MAHLE Powertrain Ltd

Costin House
St James Mill Road

  • Design & development of internal combustion engines
  • Part of MAHLE's global network of R&D centres
  • Your service provider for the entire powertrain
  • Design & development of internal combustion engines
  • Part of MAHLE's global network of R&D centres
  • Your service provider for the entire powertrain
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Our News & PR

Events & Shows

  • IMechE IC Engines Conference

    IMechE IC Engines Conference

    This conference provides a forum for IC engine experts looking closely at developments for personal

    From: 06 December 2017 08:30 am
    To: 07 December 2017 17:35 pm

MAHLE Powertrain Ltd

Engineering Services

We provide a broad spectrum of skills and capabilities to our global customers. With expert knowledge and a detailed understanding of new technologies, MAHLE Powertrain supports the international automotive industry with optimized powertrain solutions to satisfy our customers’ requirements. Engine, transmission, hybrid, software, operating strategy. From one source.

Driven by on-going market demands for fuel economy and reduced emissions, our latest engineering projects are at the highest priority level for everyone involved with the development of engines. We have fully developed our advanced downsizing engine and installed it successfully in a demonstration vehicle in 2010; developed a new fuel saving, emission reduction technology called
MAHLE Jet Ignition®; and designed a new Stirling engine for the generation of renewable electricity from solar energy, to name just a few projects. Furthermore, we have also expanded our business in the hybrid powertrain sector, with the successful development of a range extender engine (with fully integrated generator), which is now installed in a plug-in battery electric demonstration vehicle.


MAHLE Powertrain's Engineering division is focused on the development and application of new engine technologies which are continuously being generated by our parent company, MAHLE GmbH. As the specialised engineering services provider within the MAHLE Group, we have direct access to the latest systems and components for delivering higher engine efficiency, improved fuel economy and lower CO2, as well as regulated emissions.

The MAHLE advanced downsizing engine is now a recognised industry benchmark for highly optimised gasoline engine performance. MAHLE’s new twin cylinder, 4-stroke, 30 kW range extender engine was also designed and developed from a clean sheet by MAHLE Powertrain. This engine has now been installed in a plug-in hybrid electric demo vehicle. MAHLE also entered the green energy sector with a new, solar driven Stirling engine.

Furthermore, specialists at MAHLE Powertrain have recently been developing a novel combustion system called MAHLE Jet Ignition®. This technology uses a pre-chamber combustion concept that replaces a normal spark plug and offers significant fuel economy benefits with a variety of fuels.

MAHLE Powertrain Capabilities

Recent Projects

MAHLE eSupercharged Downsizing Vehicle

MAHLE Powertrain has integrated a 48 V eSupercharger into their latest downsized engine, along with a conventional exhaust driven turbocharger for high speed, full load performance.

48V hybridisation with electric supercharging
• Energy recuperation
• Extremely high specific power and torque
• Excellent transient response and driveability
• Increased levels of downsizing possible
• Greater CO2 reduction potential
MAHLE eSupercharged Downsizing Engine

MAHLE Powertrain has increased the specific output of the MAHLE downsizing engine to over 160 kW/litre through the application of 48V eSupercharging.

• Power output of 193 kW / 262 PS
• Specific power of 161 kW / liter
• Peak torque of 313 Nm (33 bar BMEP)
• Flexibility of 290 Nm @ 1,500 rpm
• Minimum BSFC of 235 g/kWh
MAHLE Downsizing Engine

• Aggressive engine downsizing > 50 %
• High specific output 100 kW/l
• Fuel economy benefit (proven) > 30 %
• CO2 emissions (NEDC) 135 g/km
• MAHLE NIKASIL® parent bore cylinder coating
• BMTS single-stage turbocharger
MAHLE Downsizing Vehicle

The general principle of engine downsizing is most relevant for large or medium-sized vehicles where the potential fuel economy and emissions benefits can be maximised. The VW Passat Estate (weighing 1,600 kg) was selected as the ‘mule’ downsizing demonstrator vehicle, with the 1.8 litre turbo gasoline variant of this car providing the dynamic performance targets.

