASE ASK SO YOU GET THE CORRECT PART FIRST TIME.
Piston systems and their components. The demands placed on pistons for gasoline engines have been continuously tightened over the past years. Higher performance requirements trigger increased thermal loads. At the same time, downsizing concepts have increased mean and peak pressures, while high-speed concepts impose greater inertia forces. MAHLE provides years of experience and innovative solutions- and continuously adjusts the existing product range to tomorrow's requirements.
The state of the art in motorsport is now used in highly loaded series production engines as well: the forged piston. For the same alloy, they have a finer microstructure than cast pistons. The production process results in greater strength. As a result, the pistons can withstand even the high loads in motorsport and in engines with exceptionally high specific output. They are already being used today in sporty series vehicles with over 130 kW/L.
Another advantage of forged pistons is the potential to produce thinner walls, thus reducing weight. Modern engines place greater requirements on cylinder components than ever before: at higher operating temperatures and pressures, emissions must be reduced.This calls for innovative concepts and materials with unprecedented high performance. With the power cell unit- consisting of the piston with rings and pin, cylinder liner, and connecting rod with bearing shells- MAHLE provides a system that offers the customer commercial and logistical advantages due to its simpler assembly and optimally coordinated design. Injection pressures of up to 2,200 bar, mean pressures of up to 31 bar, peak pressures of up to 210 bar, specific power output of up to 100 kW per liter, and ever lower exhaust gas emissions- these are the current requirements for modern passenger car diesel engines. In order to overcome severe loads due to high temperatures and pressures, MAHLE has developed passenger car diesel pistons made of aluminum as well as diesel pistons made of steel. Load capacity must be improved and wear and friction must be lowered in order to meet the current and future requirements for CO. Stop-start or hybrid systems present a special challenge as the combustion engine is frequently switched on and off. Especially during the starting process, the bearings run through the range of mixed friction and must withstand particularly high loads. As the element that transmits forces and motions, it is subjected to alternating stresses and continuously increasing performance. The trend for connecting rods, however, is toward ever lighter components. The MAHLE connecting rods product range accommodates this challenge. With high-strength and innovative materials, MAHLE can more than fulfill the current requirements. Due to the lift motion of the piston and piston rings, their partner-the cylinder surface-is also subject to high mechanical loads and must withstand increased ignition pressures and speeds. In order to reduce wear, the running surface should be smooth and the lubrication between the sliding partners must be ensured. The type and quality of the running surface effects oil consumption as well as the wear of the two components. MAHLE piston pins feature highest quality, precision, and application versatility. They are manufactured with state-of-the-art multistation part formers. Innovative and complex forms can thus be achieved for increased stress resistance.
Coatings based on PVD or DLC (diamond-like carbon) reduce wear and improve friction properties. As temperatures, pressures, and rotational speeds continue to rise, piston rings are subjected to ever increasing loads.
Concepts for lower wear and friction, better sealing, and greater break resistance are in demand. MAHLE is therefore continuously developing new coatings and ring design variants and offers the optimal piston ring or piston ring pack for every engine. The broad range of products includes compression rings and oil control rings in various designs, profiles, and technologies.Valve train systems and their components. Valves, valve seat inserts, and valve guides. MAHLE manufactures intake and exhaust valves in forged and hot-extruded versions in a multitude of materials for gasoline and diesel engines of every size. Depending on the stresses they are subjected to, the valves are reinforced around the seat, hardened, nitrided, or chrome-plated. Sodium-filled hollow valves can be used for extremely high thermal and mechanical loads. Since stresses on the components continue to rise in modern engines, MAHLE is focusing on the ongoing development of cooled valves. Additional components in this assembly include the valve stem seal, the valve spring, and the top and bottom valve spring retainer. With the ongoing development in lightweight construction and low-friction bearings for the shaft, as well as based on the extended functionality, such as for the variable valve train, the camshaft still has substantial potential for increasing engine efficiency. There is a wide selection of various camshaft designs available for different applications and requirements (such as service life, cost, weight, friction, noise, additional functions). MAHLE has developed assembled camshafts based on precision steel pipes with cam lobes made from steel and powder metal materials, making a significant contribution to optimizing the whole valve train. Due to their modular construction and flexibility, they are increasingly displacing other forms of camshafts. An assembled camshaft is up to 45 percent lighter than a cast or forged camshaft.
