Mahle shows an internal combustion engine for _electric_ trucks. With 110 kW of continuous power, it will replace one battery module.

At the IAA Transportation 2026 exhibition in Hanover, Germany, Mahle will introduce a novelty: a diesel engine for trucks. The entire system is designed to fit within the space occupied by one of the batteries and serve as a diesel-powered generator. Powered by engine oil, it reduces the vehicle’s reliance on heavy batteries and extends its range by 400 kilometers. With a continuous power output of 110 kW, it enables charging at a rate similar to that at which energy is depleted from the batteries.

A diesel engine for electric vehicles. A response to infrastructure shortcomings

Let’s start with a brief introduction: in passenger cars, batteries are installed on the floor, so they are large but relatively flat rectangular shapes, with an optional island of additional cells and electronics in the rear. In heavy-duty vehicles, there aren’t such strict limitations on thickness, so batteries tend to be thicker but narrower. They are suspended in the chassis and connected into sets. Manufacturers can adjust their number (2-3-4) to change the vehicle’s range and price. The Mercedes eActros below has three separate batteries:

Mercedes eActros, schematic showing the batteries

The chassis dimensions are fairly standard, so Mahle saw this as an opportunity to capitalize on it. The company proposes replacing one of the batteries with a combustion engine and its associated equipment (illustration below). The vehicle loses 1/3 of its claimed electric range, but gains 400 kilometers of combustion engine range, meaning instead of 600 kilometers in pure electric mode it now has “over 800” (400+400) kilometers of range in hybrid mode. The load on the rear axle decreases by about 400 kilograms, and the total vehicle weight drops by 600 kilograms, according to the company (source).

The kit includes a combustion engine with a maximum power of 130 kW and continuous power of 110 kW, a fuel tank, an AdBlue tank, and an exhaust purification system. In actual operation, emission reduction is expected to be around 80 percent; when using renewable fuel (HVO100), emissions are “practically zero.” The high-temperature cooling system (see: engine) has a capacity of 48 kW, while the low-temperature cooling system provides up to 15 kW of capacity. The main components look like this (the radiator is on the left, and the actual generator driven mechanically by the combustion engine protrudes at the bottom right):

The manufacturer also revealed that it has developed a new Power Cell Unit module, which enables higher performance, better durability, and greater engine efficiency. It can also be used with other [internal combustion] engines. Its official presentation will take place at the IAA Transportation 2026 exhibition, but a photo of it has already been shown (below). Mahle hopes that this compact power generator will help transportation companies transition to electric vehicles, even in the face of inadequate charging infrastructure.

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