Our heart beats for your engine.

Motorservice – your global partner

for engine components.

MOTORSERVICE Mission statement | 02

Motorservice is responsible for the global spare parts industry

within KSPG AG. Engine component sales is our core

competence. We have contact with our distributors all over the

world every day, who pass on our products to end customers,

repair shops and engine reconditioners. As a service-orientated

company, our goal is to ensure that drives work problem-free for

a very long time. We aim to support customers in this respect in

every way we can. and we work to achieve this every day. Only in

this way can we ship engine components all over the world in

the quickest way possible. We supply our customers with engine

components from the premium brands KOLBENSCHMIDT,

PIERBURG, BF and TRW Engine Components. We also offer our

customers a full-service package. This starts with the forgery-

proof package, the efficient, modern ordering systems and

support provided in a wide range of languages, right through to

an extensive package of technical information and trainings

on-site.

Hansjörg Rölle,

Chair of the Aftermarket Division Management

“Technical competence is just one side

of Motorservice. It is our

colleagues that make us really strong.”

Mission statement | 03

MOTORSERVICE Editorial | 04

We are prepared for the future.The KSPG Group is one of the 100 biggest automotive suppliers

in the world and embodies the field of mobility within the

Rheinmetall corporation. At around 40 production locations in

Europe, North and South America, as well as Japan, India and

China, around 12,000 colleagues develop components, modules

and systems for drive engineering of current and future vehicles.

As a development partner for car manufacturers all over the

world, the company has been accompanying the development

and sustainable improvement of engine technology with regard

to low emissions, reduction in fuel consumption and CO2

savings, as well as weight reduction and improvement in

performance, for over a hundred years. The supplier firm present

on the international automotive markets consists of the three

divisions Hardparts, Mechatronics and Aftermarket.

The KSPG Hardparts division for passenger car and utility

vehicle pistons, large pistons and crankcases, cylinder heads

and structure parts made from aluminium are combined under

the KOLBENSCHMIDT brand. Other castings, engine bearings

and continuous cast products also come under this section.

Under the PIERBURG brand name, the Mechatronics division

of KSPG specialises in modules and systems for emission

control, solenoid valves, actuators and valve train systems,

as well as oil, water and vacuum pumps for the passenger

car, truck and off-road industry.

The Aftermarket division under the MOTORSERVICE brand is

responsible for the global spare parts industry for the group

brands and other products in more than 130 countries.

And we are growing all the time. By building the Niederrhein

plant, we have gained another high-performance site which

represents one of many investments in the future for KSPG.

MOTORSERVICE

Editorial | 05

Horst Binnig,

CEO of KSPG AG,

in the production centre of the new

Niederrhein plant

MOTORSERVICE Our product brands | 06

“Without our engine components, many vehicles would not run as long.”

Under the premium brand KOLBENSCHMIDT, Motorservice

supplies a comprehensive range of requirement-oriented

products in and on the engine. Engine reconditioners have

engine components for more than 2000 different engines at

their disposal. All products in the blue KOLBENSCHMIDT box

fulfil the high demands on quality, economy and environmental

protection.

Product range: Kit sets

Filters

Engine bearings

Pistons

Piston ring sets

Camshafts

Oil pumps

Water pumps

Shaft protection sleeves

Cylinder heads

Cylinder liners

Tools and test devices

Our product brands | 07

“With our Pierburg products, we are making a significant contribution to emission control and efficient fuel consumption.”

Under the premium brand PIERBURG, Motorservice supplies

genuine brand parts “for all aspects of the engine” for the areas

emission control, air supply, fuel supply and vacuum generation.

Motorservice offers independent repair shops and parts trade

businesses a high level of quality with the Pierburg products.

Independent repair shops also receive support with first-hand

service-orientated know-how.

Product range: Exhaust gas flaps

Electric valves

Fuel supply

Lambda sensors

Air supply

Oil pumps

Emission control

Vacuum pumps

Water pumps

Water circulating pumps

Tools and test devices

MOTORSERVICE Our product brands | 08

“You can rely on our expertise in the field of diesel engines.”

“We are constantly expanding our portfolio. We offer more than 1000 high-tech valves for repair shops and trade.”

BF offers a wide range of spare parts for diesel engines for utility

vehicles, construction machines, agricultural machines and

built-in motors in original equipment quality. Tailored BF

solutions are available for the short block through to the

complete engine. Customer-specific engine components are

delivered from CNC production in low-volume production.

Product range: Crankcase

Crankshafts

Camshafts

Oil coolers

Oil pumps

Connecting rods

Fly wheels

Short blocks

Water pumps

Cylinder heads

TRW Engine Components has been producing valves and valve

train components for car manufacturers around the world for

over 90 years. Motorservice has been selling the aftermarket

valves from the TRW Engine Components Group since 2005.

High product quality, an extensive product range for passenger

cars and utility vehicles and the exemplary Motorservice

services help ensure a successful business with TRW valves for

our customers.

Product range: Valves for passenger car and utility vehicles

Valve guides

Valve seat inserts

Valve cotters

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Our colleagues | 09

Motorservice in figures

At Motorservice, motivated and trained colleagues work to ensure that customers

are completely satisfied. But what is the average Motorservice colleague like?

We have put together some KPIs to show what our colleagues do for Motorservice –

and consequently for our customers.

–1

2–10

11–20

21–30

31–45

–19

20–34

35–44

45–59

60+

AVERAGE AGE IN YEARS TIME AT THE COMPANY IN YEARS

The average colleague has 44 customer contacts per day.

He processes 72 order items per day.

He and his colleagues have contact with customers in 130 countries in 11 languages.

