Do you know what are the most important ways to properly install and ensure the long life of your new short engine block? We have a great guide for you that will perfectly outline what you should pay attention to.
- Please note that any cylinder heads supplied with the blocks may not be fully assembled. First align them with the exhaust manifold or intake manifold and then tighten the cylinder head bolts to the torques specified by the manufacturer. • All assembled parts must be thoroughly cleaned and checked for damage before assembly.
- Thoroughly clean the oil cooler, and if the engine was damaged, be sure to replace it.
- Replace the air filter element with a new one, thoroughly clean the oil air filter.
- Check the tightness of the stub pipes and suction pipes of the engine.
- Check the injection system, set the start of pressing in accordance with the parameters provided by the manufacturer.
- Check visco fan operation.
- Clean the coolant radiator, check its obstruction. Bleed the filled cooling system in accordance with the manufacturer's instructions. Thoroughly clean the charge air cooler, and if the turbocharger was damaged, be sure to replace it with a new one.
- Check engine monitoring instruments for proper operation, replace if malfunctioning.
- Never run the engine without oil and coolant.
- Pressurize the engine oil circuit manually, or fill the engine with oil and crank it without injectors (each time max. 10 - 15 seconds to rule out damage to the starter motor) until oil pressure builds up to ensure oil is supplied to all bearing points before starting the engine.
- Check the operation of the oil pump, oil pressure regulating valve, water pump and vibration damper.
- Observe the installation regulations and requirements of the engine manufacturer or vehicle manufacturer.
Things to do before starting the engine for the first time
All work on the engine must be carried out by qualified personnel. The engine oil circuit must be filled and/or pressurized with special pumps. A manufacturer-approved engine oil (not HD oil) must be used for this purpose. It is essential to adhere to the oil specifications provided by the manufacturer. Filling the engine oil circuit by cranking the engine is only permitted if a special pump is not available.
- Fill the engine with engine oil approved by the manufacturer (not HD oil) and coolant in accordance with the technical regulations.
- Crank the engine without injectors and injection pump at the "0" discharge point until the oil pressure gauge shows the correct oil pressure.
- Attention! Crank the engine for a maximum of 10 - 15 seconds each time to rule out damage to the starter motor.
- Check the engine oil level again.
Completely assemble and start the engine. After approx. 10 seconds, the oil pressure gauge must show the oil pressure. Attention! Do not rev the engine until oil pressure is indicated.
How to bring a new short engine block to optimum engine break-in condition.
Every rebuilt or new engine must go through a break-in phase. Only after that, new parts, especially guide bushings, pistons, piston rings and bearings, get the necessary smoothness of operation. The engine should be run in as part of controlled work on the engine test bench. Only if such a stand is unavailable, the engine can be run in after being fitted to the vehicle. When running in, the engine should be equipped with a thermostat and a V-belt for the water pump. For break-in, use either special engine break-in oil (first run) or normal engine oil (not HD oil). During the break-in phase, the coolant should be kept at the most favorable temperature, i.e. between 80 °C and 85 °C.
The following work and checks must be performed before running in:
- Check the oil level in the engine, injection pump and regulator.
- Check the fluid level in the coolant and fuel circuit of the fuel tank.
- Clean the fuel and oil filters, replace the cartridges.
- Clean the oil air filter and fill it with engine oil, replace the dry filter cartridges.
- Set the injection pump, regulator, injectors and start of delivery according to the parameters provided by the manufacturer.
- Clean the feed pump pre-cleaner.
- Bleed the fuel system.
Upon arrival:
- Drain the break-in oil (also from the oil filter) and add HD oil.
- Replace the paper oil filter element.
- Carry out initial maintenance according to BF regulations (see short block passport). After the engine has been run in, an oil consumption of approx. 0.5% of the fuel consumption should be considered normal.
In-vehicle engine/stationary operation (only if no engine test stand is available)
- Let the engine run for 21 hours at n=1200 to 1600 rpm and then for another 2 hours at n=1500 to 2100 rpm.
- Stop the engine, tighten the cylinder head bolts to the values specified by the manufacturer, adjust the valve clearance, check and top up the oil and coolant levels if necessary.
