WARNING: The most critical points in «life» The newly overhauled engine are the first few seconds of operation. Preparation makes the difference between a smooth step to the next «life» and more abrupt transition. The prerequisites for starting the engine are as follows: the engine must be filled with engine oil and coolant (coolant) and the valve timing must be set.
Preparation
After installing the engine, add engine oil to the correct level. If you installed a new or different oil sump, follow the instructions for filling that sump.
If the camshaft has been replaced, it is recommended that the engine be run at high idle for a few minutes. Accumulator battery (AB) should be fully charged, and the ignition timing of the injection should be tried to be set more precisely.
When the engine is started and running for the first 20 minutes «running-in», then about 500 liters of deadly carbon monoxide will come out of it. Therefore, it is necessary to ensure good ventilation of the room where the car is located, i.e. open all windows and doors. Carbon monoxide is heavier than air and can accumulate in an enclosed space for hours. The first minutes of engine operation are especially dangerous if you work in a closed garage.
Launch
At the moment, the repaired engine is ready to start. Connect a stroboscope tachometer and an oil pressure gauge to the engine. If the engine has hydraulic valve lifters, remove the valve covers before starting. Many reputable auto parts stores have spring clips that fit onto the rocker arms to deflect oil when the engine is running and the valves are being adjusted. If these clamps are not used, the oil will splatter in all directions.
It is tempting to use special starting fluid when starting the engine, but if you use a large amount of it, the engine can be damaged. It is even more potentially dangerous when the engine has just been repaired.
Bleed the fuel system. To do this, on engines with electronic fuel injection, turn the ignition on and off several times.
WARNING: Pouring fuel into the intake manifold to start the engine is very dangerous.
Engage the starter and listen for engine signs of life.
If the engine pops or backfires in the intake or exhaust manifolds, then the ignition is not properly adjusted. However, a few faint pops in the intake tract may simply indicate that a few drops of oil have entered the cylinders. Ask your assistant to move the distributor back and forth while the engine is cranking with the starter. Engine should start If the engine does not start or runs very poorly after starting, refer to the appropriate chapter.
It can be confusing for both the amateur and the professional to connect all the pipes, wires and hoses disconnected when the engine was removed.
Numbering markings and even photographing the engine compartment before removing the engine will then help you navigate this mess more easily.
Running in
When the engine starts, increase its speed immediately to 1500-2000 rpm. Stabilize engine speed. The camshaft and valve lifters run in better to each other if the engine is not allowed to idle for the first 20 minutes «new life». In an engine, the camshaft receives much less oil at idle, the rpm must be slightly higher so that the camshaft and tappets are well lubricated. Also, do not change the engine speed abruptly during the first 20 minutes of its operation. If the engine speed is not kept more or less constant, there will be unwanted stresses on new parts, on tighter tolerances, and on parts that have not yet been run. During a period of 20 minutes «break-in, it is necessary to constantly monitor the oil pressure and engine temperature. If there are any abnormal values, then smoothly transfer the engine to idle, stop the engine and eliminate the cause of this phenomenon.
During the initial break-in period, adjust the ignition timing. Although it will be necessary to re-adjust the ignition at the desired engine speed after the engine is idling, still set the approximate value of the ignition timing now to reduce the possibility of engine overheating. Carefully check for leaks of coolant oil, power steering fluid and (oils) for the checkpoint.
After 20 minutes «running-in» slowly return the engine to idle and let it idle long enough to check the ignition timing and set the idle speed. If the engine is not equipped with hydraulic tappets, now adjust the valve clearances.
Control trip
Everything is now ready for the inspection drive Start with a short drive near the repair site. Since the car has not been driven for a long time, listen carefully for unusual noises and constantly monitor the coolant temperature and oil pressure. For safety reasons, take a companion with you. If the values on the pointers are out of range, immediately turn off the engine and determine the source of the problem.
WARNING: Do not test drive until all removed parts have been installed and all systems are operating properly.
After the test drive, the vital parameters of the engine must be assessed.
Disconnect the stroboscope and tachometer. If possible, position the oil gauge so that it is visible when driving. If the gauge hose is too short, then remove the gauge, check that the oil pressure warning light works, and keep an eye on it during the trip.
Now you can make a control trip of a longer duration. During this trip, the likelihood of a malfunction in the ignition circuit is directly proportional to the distance from your garage. Keep this in mind.
After returning to the garage, check the wiring harnesses, including the high voltage wires. Check the oil level, check for oil leaks and repair if necessary. The same applies to the cooling system. If mechanical pushers are installed on the engine, then you need to adjust the valve clearances again.
When the test drive is over and the hose clamps, drain plugs and oil sump bolts are tightened, the car can be driven for several days (or weeks) until the next maintenance. The driver should be mindful of recent repairs and while driving, carefully monitor instruments and warning lights, and listen for unusual sounds.
Service in the range from 1000 to 1500 km of run
Between 1000 and 1500 km, the vehicle must be serviced. Let the engine cool down completely, preferably overnight. Loosen and retighten cylinder head bolts, adjust valve clearances using appropriate procedures. Change engine oil and oil filter. Check the tension of all belts and tight fit of the hoses. Check the oil level in the gearbox.
If all operations are carried out, and there are no traces of engine oil and coolant leakage under the car, then the engine repair can be considered successfully completed.