He has 600 colleagues all over the world.

He can offer 18,000 products.

MOTORSERVICE IMA | 10

IMA Industry | Marine | Agriculture

Agricultural machines, construction machines, materials

movement vehicles, industrial plants, block-type thermal power

stations and machinery for mining and raw material extraction

are powered by engines that are mostly exposed to extreme

stress. Due to the exacting requirements regarding minimum

endurance, regular maintenance and the replacement of wear

parts is a must.

Motorservice offers spare parts in OEM quality for many engines

in this sector.

The extensive product range includes engine components for

manufacturers such as Perkins, Kubota, John Deere, MAN,

Mercedes-Benz, Deutz, Cummins, Hatz, Volvo, Iveco.

INDUSTRYExcavators, mobile excavators, crawlers,

bulldozers, dumpers, mobile cranes,

rollers, gas engines, stationary engines,

municipal vehicles, locomotives and

railcars

MARINEShip and boat motors

AGRICULTURETractors, combine harvesters, self-

propelled pickers, shredders, shredding

machines, macerators, telescopic

handlers, garden maintenance, grape

harvesters

Actuating fields and products | 11

SOE/OES KS PERMAGLIDE®

In the Special Original Equipment (SOE) field, we supply high-

quality components in low-volume production to engine

manufacturers, retrofitters, manufacturers of construction

machines or equipment, non-automotive customers from industry,

suppliers for agricultural equipment and suppliers for renewable

energies. For optimal results, we support our customers from the

product selection process through to follow-up support.

Our Original Equipment Service (OES) is the first choice of

automotive OE customers for series and discontinued series

replacement. In addition to supplying spare parts with genuine

components from Pierburg and Kolbenschmidt, the range of

services includes a wealth of services – optimally tailored to

suit the specific customer requirements.

The name KS PERMAGLIDE®, a registered trademark of

KS Gleitlager, embodies the principle of permanently low-wear

gliding. Using a plastic on metal base material creates a

maintenance-free or low-maintenance material combination.

This material combination combines the good sliding properties

of plastic with the load-bearing and thermal conductivity of

metals.

The choice of maintenance-free P1 or low-maintenance P2

materials is based on the relevant requirements and field of

use. It is not always possible to use maintenance-free

KS PERMAGLIDE® bearings; in these cases, low-maintenance

KS PERMAGLIDE® bearings can be used.

MOTORSERVICE Forgery-proof packages | 12

Holger Roden, Senior Manager Product Management, in an interview on the

forgery-proof packages from Motorservice

in the fight against plagiarism.

_ WHY IS IT SO IMPORTANT TO MAKE PACKAGES AS FORGERY-PROOF AS POSSIBLE AS WELL AS PRODUCTS?HR: With technical products, the key char-

acteristics and attributes are not always

clear at first glance. The package acts as

transport protection, but, as a brand

ambassador, is also a guarantee for

quality and authenticity. The visual

appearance also has recognition value

for the customer.

_ SO WHAT ARE THE REASONS AGAINST BUYING AND USING COUNTERFEIT PARTS IN THE AUTOMOTIVE FIELD IN PARTICULAR?HR: Regardless of the legal aspect, coun-

terfeit products have a lower durability

and malfunction in some cases. This can

pose a danger to life and limb. A classic

example from the automotive field are

counterfeit brake discs or brake pads –

it's easy to imagine the consequences of

a malfunction in this example.

_ WHERE DO COUNTERFEIT PARTS MAINLY COME FROM?HR: It's impossible to pinpoint the origin

of the counterfeit parts to a specific

region or country. But just like in other

sectors, we do know of particular strong-

holds for the production of counterfeit

parts. These are regions where copying a

product as accurately as possible is

viewed in a positive light and is not

regarded as a crime.

_ WHAT SECURITY MEASURES DO THE FORGERY-PROOF PACKAGES HAVE?HR: The key characteristics lie mainly in

the security seal and the product label.

The security seal can not be removed

from the package without causing dam-

age and is a visible sign that the package

has been “opened”. If the package is

intact, there is a 2D matrix code on the

label with corresponding true type, the

last four digits of which must match the

four digits of the so-called holospot on

the label.

www.ms-motorservice.com

MS Motorservice International GmbH74196 Neuenstadt, Germanywww.ms-motorservice.com

KOLBEN PISTON

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(01)04052938000016(21)J2VPF2P400 440D

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FAKE

Forgery-proof packages | 13

“Product piracy has a high level

of criminal energy.

And we have the necessary packages

to take the wind out of their sails.”

_ WHAT SHOULD CUSTOMERS LOOK OUT FOR IN PARTICULAR?HR: First of all that the package is intact.

Then a check should be carried out to

ensure that the last four digits of the

matrix code true type match the holospot.

The complete true type of the matrix code

can then be checked for authenticity on

our homepage or via TecCom. The elec-

tronic check on the 2D matrix code, which

can also be scanned, is a particularly

effective means of preventing counter-

feits.

_ DO YOU HAVE ANY OTHER ACTIONS FOR COMBATING PRODUCT PIRACY IN ADDI-TION TO FORGERY-PROOF PACKAGES?HR: Another measure is to constantly

pass on information to our trading part-

ners in internal training sessions on-site.

We also train employees working in

customs and authorities so that we can

rely on government support when coun-

terfeit products are imported. Subse-

quent raids and the destruction of coun-

terfeit products are another deterrent. So

it's safe to say we don't sit idly back and

watch, but play an active part in the fight

against counterfeit products in a variety

of different ways.

