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    ENGLISH

    BASICS

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    BASICS

    18

    Important Information

    MS Motor Service International GmbH

    is the sales organisation for theworld-wide aftermarket activities ofKolbenschmidt Pierburg AG. It is oneof the leading suppliers of enginecomponents for the open spare partmarket, including the premium brandsKOLBENSCHMIDT, PIERBURG andTRW Engine Components. Our com-prehensive product range allows our

    customers to procure engine compo-nents from a single source. As aproblem solver for dealers andrepair shops, Motor Service alsoprovides an extensive service package

    as well as the technical expertiseassociated with an affiliate companyof a major automotive supplier.

    Kolbenschmidt Pierburg Group

    As long-standing partners to the car-making industry, the companies inthe Kolbenschmidt Pierburg Groupdevelop innovative components andsystem solutions with acknowledgedcompetence in the fields of air supplyand emission control, for oil, waterand vacuum pumps and for pistons,engine blocks and engine bearings.

    ServiceTips & Information

    Useful technical information can be found in

    These brochures can also be viewed on our homepage

    MS Motor Service International

    GmbH is abbreviated here to MSI.

    Although the information provided

    in this catalogue has been carefullycompiled, we cannot guarantee itsaccuracy and do not accept anyliability for errors. In particular, wedo not undertake any warranty forchanges in the equipment by themanufacturers of vehicles or enginesnor for changes in the designationof the parts. In case of doubt youare requested to contact our TechnicalCustomer Service. Any references toerrors in the catalogue which you

    may advise us of are welcome andwill lead to corrections in futureissues of the catalogue. Names,descriptions, numbers of vehicles ormanufacturers etc. are only statedfor reference. All products in the cata-

    logue are spare parts of KS quality.All figures, schematic drawings andother data serve as explanatory andillustration purposes only; hencethey must not be used as a basis for

    installation work, or as scope ofsupply and design. This appliesespecially to information providedby manufacturers.Information and data relating to origi-nal spare part numbers of vehicleand engine manufactures only servefor comparison and reference. Theyare not original designations andmust not be used when dealing withthird parties. We cannot undertakeany liability for the use of these

    reference lists in respect of changesand/or dimensional variances by theindividual manufactures.To the extent that the catalogueincludes articles not produced byMSI, the product characteristics and

    data originate from the respectivemanufacturer. Liability for thecorrectness of the data and suit-ability of the product for its intendedpurpose of application is expressly

    excluded.In order to safeguard suitability, it isessential to obtain expert advicefrom the manufacturer or itsauthorized repair shop in each spe-cific case. The parts listed in the cat-alogue are not intended for use inaircraft. When using marineengines, please note that the sameengine designations (e.g. pistons)can be used for different engineparts. This information may not bereproduced in any form, even as anexcerpt, without our prior writtenconsent and must include theproper references. The publicationof this catalogue renders all formerissues obsolete.

    Subject to change without notice.

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    Index Page

    Important Instructions ................................................................... 18

    Quality Management ...................................................................... 19

    1. Instructions for using the catalogue ............................................... 20

    2. Product information ...................................................................... 24

    2.1 Bearing types and names .............................................................. 24

    2.2 Bearing types in the engine ........................................................... 27

    2.3 High-performance bearings (HGL) Sputter ................................... 28

    2.4 Repair steps ................................................................................. 28

    3. Assembly of plain bearings Step by step...................................... 29

    3.1 Preparation .................................................................................. 29

    3.2 Assembly ..................................................................................... 30

    4. Additions to the range ................................................................... 81

    5. List of manufacturers .................................................................... 85

    6. Product range ............................................................................... 897. Piece Pair / Set / Make / Position ................ List 1 ................... 1295

    8. Pair Set / Make / Position ........................... List 2 ................... 1353

    9. Set Make / Position .................................... List 3 ................... 1369

    10. Old KS-No New KS-No ................................ List 4 ................... 1399

    11. FEDERAL MOGUL & GLYCO-No KS-No ........... List 5 ................... 1403

    12. Form Quality Information Report

    13. General Conditions of Sale and Delivery

    19

    As a sign that ourQuality Managementsatisfies the require-ments of the relevantinternational stand-ards, we are certifiedto ISO 9001.