Input and output elements are made using various production processes and materials, depending on the design. For the production of cast camshafts, chilled cast iron is predominantly used. For stringent requirements in rolling contact, cast camshafts with inductively hardened cam lobes can also be used. In order to reduce weight, the shafts can be cast as hollow cylinders or profiles. Casting production takes place in ultramodern, fully automated production facilities.A wide range of standard materials is available, as well as specialty materials for specific customer requirements. Modern machining centers and fully automated CBN grinders guarantee consistently high quality. Air conditioning systems and their components. Our HVAC modules are tailor-made to the specifications of vehicle manufacturers.
Continuous improvements in efficiency, reductions in weight and pressure loss, as well as the further optimization of acoustics are among our key development objectives. Standardized components and design features help us to economically develop and produce robust and high-performance HVAC modules. Our flat tube evaporators deliver high performance in spite of their compact and lightweight design. Our patented BehrOxal® coating technology modifies the aluminum surface such that it assumes hydrophilic properties. As a result, water runs off more easily, enabling the evaporator to dry more quickly.
This makes the evaporator more resistant to corrosion and less prone to unpleasant odors. In order to heat the vehicle cabin, the heater core has to make use of the heat emitted by the engine, i. Behr heater cores are perfectly adapted to the respective engines and their heat output. They are characterized by their compact size and low pressure drop on both the coolant and the air side. The next generation of variable displacement piston compressor technology, MAHLE's Compact Variable Compressors (CVC), are based on a swash plate simple harmonic motion mechanism.
The enhanced mechanism performance makes the CVC adaptable to both pneumatic and electronic control. MAHLE's CVC is adaptable to a full range of vehicles. While our current product portfolio includes CVC ranging from 100 cc displacement to 185 cc displacement, MAHLE can design and validate a CVC for a specific application. The CVC can be applied to both thermostatic expansion valve and orifice tube systems. Today's fuel-efficient engines do not always deliver sufficient waste heat to enable rapid heating of the vehicle cabin, particularly for cold starts and in certain driving conditions.
To keep the windows clear and ensure optimum thermal comfort in these situations, additional heating is provided by electric PTC auxiliary heaters that run on energy from the vehicle electronics. The heaters are available with or without an integrated controller. High-voltage PTC heaters provide a solution for plug-in hybrids, electric vehicles with range extenders, and all-electric vehicles.In these cases, the powertrain does not generate sufficient waste heat in the electric drive mode to warm up the vehicle cabin. A powertrain-independent heating system capable of delivering up to 7 kW is required to ensure an adequate supply of heat. The high-voltage PTC heater is an energy-efficient, compact, and safe solution for heating the cabins of electric vehicles. Thermal and acoustic comfort is crucial in vehicle air conditioning. However, the blower is one of the main sources of noise in the vehicle cabin. Our current blower design concepts meet three separate requirements: they save valuable package space in spite of increased air flow performance, they are highly efficient, and they form the basis for excellent HVAC system acoustics. All MAHLE cabin filters are distinguished by low pressure loss and long service life. The filter media used offer a large effective surface and filter even smallest particles such as soot particles. MAHLE adheres to the highest standards when developing its filter media. By eliminating odors from the environment, CareMetix® delivers maximum comfort in the cabin.
PM2.5 filter media from MAHLE achieve ultrahigh retention efficiencies over the element's entire service interval. We produce brazed, flat tube condensers that deliver high performance in spite of their compact and lightweight design. They ensure rapid cooling of the passenger compartment thanks to optimum matching of heat transfer and pressure drop on both the coolant and the air side. Engine cooling components, modules, and systems.The increasing electrification of the powertrain is one of the biggest technological trends in the automotive industry. In order to cool the lithium-ion battery and the power electronics of hybrid and electric vehicles, temperatures of below 40°C have to be reached, which is accomplished by interlinking the low-temperature and refrigerant circuits. This results in new, complex circuits that place significantly higher demands on the individual components and the control system. One of the chief measures used to reduce fuel consumption and thus CO.
