MAHLE to exhibit latest engine technology at the Tokyo Motor Show

The Tokyo Motor Show is undoubtedly the most important motor show in Asia and is regularly attended by more than 1 million visitors. Eleven exhibition halls in and around the Makuhari Convention Center cover an area of 45,000 m², thus providing the space required by almost 300 exhibitors including automotive manufacturers and their suppliers. Like the German IAA, the Tokyo Motor Show alternates between passenger cars and commercial vehicles every year.

At this year's 37th Tokyo Motor Show for passenger cars, MAHLE, in cooperation with its two Japanese subsidiaries MAHLE Izumi and MAHLE Tennex, will present a series of product innovations. These are to reveal the entire expertise of the company to the predominantly Japanese visitors.

In Tokyo, MAHLE will for the first time present its latest innovations, the mechanically fully-variable valve train as well as the light-weight valve – two developments that will enable international automotive and engine manufacturers to further optimize performance, consumption and exhaust emissions in the medium term.

At the Tokyo Motor Show, MAHLE will, for the first time in Asia, display a new steel piston for high-performance passenger car diesel engines – the MAHLE Monotherm piston, which has already proven itself in commercial vehicles. Using the new MAHLE Monotherm piston, engine manufacturers can achieve even higher peak cylinder pressures in their direct-injection, turbocharged diesel engines and thus an even more effective combustion at approximately the same weight as the light-alloy pistons used to date.

MAHLE's Filter Systems Business Unit will exhibit its latest development of the first oil filter worldwide, completely made of plastic. With this development MAHLE continues to tackle weight and cost optimization of filter systems for the automotive industry. At the same time their efficiency is considerably enhanced. MAHLE's new plastic oil filter for Audi's V8 4.0 and V6 3.0 Common Rail diesel engines is the result of comprehensive R & D. In combination with the oil module, it assumes the tasks of filtration and cooling of the engine oil, oil supply to the turbocharger, as well as the complete sensor technology of the oil and water cycle.

To demonstrate its systems capability and know-how regarding a complete engine, MAHLE has, for the first time ever, developed its own complete engine. This engine will also make its debut in Asia at the Tokyo Motor Show. It was developed for Formula SAE (Society of Automotive Engineers) – as part of a competition for prospective engineers of vehicle and engine design – and is a straight high-speed three-cylinder four-stroke aluminum engine. According to the Formula SAE rules, an output of approximately 60 kW is expected from a displacement of 609 cm3. To achieve a high specific output despite the mandatory intake restrictor, a tuned intake system with four-valve technology, two overhead camshafts and intake manifold fuel injection was developed. Light-design concepts of the crankshaft, connecting rod, and piston allow low oscillating masses and thus a quick engine reaction capacity. The engine is rigidly seated in the vehicle due to its supporting function and equipped with a balance shaft to compensate first-order tilting moments.

For MAHLE, the Asian market is of increasing significance. In fiscal year 2002, its share of the Asian/Pacific market reached about 13 per cent of MAHLE's total sales versus approximately 3 per cent in 1997. Today about 10 per cent of all MAHLE employees work in the Asian/Pacific region, compared with hardly one per cent in 1997. In the medium term, MAHLE intends to enhance the sales share in this market up to 25 per cent.

With more than 30,000 employees in a total of 60 locations worldwide, MAHLE achieved sales of 3 billion Euro in the 2002 business year. In Japan, MAHLE employs more than 2,000 people in a total of eleven locations.

Stuttgart, October 20, 2003

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