PRODUCT INFORMATION

FILTERAFTERMARKET

PROGRAM

THE EXTENSIVE

FILTER PROGRAM.

DIFFERENCETHE SMALL

THAT ISN’T ONE.

Global brands

Brand only distributed in certain regions

5

About us

Filters have a long tradition with us. MAHLE –

historically a developer of engine components

– has recognized in good time how important

optimally functioning filters are for the different

circulations of service media. After all, every

combustion is only as good as its upstream filters

no matter, whether oil, fuel or intake air has to be

cleaned. And because people only stay healthy

when they breathe clean air, cabin air filters are

another important part of our program.

Whether we supply the international automotive

industry or our trading aftermarket partners in

the component sector – our products fulfill the

same high requirements. Only the packaging is

different. Depending on the brand, it is blue for

MAHLE Filter, orange for Knecht and yellow for

Metal Leve. Our MAHLE sales companies or our

sales partners will tell you, which brands are

available in the respective countries.

Common to all brands is a comprehensive pro-

gram of filters for passenger cars, commercial

vehicles, agricultural and construction machinery

as well as motorbikes. As an innovative devel-

opment partner of the automotive industry with

R&D facilities in Stuttgart, Northampton, Detroit

(Farmington Hills and Novi), São Paulo, Tokyo

and Shanghai, we manufacture filters and filter

systems that are optimally matched to engine

characteristics, assembly conditions and appli-

cations. Our partners in trade and workshops

benefit from this with filters in original equipment

quality for oil, air, fuel, with Eco filter cartridges,

activated carbon canisters, air dryers, oil sepa-

rators, hydraulic filters and cabin air filters, which

can also be retrofitted for certain vehicles.

ATMOSPHERE WE THINK A BAD

IS EXTREMELY CONSTRUCTIVE.

Air filters

Our air filters are completely sealedUn-cleaned air in the in-

take passage can con-

taminate the air flow mass

meter and distort the

measuring results, cause

malfunctions of the fuel

injection and wear of

engine components. To

prevent bypass air, our

filter sets are fitted-in ex-

actly and the seals have

been selected carefully.

PUR seals made from

specially developed PU

foam ensure continuous

sealing between dirt and

clean side. These seals

are resistant to aging,

chemical effects and are

temperature stable. Their

flexibility is designed to fit

exactly to the geometry

of the sealing area.

MAHLE air filters in original

equipment quality clean the

intake air for passenger cars

and commercial vehicles.

Filters close to the engine for passenger cars

and commercial vehicles

7

Air filters

Clean air intake is one of the most important

conditions for optimal engine power, high torque,

low fuel consumption and minimized pollutant

emission. With MAHLE air filters up to 99.9 per-

cent of dust, soot and tire wear particles are fil-

tered out. At the same time, an optimal air/fuel

mixture is assured. The high particle uptake

capacity ensures long service life also under ex-

treme conditions such as heat, cold or chemical

influences. Our quality filters prevent premature

wear of the valves, cylinder working surfaces,

piston rings, bearings and other engine compo-

nents. To ensure perfect and lasting filter per-

formance, all filters must be replaced within the

replacement intervals stipulated by the car manu-

facturers.

In the passenger car sector, round and panel

elements are fitted in air filter housings mounted

to the engine or chassis and are stabilized with

glue beads at the dirt side and support grits at

the clean side, depending on the specifications

of the car manufacturer. For dust rich areas, an

additional pre-cleaner in form of a foam mat is

placed at the dirt side. For higher surface loads,

metal or plastic support studs are used.

In commercial vehicles, robust and at the same

time low-weight air filter systems made from

recyclable plastic are used that can also reduce

air intake noises. In order to achieve a large filter

surface at high stability, the filters are mostly

cylindrical. To improve efficiency, radial sealing

and axial supports are used. Additional safety

inserts in form of special fleece cylinders protect

the clean side of the filter element during main-

tenance and replacements.

ENGINE COMPARTMENT ONE OF THE MOST IMPORTANT JOBS IN THE

IS THAT OF THE PORTER.

