Technical Messenger

Valuable technical information and tips pertaining to all aspects of servicing and repairing MAHLE Aftermarket products keep you up to date. The Technical Messenger appears regularly, about which we will be happy to inform you via our MAHLE Insider newsletter.

Enclosed you will find all the issues of the year:

Function, storage, and testing of electronic Visco® fans and clutches

Issue no. 04/2024

PDF; 376 KB

Technical information and tips

Technical Messenger

Function, storage, and testing of electronic Visco® fans and clutches

Defective starter motors due to thermal overload

Fitting instructions for thermal switches (TSW)— delayed opening and closing times

Regenerating particulate filters in Euro 6 diesel vehicles before emissions tests

A/C system leaktightness test using forming gas

A/C system leaktightness test using a contrast agent

Notes about lines with spring-lock connectors

Causes of a defective resistor on the interior blower

Notes on the function and replacement of oil control rings (fire rings)

Problems with the installation of the OC 248 spin-on oil filter in minibus campers

Polymerization of refrigerant R1234yf

Installation notes for the oil filter insert OX 1141D

Instructions for fitting piston rings

Characteristic features of electric air conditioning compressors

Risk of confusion over air conditioning compressor safety valves

Installation note for piston pin circlips

Exhaust gas cooler leaking: important installation notes

Causes of overload protection tripping in air conditioning compressors

Corrosion on oil spin-on filters due to installation errors

Overheating of the engine due to a defective expansion tank cap

Important steps when replacing coolant thermostats

Flushing air conditioning systems properly

Damage to radiators due to wrong screws

Using PAO 68 air conditioning compressor oil

Damage caused by breaking in an engine incorrectly after repair

Flushing the cooling system to avoid consequential damage

Specific guidance for working on BMW radiators with different screw plugs

Cavitation damage in the cooling circuit

Important steps when replacing a filter-drier or accumulator

Unused radiator connections

Replacing the charge air cooler after damage to the turbocharger

Oil filter OC456: oil pressure problems after filter change in 1.8 and 2.0 TFSI engines

Oil quantity distribution in air conditioning circuits

Special considerations when working with Visco® fans and clutches (CFF and CFC model)

Leaks in the cooling circuit

Replacing switchable coolant pump CP 623 000P

Apparent leakage in MAN radiators

Ensuring correct A/C compressor oil filling quantities

Additional connection on MAN radiators

Risk of confusion: oil filter inserts OX 183/5D and OX 183/5D1

Alternators with an S terminal

Fuel filter elements with meltblown coating

Installation note on oil filter inserts with non-return mechanism

Torn-off valve due to canted valve spring

Thermostat makes rattling noises

Mechanical overload due to starting when the engine is coming to a stop

Piston dimensions and installation clearance: what you need to know

Installation note for oil filter inserts OX 379D and OX 370D1

Fluctuating coolant temperature

Defective map-controlled thermostat

Alternator not working

Damaged oil filter paper

Additional securing aids for air filter element LX

Different fuel filter elements in the same housing height

Leaves in the water tank

Connection defect when changing the starter motor

Bleeding the fuel system following a filter change

Power loss as a result of defective crankcase ventilation

Alternator failure due to oil ingress

Instructions for the assembly of non-controlled turbochargers

Leakage after fitting the oil filter insert OX 388D Eco in 1.6 and 2.0 TDI engines

Incorrectly fitted air filter element LX 2049/4 in Audi V-type engines

Piston damage due to broken piston cooling nozzles

Corrosion damage on thermostats

Shaft separation in alternators

Foreign object damage in the turbocharger

Thermal problems after a thermostat change: air in the cooling circuit

Apparent oil leakage at the new turbocharger

Leaky oil filters: oil pressure regulating valve clogged

Decline in turbocharger performance—diesel particulate filter loading limit reached

Comparison of MAHLE oil filter inserts OX 404 and OX 813/1

Fitting instructions for thermal switches (TSW)— delayed opening and closing times

MAHLE OX filters with fleece end cap

Replacing the oil filter insert OX 787D in VW TDI engines

Turbocharger mounting kits for PSA engines DV6ATED4 and DV6UTED4

Poor responsiveness and performance?

KL 82 – strange noises after replacing the filter?

Turbo tip-excessive crankcase pressure in vehicles with turbochargers 030TC14011000 or 082TC15850000