    Many of our customers,particularly automotivemanufacturers that are

    household names aroundthe world, come to ourcompany with even morestringent requirements.For Quality Management,

    these requirements are summarisedin the International Standard ISO/TS16949. In order to satisfy our cus-tomers wishes and to show that we

    can also fulfil these obligations thatgo far beyond the requirements ofISO 9001, our Quality Managementis now also certified to this StandardISO/TS 16 949.

    In the event of the occurrence ofmaterial or production faults despitecontinuous checks during theproduction process and the compre-hensive final inspection, we will ofcourse undertake to repair the engineor replace the faulty product within

    the limitation period. We must beadvised in writing of complaints ofthis nature within 30 days of theoccurrence of the fault.The limitation period for claims fordefects is 24 months, commencingfrom the delivery of the item.Claims for damages shall be void ifthe delivered item has been modifiedby a third party or parts from othermanufacturers installed, unless thedefect is not related to such modifi-

    cations. Furthermore, they shall bevoid if the item was not handled orinstalled in accordance with theapplicable regulations.

    Quality Management

    Handling resourcesresponsibly,protecting ourenvironment andcompliance withall the relevantlegal obligationsis extremelyimportant for our

    long-term co-operation with allour partners. This is what motivated

    us to satisfy the requirement stand-ard for environmental managementsystems ISO 14001, and to get ourorganisation certified accordingly.

    Environmental Management

    Normal wear and tear and damageresulting from improper handlingare excepted from the warranty.

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    Vehicle IndexEach manufacturer section starts with a comprehensive search index.Vehicle designations are sorted alphanumerically in ascending order.

    Engine IndexEach manufacturer section starts with a comprehensive search index.Engine designations are sorted alpha-numerically in ascending order.

    1. Instructions for using this catalogue

    Item number

    Item number

    Manufacturer

    Manufacturer

    Engine

    Vehicle

    20

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    Product DataThe catalogue pages consist of the informationblocks listed below:

    Manufacturer linePictogram line

    Plain bearing data (mm)

    Item number

    Engine line

    Cylinder- nominal

    Model year from to

    Number of

    cylinders

    Engine rating from to

    Type of charging*

    Type of fuel*

    Engine number/identificationnumber

    engine designation with type

    of catalytic converter/pollutantNumbers of valves

    Notes

    Engine line

    Item number:

    (Sequential numbering withineach manufacturer)

    Stroke

    Compression ratio

    Reference to notes

    Piston families for the en-

    gines listed. With respect todetails of use seePiston Cataogue.

    Swept volume

    * See list of abbreviations

    Manufacturer

    21

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    Assembly position:

    = top

    (rod or housing))

    = bottom (cap)

    Materials* Overall bearing length (mm)

    Housing bore (mm)max.min.

    Number of bearing pairs or

    thrust washers per engine

    Repair steps

    Notes on

    plain bearing

    Bearing position Art. No for bearing pair

    and individual part

    Art. No. for bearing set

    and thrust washers

    (Standard) shaft diameter (mm)max.min.