MOTORSERVICE Motorservice E-Business | 14

Online purchase orders have a high level of acceptance among Motorservice customers:around 50 % of the turnover is achieved electronically via the

Motorservice OnlineShop and TecCom. The benefits are clear:

• There are no mistakes when entering data.

• Customers can import the desired articles from their own ERP

system directly into the shop as a list.

• Customers receive an order confirmation right away.

• The “My account” function shows whether the goods have been

shipped and which products from which purchase orders will

arrive with which delivery, list of back orders.

• Complete information available for customers at any time.

The OnlineShop is always open, all over

the world, 24 hours a day, 7 days a week.

Purchase orders in the Motorservice

OnlineShop can only be placed by

Motorservice customers by logging in

with their customer number. For repair

shops, the shop is a “Catalogue with cart

function”: the repair shop finds the

required article, places it in the cart and

can then send it to the responsible/

chosen Motorservice distributor in the

region.

All incoming purchase orders are checked

and confirmed via e-mail. The

commissioning is also initiated here in

agreement with the customer.

Motorservice uses state-of-the-art

logistics to ensure that the process is as

quick as possible. All ordered articles are

commissioned using electronic readers,

ABC classification, conveyor technology

etc. Over 3,000 pick positions are

retrieved from stock every day.

24/7 availability Purchase order Commissioning

Motorservice E-Business | 15

Online to all products:

E-business at Motorservice.

The compiled articles are packaged at

different packing stations according to

the customer specifications. Whether by

road, water or air freight – the delivery

makes its way to the customer by every

conceivable method. The mode of

shipping is usually saved in the customer

data or agreed with the customer

depending on the purchase order.

Customers also have a wide range of

options after the purchase order has

been shipped. They can decide how they

would like to receive the invoice. Under

“My account” in the OnlineShop,

customers can view a wealth of

information and details of the number of

points and sales. The development of

sales over the past two years can be

called up completely online, as well as

credits, charges or due dates of invoices.

A podcast explains the completely

revised Motorservice OnlineShop.

Dispatch Customer service Podcast

MOTORSERVICE

“Notre équipe jeune, dynamique et multiculturelle se tient à l’entière disposition des clients en France et au Maghreb. Nous répondons aux exigences des clients avec rapidité, proximité et une vaste gamme de plus de 20 marques.“

“Our young, dynamic and multicultural team is fully committed to serving customers in France and the Maghreb. We fulfil customer requirements quickly and with proximity to the market with an extensive product range comprising more than 20 brands.“

“Wir legen besonderen Wert auf den persönlichen Kontakt und die regionale Nähe zu unseren Kunden. Aktuelles Fachwissen rund um Produkte und Technik vermitteln wir persönlich in Schulungen, Hausmes-sen und speziell beim Motorservice Kolloquium.“

“We place great importance on personal contact and regional proximity to our customers. We personally pass on up-to-date professional knowledge of products and technology in trainings, in-house trade fairs and specifically in the Motorservice colloquium.”

Homero Arellano,Export Manager

Tobias Hocker,Managing Director

MS Motorservice France

Paris, Frankreich

“Nossa equipe de profissionais presta serviços de excelência e treinamentos técnicos a seus clientes com o objetivo de estabelecer parcerias sólidas e duradouras. A cooperação estreita com o centro de produção local da Kolbenschmidt é uma ajuda fundamental.“

“Our professional team provides customers with outstanding service and technical trainings, combined with the goal of a long-term partnership. This approach is supported by the close cooperation with the Kolbenschmidt production sites on-site.“

Denis Favari,Sales Supervisor

MS Motorservice Brazil

Nova Odessa, Brasilien

“Abadiano es el lugar donde se ubica la exitosa fábrica Pierburg, así como su exitosa empresa Aftermarket. La cercanía a los clientes españoles nos permite reaccionar a sus demandas de forma rápida y flexible.“

“Abadiano is the site of a large Pierburg plant and a successful aftermarket sales company. The proximity to customers in Spain means that we can react quickly and flexibly to their enquiries.“

Naiara Lasuen,Marketing

MS Motorservice Aftermarket Iberica

Abadiano, Spanien

MS Motorservice Deutschland

Asperg, Deutschland

Motorservice worldwide | 16MOTORSERVICE

“Premium Marken, Premium Produktqualität und Premium Service gehören bei Motorservice zusammen. Wir nutzen modernste Instrumente in Auftrags bearbeitung und Logistik, um unsere Kunden schnell und zuverlässig zu bedienen.“

“Premium brands, premium product quality and premium service go hand in hand at Motorservice. We use state-of-the-art tools for order processing and logistics to provide a quick and reliable service for our customers.”Luca Evangelista,

Senior Manager Order Processing

“Türkiye’nin kendine has özelliği olan yedek parça piyasasına, 20 yılı aşkın süredir Motorservice Şirketlerinden biri olarak hizmet sunmaktayız. Yüksek ürün kalitemiz, ülkeye özgü geniş ürün yelpazemiz ve elbette mükemmel müşteri danışmanlığımız ile tanınmaktayız.“

“A Motorservice company has been serving the large spare parts market in Turkey with its many unique features for more than 20 years. We are known for our high product quality, our large country-specific product range and, of course, our excellent customer service.“

“梅施亚太作为汽车服务集团远东地域技术中心，

通过优秀的产品、高水平的技术知识和卓越的服务

保证强大的市场存在感。因此，我们为我们的客

户提供专业、有效和高效的服务。“

“As a centre of excellence for the Far East region within the Motorservice group, MS Motorservice Asia Pacific guarantees a strong market presence with excellent products, a high level of technical know-how and outstanding service. This enables us to offer customers a professional, effective and efficient service.“

Olcay Oldaç,Product Manager

Dennis BaumannPresidentMS Motorservice

IstanbulIstanbul, Türkei

MS Motorservice Asia Pacific

Shanghai, China

MS Motorservice International

Neuenstadt, Deutschland

Guaranteed global presence

Proximity to the market.