Emissions is to reduce the swept volume, typically in combination with turbocharging, in order to maintain or improve power output and torque. As the degree of turbocharging increases, the necessity of cooling the compressed air grows simultaneously. Charge air cooling therefore takes on an ever more critical role.
The latest stage of development at MAHLE includes indirect cascaded charge air cooling, integrated in the intake pipe, which provides minimal pressure loss and significant packaging advantages. It produces charge air temperatures close to that of the coolant by using a two-stage cooling process. Reaching the optimal operating temperature of a combustion engine more quickly is one of the remaining levers for further reducing CO. Keeping the coolant flow at a standstill after cold-starting the engine supports an effective warm-up phase, as the coolant in the engine will not immediately dissipate any heat generated by the engine.
MAHLE has developed a hydraulically controlled coolant pump, a system that due to its simple and robust design has a low system weight and can be adapted to existing engine cooling circuits. Cooling modules comprise multiple engine cooling components as well as the condenser, which forms part of the air conditioning circuit. For maximum efficiency, all components are optimally matched. The modules are assembled according to the vehicle design concept, thus reducing development, production, and logistics costs.
The new emissions standards for diesel passenger cars and commercial vehicles can no longer be met with adjustments to the engine alone. One approach to complying with the new emissions limits is to incorporate cooled exhaust gas recirculation (EGR).This involves extracting a portion of the main exhaust flow between the engine outlet and the turbine, cooling it in a special heat exchanger, and feeding it back to the intake air downstream of the charge air cooler. The combustion temperature in the engine is thereby lowered, thus reducing the formation of nitrogen oxides (NOx). The cooled EGR technology has been available in series production passenger cars since1999. In gasoline engines, cooled EGR will be implemented in the coming years to reduce fuel consumption.
One outstanding feature of MAHLE's laser-welded exhaust gas heat exchangers is their excellent corrosion resistance. We also offer switchable exhaust gas heat exchangers featuring a bypass section integrated into the cooler housing. To keep pollutant emissions at a constantly low level, the bypass disables the recirculated exhaust gas cooling function in certain driving situations, e. During the cold start phase.
In an indirect charge air cooling system, rather than being released directly to the ambient air, the heat from the charge air cooler first passes through a separate, low-temperature coolant circuit (LT cooling circuit) before being discharged to the ambient air by a downstream, low-temperature radiator (LT radiator). The LT radiator of the indirect charge air cooling system is mounted onto the engine cooling module and can be designed more compactly than the direct charge air cooler, without sacrificing performance. This is because heat is transferred from the air to the coolant. The LT radiator can also be optionally used to ensure optimum thermal management of a temperature-sensitive lithium-ion battery, its power electronics, and soon also the condenser of the refrigerant circuit. Oil heating and cooling systems.
Heat exchangers for heating and cooling modules typically have a lamellar design and ensure an as balanced as possible thermal cycle for lubricating oils in the engine and transmission. This allows the lubricant to heat up quickly, which significantly reduces fuel consumption at cold start. At high oil temperatures, heat exchangers prevent overheating and premature aging of the oil, allowing oil change intervals to be extended. Current MAHLE heating and cooling modules are also able to handle channel guidance, temperature regulation, and filtering of the coolant flow. An optimized channel guidance and distribution of the coolant flow provides coolant to the heat exchangers of the engine and transmission as well as for fuel as needed.
The most important component of the cooling module is the radiator, which consists of the radiator core and plastic tanks with all requisite connections and fastening elements. The radiator core is usually made of aluminum, while the coolant tanks are made either of aluminum-just like the core-or fiber glass-reinforced polyamide. The wide variety of engine cooling tasks can be achieved only by intelligently controlling the energy flows that arise. Various systems and engine components must be supplied with coolant as required.