    Bearing design

    Standard wall

    hickness (mm)

    Reference to

    notes

    Plain bearing data

    * See list of abbreviations

    Manufacturer

    22

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    Repair step with machining

    allowance

    Thrust washer thickness (mm)

    Axial clearance Flange span of flanged

    crankshaft (mm)

    Bearing pair

    or bearing set number

    Bearing half number

    Illustration of a plain

    bearing

    Thrust washer inside

    diameter (mm)

    Thrust washer outside

    diameter (mm)

    Note: Restriction (model year or engine

    number) of product in relation to engine

    Plain bearing data

    23

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    2.1 Bearing types and names

    Plain bearing shells

    Plain bearing shells are used for bothconrod bearings and main bearings.They are mostly designed as thin-walled composite bearing shells.Bearings made of two materials havea steel back onto which the bearingmetal, typically aluminium with tinand copper additives, is plated. Inthe case of bearings made of threematerials, the bearing metal is copperwith additives of lead and tin castonto the steel back or applied by thesinter-rolling-sinter method. A nickeldam (diffusion seal) separates the

    bearing metal and the galvanicsliding layer.

    Parting face Bore relief

    Wall thickness

    Thrust face

    Left locking lug

    Oil hole

    Internal oil groove

    Overall

    length

    Lock hole

    Right locking

    2. Product information

    Plain bearings are an importantcomponent of internal combustionengines.The development of plain bearings

    is therefore closely linked with enginedevelopment. Today, the complexrequirements and increased stressesimposed on the bearings of themoving engine parts, such as crank-shafts, conrods, tappets and cam-shaft generally call for the use ofmaterials that are carefully tuned tothe respective application. The largenumber of proven material combina-tions available meanwhile enablesthe design engineer to select theoptimally suited bearing system.

    24

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    Spreading for easier assembly

    The bearing shell is larger than thediameter of the housing holder(pretention). During assembly, thisprovides a good contact with thebore and prevents drop-out or twist.

    Press fit by crush height

    The circumferential length of thebearing shells is larger than that ofthe bore. On assembly, this bearinglength is reduced by elasticdeformation. The resulting stressgives the press fit which ensures

    correct location of the bearing.

    Oil groove

    Wall thickness Joint bush length

    Oil distributing pocket

    BushesWith few exceptions, thin-walledsteel composite bushes are used asconrod, camshaft or rocker armbushes. Blanks are punched out fromcoated band steel, which are alreadyprovided with oil holes, oil grooves,oil distribution pockets or locationgrooves. These blanks are thenrolled to form bushes. Grooves andholes may become deformed in theprocess. Both butted and locked

    joints are possible.

    Bearing shells without locking lugsThe locking lugs on the bearing shellsare used to make manual installationeasier. The lugs are an obstructionwhen assembling engines mechani-cally. For this reason, various bearingshells for new engines are no longer

    produced with locking lugs.

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    Thrust washers

    Thrust washers in conjunction withplain bearing shells are a substitutefor flanged bearings in the engine.The axial guidance of the crankshaftis in this case performed by the thrust

    washers. Crankcases are specificallyconfigured to accommodate thrustwashers. The reliable guidance atthe outside diameter of the thrustwashers and rotational lock must beensured.This is why housings which aredesigned for the installation offlanged bearings cannot be fittedwith thrust washers.

    In some cases it would theoreticallybe possible to equip engines origi-nally fitted with thrust washers, withflanged bearings when recondition-ing. In practice, however, thrust

    washers have to be refi

    tted! This isthe only way to ensure the optimumcondition with respect to dimensions(bearing face) and material. Thrustwashers are not included in the mainbearing set. They have to be orderedseparately!

    Oil groove Locking lug

    Flanged bearing shells

    Flanged bearing shells are respon-sible for the axial guidance of thecrankshaft in the crank drive bearingsystem. The flanges of these bearingsare ready for assembly and must notbe remachined. Exceptions are clearlymarked in the catalogue.Depending on the engine design, one

    or two flanged bearing shells areinstalled.

    Thrust face relief Parting face relief

    Oil groove onthrust face

    Overalllength

    Bargage

    Flange thickness Crescent groove

    Oil distributingpocket

    Thrust face

    Sliding surface

    casing

    Guiding forces

    radial bearingthrust bearing

    clutch pressure

    The axial loads resulting from theclutch pressure are supported by theflanks of the flanged bearing shellsand / or the thrust washers.