1000 customers in 130 countries and

7 Motorservice sites guarantee a reliable goods

supply.

Motorservice worldwide | 17

MOTORSERVICE Customer statements| 18

Automechanika, the largest spare parts trade fair in the world, is the meeting place for the sector.

At the large Motorservice stand, customers meet to talk with Motorservice and for the traditional

caipirinha after 5 pm.

“All customers expect us to provide reliability, a wide range of products and, of course, quality. Motorservice stands for all these things.”

“We have an extremely customer-orientated

approach to work and offer a wide range of

services. We therefore need a partner who works

well with us. With a large number of sites

throughout the country, it is also a real logistical

challenge to cover the demand for parts.”

“The logistic aspect is a major challenge for us. In order to manage the ever larger volume of orders, we need a partner like Motorservice, who supplies us reliably with engine components.”

“We specialize in trucks and off-highway vehicles and quality plays a big role. It is essential that the vehicles work without problems and are always ready for use.”

“Demand for our electronic spare parts is increasing all the time, as the old cars are gradually disappearing from the roads and a large number of new vehicles are taking their place.”

Customer statements | 19

Motorservice customers chat

at Automechanika.

“The number of modern cars is increasing and our turnover with the Pierburg products is going well.”

“We will work even more closely with Motorservice in the future, specifically in the field of industrial engines. We are very interested in the wide range of IMA parts. One major advantage of Motorservice is the technical information material we can pass on to our customers. That is a factor which should not be underestimated.”

“The quality of the products is an important factor, but it's speed and reliability that are most important for us. We are therefore extremely satisfied with the cooperation with Motorservice.”

“I really like the fact that we will be able to log claims directly in the OnlineShop in the future. This will make the whole claims process much easier and more transparent.”

“We will react to the changing market with an even closer cooperation with Motorservice. Our focus in on further expansion and building on our position as market leader.”

“Price is often the deciding factor. For us, quality comes first. And that is why I rely on the products supplied by Motorservice.”

MOTORSERVICE

KOLBENSCHMIDT Products in Focus

Water pumps with mechanical drive

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The originally installed fuel delivery mod-ule has an additional hose with an external suction jet pump (see fig. 2, left). Due to technical further development this external suction jet pump is no longer needed in the PIERBURG fuel delivery module.

The respective hose junction in the fuel delivery module is supplied with a blind-mate connector (see fig. 1), which can be seen when looking into the fuel delivery module from above.When removing the old fuel delivery mod-ule, the hose with the suction jet pump must also be removed from the fuel tank.

Potential complaints:• Missing connection• The installed fuel delivery module has

three connections, but the spare part only has two.

Vehicles: Product: Fuel delivery module

Volkswagen PIERBURG No. Ref. No.*

Passat 1.9/2.0 TDI 7.02550.32.0 3C0919050B/3C0919050E/3C0919050G

7.02701.02.0 3C0919050/3C0919050AB/3C0919050D/3C0919050F

Fig. 2: left: originally installed fuel delivery module with external suction jet pump right: fuel delivery module 7.02550.32.0

Fig. 1: View into the fuel delivery module (cut-away (view)) with blind-mate connector

The right of changes and deviating pictures is reserved. For assignment and replacement parts, refer to the current catalogues, TecDoc CD or respective systems based on TecDoc.* The reference numbers given are for comparison purposes only and must not be used on invoices to the consumer.

Fuel delivery moduleSuction jet pump no longer needed

For technical personnel only!Page 1/1

Motorservice Group. Quality and service from a single source.The Motorservice Group is the sales organisation for the worldwide aftermarket activities of KSPG (Kolbenschmidt Pierburg). It is one of the leading suppliers of engine components for the independent aftermarket including the premium brands KOLBENSCHMIDT, PIERBURG, BF and TRW Engine Components.

www.ms-motorservice.com

Our heartbeats for

your engine.

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The right of changes and deviating pictures is reserved. For assignment and replacement parts, refer to the current catalogues, TecDoc CD or respective systems based on TecDoc.

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KOLBENSCHMIDT engine bearing shells for MANDesign differences in the locking lugs

For technical personnel only!Page 1/1

Rectangular locking lugs at KOLBENSCHMIDT engine bearing shells

Locking lugs of the OE engine bearing shells. This shape, which is also known as "moon version", is also protected by patent.

SituationMAN uses conrod bearing shells with round locking lugs for newer engines. The locking lugs of the corresponding conrod bearing shells from KOLBENSCHMIDT have a rectangular shape for patent reasons.

Background information Locking lugs make it easier to establish the correct axial positioning of the engine bearing shells during mounting. The function of the locking lugs is no longer required during engine operation.

It is often assumed that the locking lugs should prevent the engine bearing shells from twisting. This assumption is incor-rect. Engine bearing shells have a press fitting in the housing bore in mounted state. The press fit is achieved by making the diameter of the engine bearing shells a few 1/100 mm larger than the housing bore. When the bearing caps are tightened, the engine bearing shells are held securely in the bore via the surface pressure on all sides.

SummaryAlthough the locking lugs of the KOLBENSCHMIDT engine bearing shells look different than the corresponding OE version, the function is the same.

In the event of disruptions in operation, e.g. caused by inadequate lubrication, seizures, overheating or a damaged or excessively large bore, the locking lugs are unable to prevent the engine bearing shells from twisting. In this case, the locking lugs are bent back or shorn off.