Oil filters

The engine oil reduces friction and wear of the

engine, cools the engine components, protects

the inside of the engine from corrosion and

seals the combustion chamber with a thin oil

film between piston, piston ring and the working

surface of the cylinder. This puts constant stress

on the oil: combustion residues, dust, carbon,

soot, abrasion particles and condensates can

contaminate the oil and promote premature

wear of engine components.

MAHLE oil filters reliably prevent dirt particles

from entering the lubricant circuit and maintain

oil quality as well as the performance and effi-

ciency of the engine. Thanks to stable pleat

geometry, cold start stability is assured.

Load peaks up to 20 bar are compensated due

to the high pressure resistance of the housing.

A pressure relief valve guarantees the oil supply

under all conditions – for viscous oil as it is en-

countered during cold start or at low tempera-

tures and also for strongly contaminated filter

elements, when the replacement intervals have

been exceeded. An anti-drain valve prevents the

draining of the filter when the engine is switched

off and secures fast oil supply when the engine

is started. High-grade sealing materials and

custom-fit connecting pieces assure a reliable

separation between contaminated and filtered oil.

However, an important condition for the correct

functioning of the oil filters is that filters are

replaced within the maintenance intervals stipu-

lated by the car manufacturers.

Spring

Bypass valve

Internal support frame

Filter element made

of special paper

Anti-drain valve

clean side

Anti-drain valve

dirty side

Cover plate

Sealing

Housing

Oil filters

Oil filter cartridges, the

ecologically sensible and

economical solution.

Filters close to the engine for passenger cars

and commercial vehicles Oil filter cartridges With filter cartridges from

the OX and OX-Eco pro-

gram we offer particularly

economical solutions for

workshops: instead of re-

placing the complete filter,

only the dirty filter element

has to be exchanged. An

ecologically sensible so-

lution that saves material

and disposal costs. In the

OX-Eco version, the car-

tridges are metal-free and

can therefore be inciner-

ated completely. Oil filter

cartridges are available for

all oil filters with housings

that can be split.

More efficientreplacements

Spin-on oil filterOC spin-on oil filters can be

changed easily. The deep-

drawn steel sheet housing

with powdered coating has a

multifaced collar to facilitate

fast loosening of the filter.

The cover plate has a thread

for the screw-on spigot and

a groove for the seal. The

filter element has an internal

frame as support against the

oil pressure that is directed

from the outside to the inside.

9

Special spin-on filters and

filter cartridges that are

matched to hydraulic oil

are available.

Hydraulic spin-on filtersand filter cartridges Hydraulic spin-on filters

with increased wall thick-

ness and stable end

plates are specially

matched to the high pres-

sures in hydraulic systems

of up to 40 bar. Often the

multifaced collar is aban-

doned to allow higher pul-

sation closeness. More

durable materials such as

special fleeces and syn-

thetic medias are used in

hydraulic spin-on filters

and filter cartridges, since

hydraulic oil contains dif-

ferent components.

LEFT OVER.

WE TAKE CARE OF

ANY DIRT

Fuel filters

Modern fuel injection concepts require extremely

clean, homogeneous and pulsation-free fuel

supply. However, foreign particles can get into

the fuel during the production and transport

process and need to be filtered out. MAHLE fuel

filters hold back foreign particles reliably. Thanks

to high-quality filter media, the fuel system is

protected from smallest dirt particles and there-

fore from corrosion damage. This safeguards the

engine function and assures the efficient opera-

tion of the vehicle. The required constant fuel

supply is achieved with pressure regulation and

recirculation of the surplus fuel from the injec-

tion pump to the tank. Pulsation damping com-

pensates for the pressure fluctuations caused

by the fuel pump. Our fuel filters comply with

the correspondingly high safety standards of the

car manufacturers and ensure sealing tightness

even in the event of accidents.

However, an important condition for the correct

functioning of the fuel filter is that filters are

replaced within the maintenance intervals stipu-

lated by the car manufacturers.

Diesel fuel filters

In order to prevent paraffin separation and clog-

ging of the filter at low ambient temperatures,

pre-warming with electric heating elements or

recirculation of fuel that has been warmed by

the engine is used in our fuel filters.

For newer generations with even higher require-

ments, MAHLE has opted for two separate

process stages during water separation.

