Air intake management

Before unfiltered air enters the combustion chamber, it must be fed through the engine compartment and cleaned of dirt particles as efficiently as possible.

The MAHLE product portfolio covers the entire scope of air intake management: from air guidance to air filtration to air intake modules with electrical intake pipe actuators—but also resonators and sound generators.

MAHLE air intake systems include the entire scope of the system, from raw air intake with preliminary removal of dust and water to the air filter module with the main filter element and safety insert to the turbocharger inlet interface. As a result, MAHLE is able to fully respond to system inquiries and to develop and produce modules completely in house.

Critical package constraint situations present a formidable challenge to the development of air filters for commercial vehicles. MAHLE air filter modules are individually customized according to customer requests with regard to package constraint, weight, and interfaces to other systems. Another development focus of MAHLE is on achieving long maintenance intervals. Mechanical and electrical sensors reliably display the maintenance status of the filter system. The filter is freely accessible and tool-free maintenance is possible.

MAHLE is also a leader in environmental protection. Metal components are therefore eliminated as early as in the design phase of the air filter modules, in order to simplify the disposal of used filter materials.

Depending on the customer's requirement, MAHLE delivers plastic cylinder head covers either as integrated in the intake system or separately as a functional or design component. These products stand for strongest stability and low weight. They meet high requirements with respect to engine acoustics and leak tightness, as well as the increased design demands by vehicle and engine manufacturers. The latest generation of MAHLE cylinder head covers for commercial vehicle has even more to offer: it allows functional integration, such as an integrated oil mist separator, and is modular in design so that it can be used cost-effectively in engines with different numbers of cylinders.

Crankcase ventilation systems reliably remove the gases from the crankcase that are contaminated with oil mist. The oil mist separator integrated into the ventilation separates gaseous and liquid components. The separated oil is recirculated into the oil circuit and the residual air is recirculated into the intake system. The oil mist separator must ensure a high level of oil separation for all engine-specific requirements that lead to varying volume flow rates and fluctuating amounts of oil.