The KOLBENSCHMIDT engine bear-ing shells with rectangular locking lugs are made especially for these applications and can be used without restriction.

Engine manufacturer Engines Product

MAN D2066… (various)D2676… (various)D2868… (various)

Engine bearing shells (e.g. conrod bearing shells)

Support for the trade | 20

With our extensive sales promotion measures, we are increasing

the comfort and product benefit for our customers by offering

support in the form of a wide range of brochures, leaflets and

short instructional films known as podcasts. This not only

includes detailed information on technical specifications and the

make-up of the products, but also installation instructions to

make use in practice easier. These documents are available in

over 30 languages.

A wide range of promotional items are available for in-house

trade fairs, shops and businesses.

Essential even in the digital age: print product catalogues.

Motorservice offers 10 different, product-group specific

catalogues for trade and repair shops.

PROMOTIONAL ITEMS

PRODUCT INFORMATION

Promotional items

Product Information (PI) Service Information (SI)

BROCHURES

TRADE FAIR

Technical brochures

Mobile exhibition stand

CATALOGUES

ADVERTISING

Catalogues

Example of an advert

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Test, bore and hone cylinder Honing tools Only for engines with liners

General

Engine trial run After running in

Assembly of piston and conrod Placing the piston into the cylinder bore

Piston ring assembly

Installation of PistonsStep by Step

• Prehoning: grain size 150 (material removal approx. 0.06 mm referred to the diameter)• Finish honing: grain size 280 (material removal 0.02 mm referred to the diameter)• Platform honing: grain size 400–600 (remove profile peaks in a few strokes applying light

contact pressure)• Honing and brushing: use hones of grain size 120, 150, 180 for honing. For block engines

(grey casting) bond 5-7, for liner (centri fugal casting) bond 5 max. Material removal: between 0.03 and 0.05 mm referred to the diameter. Using honing brushes removes peaks that occur on the surface of the cylinder during the final honing operation. This requires at least ten strokes and the use of honing oil. To achieve optimum results, the rotation direction of the honing machine should be reversed after half of the proces-sing time. The honing brushes reduce cylinder diameter by between 0.001 and a maximum of 0.01 mm.

• Check the cylinder diameter at top, centre and bottom as well as in longitudinal and transversal direction (90° off-set).

Fine-bore the cylinder with fitted main bearing caps. Make a honing allo-wance of approx. 0.08 mm (referred to the diameter). Well-honed cylinder bores should have at least 20 % open graphite veins. Only use the honing oil recommended by the honing machine manufacturer. The honing angle should be between 40–80 degrees. Provide for a certain cylinder surface roughness to ensure perfect adherence of the oil film: there are three current measuring methods as outlined in Table.

Wet liner:Clean liner flange seat in crankcase carefully, do not use cutting tools. Flange seat A must be plane parallel and free of dirt. Treat sealing rings carefully with assembly grease (e.g oil). It must be possible to introduce the cylinder liner without great effort; avoid by all means hard impacts or moving of the liner. The liner projecting length B should be as speci-fied by the engine manufacturer (e.g. 0.05 – 0.1 mm).

Dry liner:Apply anti-seize agent to the outside diameter of the cylinder liner. Dry liners have typically an overdimension compared with the cylinder block, having to be pressed in (interference fit). The edge chamfer C in the case should correspond to radius D at the cylinder liner.

Clean cylinder bore and cylinder blocks after honing (e.g. ultrasonic cleaning).

nominal dimension range

cylinder tolerrance to be complied with

Ø 30–50 mm 0.011 mmØ 50–80 mm 0.013 mmØ 80–120 mm 0.015 mmØ 120–180 mm 0.018 mm

standard honing

hone brushing

plateau honing

Attention

surface roughness

cylinder surface before running

Rt (value measured by instrument)

3–6 µm

Ra (value measured by instrument)

0.4–0.8 µm

R3Z (diagram evaluation) 4–7 µm

If shaped pins are specified, please use.

KS pistons are available ready for installation. It is not necessary to assemble the rings which could lead to excessive strain. If you want to install a KS ring set in a used piston, please use a special tool. Be aware that the assembly direction of some ring types is identified with “TOP” (“TOP” should face to the piston crown). Napier rings and oil control rings should be installed such that the oil is scraped down to the bottom skirt end. See to it that the joint ends of the spiral expander in the oil control ring are always located opposite to the ring joint. In the case of tripartite oil rings (expander spring with lateral segments), the segment joints should be off-set by about 120°.

KOLBENSCHMIDT uses preservatives that do not affect the engine oil; it is not neces sary therefore to clean the pistons. Data about piston diameter, assembly clearance and assembly direction (e.g. arrow) are to be found on the piston crown. Be aware that the cylinder dia meter comprises the piston skirt dia meter plus assembly clearance. For pis-tons with a graphite layer, deduct 0.015–0.02 mm layer thickness from the dimension measured to get the stamped-on skirt dimen-sion. In the case of pistons graphitized according to the screen printing process, measure the skirt dia meter only at the speci-fied measuring points – small areas without graphite layer.

Do not start the newly overhauled engine until it is assembled comple-tely with all fittings and filled with oil and cooling water. Ensure that the engine starts at the very first starting attempt since the first fuel revolutions are subject to critical lubricating conditions and decisive for the subsequent operating behaviour of the engine. After warm running of the engine, check it again for leaks, ignition, valve clea-rance, etc. Then start running the engine in on the test bench or in the vehicle. Operate the engine at not more than two-thirds of its nominal speed at moderate load changes; later on, the number of revolutions may be increased gradually.

