The following was taken from a
study about the effect intake airfilter condition has on vehicle fuel economy
(See page 16)
"A factory OEM indicator was taken from a 2001 Chevrolet Silverado with 5.3L V8 and tested to find the
Outlet DP (pressure differential) required to set the indicator or move the yellow indicator into the red zone. Using a vacuum pump and water manometer to test the indicator, the authors determined that an Outlet
DP of about 5.7 kPa was needed to set the indicator to the level corresponding to a clogged air filter.
Other air filter indicators from diesel applications were also tested. Both of the other two air filter
indicators tested were factory equipment for Dodge Ram pickup trucks with 5.9L diesel engines. One was
purchased new from the Chrysler dealer and the other was taken from a 2006 Dodge Ram pickup
equipped with a 5.9L diesel engine. Using the same vacuum pump and water manometer, the authors found that the vacuum needed to set these indicators was slightly less than that required by the indicator
taken from the gasoline application. These air filter indicators only required about 4.2 kPa to move the
indicator to the level corresponding to a clogged air filter.
It is common for air filter service indicators to be set between about 5.0 and 7.0 kPa."
4.2 kPa = 0.609 psi = 16.861 inches of water column.
5.7 kPa = 0.827 psi = 22.883 inches of water column.
pressure-units-conversion calculator
There's some good information in that study related to air filters and restriction levels but the one thing we can get from it, at least, is what the car manufactures consider to be the maximum restriction that an air filter should have.
The study also says:
"It is common, however, for servicing to occur when the filter appears dirty. Engine air filters are designed to actually increase their efficiency by using this initial layer of dust as an added filter layer. Initial filter efficiency is usually approximately 98% but increases to more than 99% by the end of the service life of the filter. Therefore, changing an air filter before the useful service life is
achieved can result in premature engine wear."
This mirrors what others has often said- that a slightly dirty filter actually filters better than a brand new one.