Key figures:
• Fuel economy of 5.8 l/100 km (~49 UK mpg)
• CO2 emissions of 135 g/km on the NEDC
• High torque at low engine speed

The MAHLE Downsizing Engine delivers the best of both worlds: flexible and dynamic performance, combined with excellent fuel economy and low emissions.
MAHLE Range Extender Demonstrator Engine

• Enhanced range & dynamic performance for EVs
• Design / development / prototyping within 9 months
• Fully integrated axial-flux generator
• Range Extender optimised for:
Weight (< 65 kg, incl. generator)
Package volume
MAHLE Range Extender Demonstrator Vehicle

MAHLE Powertrain’s compact range extender engine powers an electric vehicle when the battery level is low. A range extender demonstrator vehicle showcases this technology and to assist in the further development and optimisation of the engine, associated hardware and control systems.

Key figures:
• Capability of achieving 45 g CO2/km on the legislated NEDC test
• Combination of battery + engine range of up to 500 km
• Minimum ‘electric only’ range of 70 km
• Maximum speed of 145 km/h with the ability for continuous (charge sustaining) driving at 120 km/h
• Capability of maintaining 90 km/h on a 6 % gradient
• Retaining all of the original passenger and luggage space

The MAHLE range extender demonstrator vehicle provides the optimum combination of extended range and flexibility of use with zero tailpipe emissions capability and class-leading fuel economy.
MAHLE Flexible ECU

The MAHLE Flexible ECU (MFE) is a robust, open architecture controller based on the proven AFT PROtroniC platform. It has the capability to control any powertrain application utilising MAHLE's highly optimised functional software.

• Complete flexibility
• Controls all engine functions
• Fully configurable / modular software
• Covers current and future engine technologies
• Torque based structure
• Simple to use
• Matlab/Simulink compatible
• Intellectual Property Rights (IPR) protection
• Comprehensive documentation

MAHLE Jet Ignition®

MAHLE Jet Ignition® enables homogeneous ultra-lean combustion in modern gasoline engines.

The MAHLE Jet Ignition® system is a new combustion technology which replaces the standard spark plug in SI engines with a jet ignition chamber assembly. MAHLE Jet Ignition® facilitates the implementation of ultra lean-burn operation in gasoline engines, improving their efficiency and reducing the formation of pollutants such as nitrogen oxide and particulates. MAHLE Jet Ignition® is an exciting new combustion system that provides great potential for further CO2 emissions reduction in latest generation gasoline engines.

MAHLE Interactive Vehicle Interface (MIVI)

MAHLE Powertrain offers powerful, robust and cost effective driver display units which are fully configurable to suit any demo or development vehicle application. Using this approach, a bespoke driver display unit (or HMI) has been developed for our Range Extender demo vehicle.

The displays are based on high-definition LCD screen in a range of sizes with capacitive touch control, integrated 800 MHz CPU and CAN communication interface.

The unit provides direct access to vital information from the vehicle systems in real time and allows the driver to control a number of system functions and parameters as well as providing the ability for easy data logging during a drive.

Key display elements and functions:

• Traction motor data and trip data
• Battery power, state of charge and charging status
• SoC hold and target setting
• Record engine operating points

Jobs and Career at MAHLE

If you have goals and are ready to grow with your challenges, MAHLE can give you the perfect start to your career.

We have an array of career launching opportunities for research and development, procurement and controlling, technical sales and production.

If you are ready to take on new challenges as part of a strong team, within international projects then please get in touch today.

Products and Services

Opening Hours

Monday -   08:00 to 17:00
Tuesday -   08:00 to 17:00
Wednesday -   08:00 to 17:00
Thursday -   08:00 to 17:00
Friday -   08:00 to 14:30
Saturday -   Closed
Sunday -   Closed

Key Personnel

Daren Mottershead

Daren Mottershead
Sales & Marketing Manager

Tel: 01604 738 226

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Our News & PR

Events & Shows

  • IMechE IC Engines Conference

    IMechE IC Engines Conference

    This conference provides a forum for IC engine experts looking closely at developments for personal

    From: 06 December 2017 08:30 am
    To: 07 December 2017 17:35 pm