The quickly flowing hot oil will clean the engine from all foreign matter that may still adhere after the over haul. These particles will collect in the engine oil and oil filter. A distance of 50 km is suf-ficient for most of all dirt particles to accumulate. Do not operate the en gine for more than 500 km with the first oil fill.

Check conrods for deformation and torsion using a suitable testing instrument before installing them. The maximum tolerance must not exceed 0.02 mm per 100 mm. Put the

piston and the conrod in place in accordance with the assembly direction. Next the conrod eye may take up the gudgeon pin. Slide the oiled pin gently into the pin bores of the piston and the eye of the conrod. Avoid any jerky movement.

Floating pins:Fix the pin, use the enclosed retainer rings and avoid excessive compression which might produce permanent deformation. Please use a special tool. Turn the rings slightly to make sure that they have safely engaged in the grooves. Place the joint of the retainer in running direction of the piston.

Assembly of conrod with fixed pin:The conrod eye bore must provide for an overlap with respect to the pin 0.02–0.04 mm. Heat the conrod to 280–320 °C (no bare flame!). After oiling the pin and allowing it to cool, introduce it swiftly into the eye using a device. Then check the correct piston fit using a testing instrument.

Clean the cylinder block carefully after making sure that all sliding surfaces are free from dirt and well oiled. Compress the piston ring using a squeezer in order to allow the piston to slide smoothly into the cylinder bore. Measure the gap dimension in the case of diesel engines and abide by all means by the manufacturer´s instructions.

Anodized pistons:For pistons with anodized piston crown, the crown must not be turned to adjust the gap dimension. These pistons are recognizable by the black colour of the crown surface. Certain piston types with anodized crowns have, besides the standard piston, pistons with reduced compression height for adjustment of the gap. In most cases, the compression piston dimension is staged from 0.2–0.6 mm.

Correct flange seat

Incorrect flange seat

measuring points

Attention

The Motorservice Group is the sales organisation for the worldwide aftermarket activities ofKSPG (Kolbenschmidt Pierburg). Under the premium brands KOLBENSCHMIDT, PIERBURG, BF and TRW Engine Components, we supply a comprehensive and tailored range of productsfor inside and outside the engine.

Information about our product range can be found in our ca-talogue “Pistons and Components”.

Further information can be obtained directly from your local Motorservice partner or at www.ms-motorservice.com

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Fault code Displayed fault code Possible causes

P0170 Fuel mixture, cylinder bank 1 – malfunction

Leakage on intake sideFuel pressureFuel injectorsInjector nozzlesHeated oxygen sensorActivated carbon filter solenoid valveSecondary air injection systemFuel pump

01 0602 0703 09

Fault code Displayed fault code Possible causes

P0410 Secondary air – malfunction

Engine control unitWiring harnessRelays Leaking vacuum linesCondensation/splash waterSecondary air valveSecondary air system solenoid valve

12 14

Fault code Displayed fault code Possible causes

P0400 Exhaust gas recircula-tion (EGR) – flow mal-function

Engine control unitWiring harnessInjection systemSticking or cokingBasic setting not performedHoses leaking or blockedEGR valveEGR control valve

17 18

Details on the subject of OBD and emission control are provided in the brochure “Service Tips & Infos – Emission control and OBD”.

Fault code Displayed fault code Possible causes

P0505 Idle speed control – malfunction

Engine control unitWiring harnessSticking or cokingIdle controllerIdle air control valveThrottle valveThrottle valve positioner

02 0701

A C

DB

061511 13 21 2219 20

OBD – On-Board-Diagnosis and PIERBURG ProductsFault codes – often caused by the system.

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The fault indicator lights up continuously,

– when the ignition is switched on (lamp function check)

– when a fault is detected during the self test of the control unit

– after an emissions-relevant fault, when permissible emission values are exceeded.

The fault indicator flashes

– when faults occur that lead to cylinder shut-off or to damage/failure of the catalytic converter (e. g. misfiring).

The fault indicator is also referred to as the malfunction indicator or MIL (Malfunction Indicator Light).

Fault indicator/Malfunction indicator light „MIL“

The P0-Code

A - Which system set the fault code?P = PowertrainB = BodyC = ChassisU = Network

B - Which fault group is displayed?0 = Manufacturer independent code1 = Manufacturer specific code (not required)

C - Which assembly does the fault refer to?1/2 = Fuel and air delivery3 = Ignition system/misfiring4 = Systems for exhaust gas purification5 = Cruise control and idle speed control6 = Control unit and its output signals7/8 = Transmission

D - Which component is affected by which fault?Refer to table of fault codes! (here: exhaust gas recirculation malfunction)

The nine operating modes of the scan toolMode 1: Read out the diagnostic values (actual values) of the system

Mode 2: Read out the operating conditions when the fault occurred (freeze frame)

Mode 3: Read out the emissions-relevant faults which caused the fault indicator to come on

Mode 4: Delete the emissions-relevant fault codes and reset the freeze framesMode 5: Display the test values and signal curves of the oxygen sensorsMode 6: Display the measured values of intermittently monitored systems

Mode 7: Read out the stored faults which have not yet caused the fault indicator to light up

Mode 8: Status display of OBD test functions (readiness code, component testing)

Mode 9: Display vehicle information data (engine code, vehicle identification number etc.)