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    2.2 Bearing types in the engine

    Camshaft bearing (NW-L) Rocker arm bush (KH-B) Conrod bush, small end (PL-B)

    Main bearing (HL) Thrust washer (AS) Connecting rod bearing, big end(PL)

    Flanged bearing (PASS-L)

    27

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    2.3 High-performance bearings(HGL) - Sputter

    Enhanced engine performance callsfor materials of significantlyincreased fatigue strength, lowerwear rate in mixed friction operation

    and good corrosion resistance atelevated temperatures, especiallyfor conrod bearings. This complexrequirements profile is met usingphysical vapor deposition (PVD).Under high vacuum, extremely fineparticles are beaten out of a dis-penser. By means of electromagneticfields, they are uniformly applied tothe part to be coated. These magn-etron layers distinguish themselvesby extremely fine distribution of theindividual microstructure compo-nents. The basis of this design is thewellknown composite bearing madeof three materials. The basic designhas been retained. The galvanic sli-ding layer is replaced by a sputteredsliding layer.

    2.4 Repair steps

    KS offers plain bearings in standarddimensions (STD) and undersizedgrades. We recommend only to use

    undersize grades which are alsoemployed by the engine manufac-

    turer. The use of larger undersizestages will increase the risk ofengine failure (e.g. shaft rupture),

    so that we cannot accept liability forthe installation of such bearings.

    Sputtered bearing shells are prima-rily used on the pressure side ofbearings. The opposing shells areconventional two or three-materialbearings. In conrod bearings, thesputter bearing is normally used onthe rod side (top) and in main bea-rings on the cover side (bottom). Forthe main bearing, the lower half issputtered. The correct installationposition of the sputtered bearing

    shell is a prerequisite for satisfac-tory operation. To this end, thearrow direction in column 1 in theProduct Program of the cataloguemust always be observed.KS sputter bearings are markedsputter on the back.

    28

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    A

    B

    C

    C

    B

    A

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    29

    3. Assembly of plain bearings Step by step

    3.1 Preparation

    The tightening specification must be observed for everymachining and measurement process. Two measurements

    are necessary as shown in the diagram:1. Measuring the support bearing dimension

    (without bearing shells).

    Note:Observe manufacturers specification ifconnecting rods have cracked!

    2. Messung mit eingesetzten Lagerschalen.

    Average the dimensions A and B and compare this withdimension C.The result shows if the bearing is round. If a differencebetween values A and B is found, a cap offset of half thedifference is indicated.

    approx.

    25

    approx.

    25

    approx.

    25

    approx.

    25

    1. Measuring the support bearing dimension 2. Measurement with bearing shells inserted

    Admissible deviations:

    Total concentricity of all bearingcounter bores max. 0,02 mm

    Concentricity between adjacentbearing counter bores max. 0,01 mm

    These tolerances are guide values unless themanufacturer specifies different data.

    For the bore dimensions, the tolerances stated in theCatalogue shall apply.

    Permissible taper and roundness:

    Diameter (mm) Taper (m) Roundness (m)

    up to 25 max. 3 max. 325 to 50 max. 5 max. 550 to 120 max. 7 max. 7

    Diameter and roundness measurements on straight or inclined split connecting rods

    Concentricity of main bearing counter bores on engine block

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    During the crankshaft reconditioning, several crack checks are necessary, in each case after aligning, harden-ing, grinding!

    3.2 Assembly

    Final inspection of every crankshaftFor the shaft diameter, the tolerancesindicated in the catalogue shall apply.Individual checking for compliancewith the roundness and parallelismtolerances.Permissible out of round up to aquarter of the shaft tolerance.

    Maximum values for tapered, convexor concave ground shafts:

    Width (mm) Tolerance (m)

    up to 30 3above 30 to 50 5above 50 7

    Check: Inspect the crankshaftfor concentricity

    It is necessary to carry out a concen-tricity inspection on every recondi-tioned crankshaft, especially afterrehardening. The concentricity ismeasured with support at the outermain bearing journals.