In modern systems, this takes place with different temperature levels and separate cooling circuits. Intelligent control systems from MAHLE, such as engine operating map thermostats, ensure demand-actuated and precise temperature regulation and thus promote more efficient operation, reduced consumption, less wear, and lower emissions. Based on a modular design, MAHLE offers a 12V pump with up to 450 watts electrical power consumption and a 48V pump with up to 1kW.
Due to the individually controllable coolant flow with low mechanical losses, our customers achieve significant reductions in fuel consumption and up to 5% lower carbon dioxide emissions (CO2). The brushless electric motor as well as the bearing concept ensure maintenance-free operation with high reliability. Besides that, the directly cooled electronics allow a maximum power utilization. As the processes in the engine become ever more complex, the demands on the intake system also increase. Emissions regulations and consumption specifications, shorter model cycles, and rising expectations for performance in shrinking packages are the cornerstones of modern development.
For example, MAHLE was recently able to take another substantial step forward in the development for modern combustion engines with the integration of charge air cooling in the air intake module. Increasingly smaller package constraints require higher filtration performance, especially with respect to particle retention efficiency. This trend requires the use of high-performance filters, more complex flow guidance design, and new filter element concepts.
As a technology leader in the area of plasticized filter elements, MAHLE can react flexibly to any package constraint with the application of a wide range of design types. Electrical heaters for blow-by systems. Electric blow-by heaters are used between the air intake module and the cylinder head cover to prevent icing. They work with PTC technology and are available in modular versions within a power range of 200 to 600 watts. The optimized heating function and the possible high level of integration into the motor periphery are advantages of the MAHLE heaters.The electric wastegate actuator from MAHLE ensures the best possible interaction between the combustion engine and turbocharger, especially in downsizing engines. The electrical actuator can reach any desired wastegate position in a flash, regardless of the negative or positive system pressure. Its high clamping force ensures minimal leakage and consequently rapid boost pressure build-up.
The result is very spontaneous responsiveness. Actuator for Turbocharger with variable turbine geometry (VTG). MAHLE electric actuators for turbochargers with variable turbine geometry (VTG) optimally adjust the incident flow from the turbine for current operating conditions, ensuring high performance, low emissions, and low fuel consumption.
MAHLE has specifically designed these electric actuators to meet the requirements of modern combustion engines: The models for VTG applications are therefore extremely compact and lightweight, weighing in at less than 250 g. They also allow for maximum flexibility in vehicle applications thanks to a generous adjustment angle of up to 130° and an application temperature range of -40°C to +160°C as standard. Besides the focus on efficiency, vehicle and engine development is still about emotions.The sound of an engine plays a critical role: it represents the performance characteristics of the powertrain, and is also an inherent component of a brand's unique properties and its recognition factor. Turbocharged engines, in particular, lose much of their "natural" sound, which is why sound design plays an important role in development. MAHLE uses cutting-edge simulation methods to optimize acoustics in line with customer requirements when developing resonators or sound generators that are integrated directly in the air guidance system. Oil mist separator systems reliably clean the gases from the crankcase that are contaminated with oil mist. Oil consumption can thereby be further reduced and the influence of combustion minimized. The oil mist separator integrated in the crankcase ventilation system separates gaseous and liquid components. The separated oil is fed back into the oil circuit and the cleaned air is recirculated to the intake system. Engine and cylinder head covers. Weight reduction and the functional integration of a thermoplastic cylinder head cover are essential elements in a modern engine. MAHLE maximizes these advantages by optimizing its use of materials, minimizing material inputs, and implementing highly complex geometries.
Modifications to suit higher loads and temperatures, zero-maintenance requirements over a product's service life, and compliance with acoustic specifications are an integral part of the development process. The trend toward a modular system approach demands more flexible and lightweight components that can be employed even under very tight installation space conditions.Another challenge consists in the low-cost, effective production of what are often very complex shapes. The increasingly difficult installation and removal conditions for service purposes are central aspects in the development of current air guidance products. The materials used thus far include mainly petroleum-based plastics. In its search for alternatives, MAHLE has investigated various bio-based plastics and most recently validated a material for air duct components as ready for series production, which protects the environment and does not affect the food chain.
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