Fuel system

Exhaust gas

Pneumatic system

Vacuum system

PIERBURG PRODUCTSFuel supply1 Fuel feed unit2 In-tank pump/pre-delivery pump3 In-line pump4 Fuel filter5 Fuel tank pressure valve6 Active carbon filter valve/purge valve7 Fuel check valve8 Active carbon filter shut-off valve9 Pressure regulator

Secondary air system10 Non-return valve11 Electronic switchover valve12 Combination valve13 Electronic secondary air pump14 Switchable non-return valve

Exhaust gas recirculation15 EGR valve/exhaust gas recirculation valve16 Electro-pneumatic pressure transducer for actuation of EGR valve17 Electronic switchover valve18 Electric pressure transducer

Air supply19 Mass air flow sensor20 Throttle neck (incl. ancilliaries such as the throttle valve switch, idle air control valve, idle air charge controller etc.)21 Suction pipe (incl. ancilliaries such as the electronic drive module EAM-i)22 Electro-pneumatic pressure transducer for actuation of the turbocharger (VTG charger)

Components which are not yet monitored by the OBD23 Vacuum pump24 Exhaust flap

Products of other manufacturers25 Active carbon filter26 Catalytic converter27 Oxygen sensor (before catalytic converter sensor)

Fuel supply Secondary air system Exhaust gas recirculation Air supply

Possible Fault Codes:P0170 – P0179P0190 – P0194P0200 – P0212P0263 – P0296P0301 – P0314P0440 – P0469P0100 – P0114 (indirect)

Possible Fault Codes:P0410 – P0419P0100 – P0114 (indirect)

Possible Fault Codes:P0400 – P0409P0100 – P0114 (indirect)

Possible Fault Codes:P0033 – P0035P0105 – P0109P0120 – P0124P0220 – P0229P0234 – P0235P0243 – P0250P0505 – P0510P0638, P0639P0100 – P0114 (indirect)

Example Example Example Example

PIERBURG Parts

2015

MS Motorservice International GmbH

Wilhelm-Maybach-Str. 14-18 · 74196 Neuenstadt · Tel. +49 7139 9376 -3333 · Fax +49 7139 9376-2864 | Hamburger Str. 15 · 41540 Dormagen · Tel. +49 2133 267-100 · Fax +49 2133 267-111 Sitz der Gesellschaft: Neuenstadt · Registergericht Stuttgart · HRB 105964 · Geschäftsführung: Hansjörg Rölle (Vors.), Stefan Ives · www.ms-motor-service.com

Commerzbank AG Heilbronn (BLZ 620 400 60) Ktn 310 3298 00 · BIC: COBADEFF620 · IBAN: DE23 6204 0060 0310 3298 00 BW Bank Stuttgart (BLZ 600 501 01) Ktn 401 2489 · BIC: SOLADEST · IBAN: DE20 6005 0101 0004 0124 89

03.2014

More technical details: http://onlineshop.ms-motorservice.com

PIERBURG

productnews

News from PIERBURG

NEW PRODUCTS PIERBURG Full details of all new products introduced in the last 2 months are brought to you in the PIERBURG new products 4/2014. It contains the new item numbers with product illus-trations in colour, the OE reference numbers and a vehicle assignment overview.

All this information is also available in a PDF file on our home page: www.ms-motorservice.com/en/pgnews

NEW PODCAST Secondary air system - basic information When a petrol engine is cold-started, large quantities of carbon monoxide and unburned hydrocarbons are generated. The secondary air system is the most trusted method of reducing these pollutants.

NEW CATALOGUES6 new catalogues for automechanika available from stock The new catalogues Filters, Valve Trains, Pistons, Piston Rings, Pierburg Parts and, for the very first time, the Pumps catalogue from Kolbenschmidt/Pierburg, are available from stock for automechanika 2014:

Pistons and Components catalogue | Item no. 50 003 945Piston Ring Sets catalogue | Item no. 50 003 941Valve Train Components and Cylinder Heads catalogue | Item no. 50 003 645Filters catalogue | Item no. 50 003 929Pierburg Parts catalogue | Item no. 50 003 566Pumps catalogue | Item no. 50 003 865

This podcast shows the construction, operating method and components of the secondary air system.

NEWS FOR YOU AUGUST 2014

NEWS FOR YOU AUGUST 2014

1 Tag im Qualitätsmanagement

Juli

2014

06:30 Los geht‘s. In Shanghai ist es bereits Mittag. Telefonkonferenz mit den

Kollegen von der MS Motorservice Asia Pacific:

- Durchsprache von Reklamationen. Klassifikation der Fehler und

Definition von Abstellmaßnahmen.

- Diskussion von Auditreports und Massnahmenpläne neuer

Lieferanten. Abstimmung der weiteren Vorgehensweise.

07:00 Anruf vom Produktmanagement. Ein Kollege benötigt Unterstützung

im Dokumentenverwaltungssystem (Xeri). Es wird eine neue

Dokumentenversion benötigt. Gemeinsam richten wir diese ein.

08:00 Qualitätsprüfung. Eine Sendung Zylinderlaufbuchsen wird im Waren-

eingang angeliefert. Zur Absicherung der Qualität wird nach Prüfplan

eine Stichprobe auf der 3D- Koordinatenmessmaschine vermessen. Die

Ergebnisse werden mit Prüfentscheid dokumentiert. Die Teile waren

innerhalb der Zeichnungsspezifikation und können somit weiter verwendet

werden.

09:00 OES-Telefonkonferenz mit BMW. Besprechung der Bemusterungsanfor-

derungen für die nach PPT (Pierburg Pump Technology) Lanciano verlagerten

Ölpumpen. BMW verlangt Messbericht und Werkstoffdaten für die erste

Lieferung.