The first filter phase consists of a cellulose filter

medium with an untreated melt-blown contact

surface for increasing the dirt absorption capac-

ity. This melt-blown contact surface optimally

causes the many small droplets to coalesce into

larger ones. The particle filter designed as a pleat

star even agglomerates the finest water droplets.

The second filter phase consists of a water sep-

arator, whose hydrophobic fabric with a mesh

width of 25 μm divides the emulsion now only

slightly stable, thus separating the water. As this

occurs on the clean side of the filter, it is re-

ferred to as a clean-side water separation.

Inline fuel filters

Inline fuel filters are mounted in line with the fuel

line as the name indicates. They are made from

steel sheet material with corrosion protection,

stainless steel, aluminum or plastic. Optional

functions such as pressure regulation, pre-heat-

ing, cooling and water separation are available.

Emulsion

after pump

Particle separa-

tion and agglo-

meration of

water droplets

Clean diesel with

water droplets

Hydrophobic fabric

Water collection volume

Filtrated fuel

Fuel filters

Also for fuel filters:spin-on filters and fil-ter cartridges that aremore economical andenvironmentallyfriendlyFuel spin-on filters are de-

signed for easy and fast

replacement. Depending

on their type, they are

supplied with a thread to

connect a water drain

plug or water level sensor.

For replaceable filter ele-

ments, only the dirty filter

cartridge is replaced.

These filter elements are

also available in versions

that can be incinerated

completely easing the bur-

den on the environment.

Filters close to the engine for passenger cars

and commercial vehicles

Schematic diagram two-stage filter element with integrated

water separator.

11

DESIGNED FOR

FRESH AIR.

Cabin air filters

Cabin air filters do a clean job. During only one

hour driving, an air volume of up to 100,000

liters is blown into the vehicle interior. All the more

important is regular change of filter elements.

MAHLE recommends changing the cabin air filter

every 15,000 km – however, at least once per

year. Because, if the cabin air filter fails or when

it is clogged up, the pollutant concentration in

the interior of the vehicle can increase to six

times of that of the outside air. MAHLE cabin air

filters supply the driver and passengers reliably

with cleaned air to breathe and safeguard their

health, well-being and power of concentration of

the driver even in the event of smog or high pollen

count. They also reduce the load on the blower,

protect heating and climate control from con-

taminations, improve air circulation and prevent

dangerous misting up of the windows. In addi-

tion, the inside of the windows and fittings remain

clean for longer.

The pleat geometry of our cabin air filter ele-

ments is designed to provide a long service life.

The low flow resistance minimizes the load on the

blowers. Thanks to the accurate fit of the filter ele-

ments into the housings, bypass air is prevented.

Our cabin air filters do not produce harmful

emissions, as solvent-free methods are used for

their production such as ultrasound technology

for welding.

Cabin air filters with activated carbon

Cabin air filters with activated carbon elements

keep back harmful exhaust fumes, dirt and dust

as well as high ozone concentrations and un-

pleasant smells. Their pleat bellows consist of

three layers: an activated carbon layer is sand-

wiched between two layers of fleece. The filter

layers are fused by means of heating which

means that glues or solvents are not used at all.

Depending on the vehicle type, activated carbon

filters are also available that can be used instead

of conventional cabin air filters.

Cabin air filters

Cost-effective back-fitting for certain older vehicle modelsVehicles that were not

originally equipped with

cabin air filters can be

retrofitted with our cabin

air filters, including those

with activated carbon.

For that purpose, a filter

element of our compre-

hensive program is com-

bined with a housing that

is matched to the assem-

bly situation in the par-

ticular vehicle.

Filters for the cabin

13

WE WORK

BEST UNDERPRESSURE.

Air-drying cartridges

Especially for commercial vehicles

15

Air-drying cartridges

Many control and closed-loop control processes

in commercial vehicles work with compressed air,

as for instance in brake systems. However, air

contains moisture and this in turn can cause

damage in piping and containers, can contami-

nate lubrication films and freeze at low tempera-

tures. Air dryers are used in order to assure fail-

ure-free operation of the safety systems. They

remove moisture from the air, prevent corrosion

in pipes and containers and guard against pre-

mature wear and malfunctions. To guarantee

the operational safety of air brake system it is

imperative that air dryers are replaced according

to the manufacturers regulations.