    Permissible misalignment of mainbearing pins:

    Adjacent journal 0,005 mmTotal 0,01 mm

    These tolerances are guide values,unless the manufacturer has speci-fied different data.

    Check: radius

    The radius must be within the manu-facturers specification. Crankshaftfracture is caused by too small radius.With radius hardened bearing jour-nals, particular attention should be

    paid to the maintenance of surfacequality and shape tolerance.

    Measure radius

    If the correct radius gauge is selected,there must be no visible clearancegap.

    right

    wrong

    Radius check Measure radius

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    Final check: Are the bolts o.k.?

    Bolts tightened by torque and anglecan become permanently deformed.If they reach a maximum length orminimum diameter, they must be

    replaced. This also holds true formechanically damaged bolts.

    Check: Is this the correct bearing?

    Make a comparison with the strippedbearing. In this way you can confirmthat your selection from the KS

    Catalogue was correct.

    That fits: Lug in groove

    With this assembly aid, the bearingshell is correctly located.

    Selection:Only with the KS Catalogue

    KS supplies the bearing shells ready

    to fit, whatever the undersize grade.The bearings must not beremachined, unless otherwisespecified in the Catalogue.

    Still hard? Inductiveor flame hardened shafts?

    Sufficient hardness depth is availableon crankshafts to enable grinding toall undersize grades withoutrehardening, unless the journal has

    been softened by overheating.Nitrided shafts must, however,always be retreated.

    Hardness test with rebound hardness tester(Part No. 50 009 812)

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    Keep it clean: Oiling the shells

    Use an oil can. A brush may transferdirt particles from the oil container.

    Make it safe: Tighten all parts

    Strictly follow the tightening specifi-cations. This is important to obtainthe required press fit, giving firmlocation and correct clearance.

    Plain bearing board in english:

    All clear? Axial clearance

    The flanged bearing is designed withextra width for service purposes.Grind the crankshaft to match thisbearing shell width, thus maintainingthe axial clearance.

    Testing Axial Clearance

    Correct specifications can be

    obtained from the engine manufac-turer or from the KS Plain Bearingscatalogue.

    Attention!

    Repair grades of flanged bearingsand thrust washers are partlydesigned with lateral allowances.

    Dial gauge(Part No. 50 009 884)

    Magnet measuring tripod(Part No. 50 009 886)

    Installation support for workshops

    A large board (size: 70x100 cm)

    illustrates the installationrecommendations step by step.

    Plastigage bearing measuring tape(Part No. 50 009 880)

    Testing the plain bearing clearance with

    KS Plastic Gauge

    Countdown to startAll engine components must besufficiently lubricated. Partic-ularly with newly assembledengines, the oil requires sometime to reach all the bearingsfrom the sump. The danger ofpremature damage due to dryrun is high. This can be preven-ted by pressurizing the com-plete oil network.

    KS Plastic Gauge plain bearingmeasuring tape

    Enables swift and accurate checkingof the bearing clearance on cross-divided plain bearings. It is espe-cially well suited for checking the

    clearance of crankshaft main bear-ings, conrod bearings and camshaftbearings on the engines of passen-ger cars and commercial vehicles.

    KS Plastic Gauge is a thin, calibra-ted plastic strip which is insertedinto the oil-free bearing position tomeasure the bearing clearance.When the bearing cap is tightened,the width of the strip is contracted.After loosening and removing thebearing cap, the resulting width of

    the plastic strip and consequentlythe bearing clearance can be deter-mined with the aid of the enclosedreference scale.

    The bearing clearance can be readin mm and inch.

    Measuring range:0,025 to 0,175 mm

    Scope of delivery:10 measuringstrips, measuring instructions andmeasuring scale