10:00 Projektbesprechung. Absprache mit dem externen Dienstleister

hinsichtlich automatisierter Lieferantenbewertung und Ermittlung der

Qualitätskennzahlen im Delta Master. Programmierte Berechnungen werden

verifiziert und die nächsten Schritte definiert.

11:00 Wareneingang. Bei der Wareneingangsprüfung wurde eine Wasserpumpe

entdeckt, die nicht der Spezifikation entspricht. Eine Sicherungsschraube

fehlte. Eine SAP-Qualitätsmanagement-Meldung inklusive Foto-Dokumenta-

tion wird erstellt. Das Anlieferlos wird gesperrt und der Lieferant informiert.

Weitere Maßnahmen werden zusammen mit dem Lieferanten festgelegt.

12:00 So, und nun gibt es die verdiente Mittagspause.

8:00

1 day in ...Today in our "1 day in..." series, we will take a look at Quality Management. Get an insight into the topics dealt with by the colleagues in Quality Management.

News from MOTORSERVICE

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INFO 08.2014Nur für Motorservice Kunden

Seite 1/2

BMW i3KSPG Lieferanteil• Sekündärluftventil

Mercedes GLAKSPG Lieferanteil• Elektrisches Schubumluftventil• Zylinderkurbelgehäuse• Kolben

Skoda OctaviaKSPG Lieferanteil• Gleitlager• Elektrische Abgasklappe

Porsche Panamera S E-HybridKSPG Lieferanteil• Magnetventile• Zylinderkurbelgehäuse

KSPG (Kolbenschmidt Pierburg). Renommierter Zulieferer der inter-nationalen Automobilindustrie.Als langjährige Partner der Automobil-hersteller entwickeln die Unternehmen der KSPG AG innovative Komponenten und Systemlösungen mit anerkann-ter Kompetenz in Luftversorgung und Schadstoffreduzierung, bei Öl-, Wasser- und Vakuumpumpen, bei Kolben, Motor-blöcken und Gleitlagern. Die Produkte erfüllen die hohen Anforderungen und Qualitätsstandards der Automobilin-dustrie. Niedrige Schadstoffemission, günstiger Kraftstoffverbrauch, Zuverläs-sigkeit, Qualität und Sicherheit sind die maßgeblichen Antriebsfaktoren für die Innovationen von KSPG.

Motorservice Gruppe. Qualität und Service aus einer Hand.Die Motorservice Gruppe ist die Ver-triebsorganisation für die weltweiten Aftermarket-Aktivitäten von KSPG (Kolbenschmidt Pierburg). Sie ist ein führender Anbieter von Motorkomponen-ten für den freien Ersatzteilmarkt mit den Premium-Marken KOLBENSCHMIDT, PIERBURG, BF und TRW Engine Compon-ents. Ein breites und tiefes Sortiment ermöglicht den Kunden, Motorenteile aus einer Hand zu beziehen. Als Pro-blemlöser für Handel und Werkstatt bietet sie darüber hinaus ein umfang-reiches Leistungspaket und die techni-sche Kompetenz als Tochtergesell-schaft eines großen Automobilzuliefe-rers.

Neu im KSPG Produktionsprogramm

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Information from the OE divisions of the KSPG Group:

What products does Kolbenschmidt Pierburg supply and for which vehicles?Today in "OE Info 08.2014": what KSPG supplies for 4 different vehicles. Including the information "Umbrella and brands focused on a single message" explaining the new brand organization at KSPG with its contemporary image.

News from KSPG

AUTOMECHANIKA IN FRANKFURT FROM 16-20.09.2014

Visit us at our exhibition stand in Hall 5.1 – Stand A 42.

A wide variety of innovations await you over an area of 500 m², which we would be delighted to show you in person. We look forward to your visit!

To make sure that our newsletters reach the right person in your company, please update the enclosed form and return it to us. Fax no.: +49 7139 9376-3039. Thank you.

Yours sincerely,MS Motorservice International GmbH

Markus Breuer Senior Manager Marketing

Tel.: +49 7139 9376-2620 · Fax: +49 7139 9376-12620 · markus.breuer@de.kspg.com

Support for the trade | 21

Our sales

promotion measures give you

useful tools at your disposal.

HOMEPAGE

SOCIAL MEDIA

Homepage with customer portal

myMotorservice

NEWSLETTER

Newsletter by e-mail

OBD poster: Finding and remedying faults

MAILING

TECHNICAL POSTERS

Mailing by post

Installation and service poster

MOTORSERVICE Technical trainings and seminars | 22

The number of newly developed components and modules for engines is increasing constantly. The design and function of

systems are increasingly complex and often electronically

controlled, networked and monitored. These days, without

access to the latest information, targeted work on modern

engines is virtually impossible. Our training programme teaches

the expertise of an OE manufacturer directly to employees at

repair shops and trade in an interesting and appealing way.

“Live trainings are the most efficient trainings”: Each year,

around 4,500 mechanics and engineers benefit from our training

and seminars, which we run on-site around the world, and also

in our training centres in Neuenstadt and Dormagen (Germany).

Technical trainings and seminars | 23

Professional knowledge for the workshop,

directly from Motorservice.

Service hotlineOur service engineers provide quick and

competent help.

Products in focus – onlineDiscover interesting facts about products

and applications with interactive

elements, animations and video clips.

Technical podcasts Sharing knowledge by video in an illustra-

tive way: The technical podcasts offer

repair shops practice-orientated fitting

instructions and system explanations.

Headquarters:

MS Motorservice International GmbH Wilhelm-Maybach-Straße 14–18

74196 Neuenstadt, Germany

www.ms-motorservice.com© MS Motorservice International GmbH – 50 003 952-02 – 09/14 EN