MAHLE air-drying cartridges operate indepen-

dently of the temperature. They contain a drying

agent that is regenerated under system control.

At the same time, contaminations from the pre-

filter and condensed water are removed. Our air-

drying cartridges are resistant to corrosions from

the inside and outside, are completely sealed

and, of course, are pressure stable.

CATCHING

THE LOT.

MeltblownDirt side

Cellulose

Clean side

Filter media

The impregnated cellulose

fibers under the microscope.

Readily pleated paper for use in filters. Multilayer filter medium with plastic fleece at the dirt side

and paper at the clean side.

Funnel effect of the filter

fleeces: density and fine-

ness of the fibers increase

from the dirt to the clean

side.

Filter paper after embossing.

Block forming in air fil-ters for example an ex-pensive phenomenonWhen the pleat geometry

is insufficiently stable

and the folds are too close

together, no air or not

enough air can flow in

these areas through the

filter. This increases the

flow resistance, the filtra-

tion deteriorates, the life

span of the filter is re-

duced and the fuel con-

sumption and pollutant

emission increases sig-

nificantly.

In order to prevent loss of

stability and shape, our

filter papers are impreg-

nated with special resins

during a complex treat-

ment process.

➡➡

17

The filter media inside our filter program consist,

depending on specifications and applications,

either of specially treated papers, fleeces or multi-

layer filter media.

Filters made from paper

The papers for our filters are made from high-

grade cellulose fibers impregnated with special

resins. These materials are treated in a special

production process: special pre-warming pre-

pares the paper for the embossing of vertical

ridges. Afterwards, the paper is folded accord-

ing to requirements. Then the impregnation is

cured to make the paper mechanically stable

and to make it resistant to chemical and thermal

influences. The outcome: filters with stable pleat

geometry that prevent the feared forming of

blocks (see right column) also under high load

and ensure that air, oil or fuel can flow freely

through the paper at all times. The fineness of

the filters can reach 1 μm depending on the re-

quirements and offers safe conditions for highest

dirt elimination.

Filters made from paper are used in air, fuel, oil

and hydraulic filters.

Filter fleeces

Fleeces, on the other hand, consist of plastic

fibers with thickness in the μm-range: the finer

the fibers, the better the collection. The fleeces

are applied in layers whereby the density and

fineness of the fibers increase from the dirt to

the clean side. This so-called funnel effect

allows efficiencies up to 99.9 percent with low

flow resistance at the same time.

Filter elements made from fleece are used in

combination with a stable base paper in fuel

filters. Also for cabin air filters filter elements

made from fleeces are available.

Multilayer filter media

These are combinations of fleece and paper

that have been fused in a complex production

process. They are characterized by a dirt collec-

tion capacity that is up to 40 percent higher

than that of conventional paper filters at a dirt

collection efficiency from 3 to 5 μm.

Multilayer filter media are used for modern diesel

fuel injection systems (in turbo diesel direct injec-

tion, common rail or pump injector technology).

WITH EVERY OF OUR FILTERS.

WHAT ELSE WE HAVE BUILT-IN

Quality and service

19

When we talk about quality we mean, of course,

primarily the quality of our products. We have

already mentioned that they match original equip-

ment quality in every case. We also would like to

mention, that we are continuously in dialog with

car manufacturers and are advancing together

the development of our filters – and also the

fact, that we are certified by all renowned car

manufacturers and certification authorities.

But quality is still that little bit more. For example,

quality of service. And this begins with complete

consultation – and includes our very popular

Customer-Information-System (KIS) and a train-

ing program to match.

In order to optimize the flow of goods and sales,

we do not just assure you of our high readiness

to deliver – we also provide you with practical

sales documentation and make it easier for you

with distinctive and informative design of the

packaging.

In addition, we get involved in workshop co-

operations and also participate in individual

advertising campaigns.

Comprehensive public relations work and our

presence in the relevant trade and consumer me-

dia also assure that we are widely recognized and

contribute to the excellent image of our brands.

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