Engine break-in is performed in cases where the engine has just been released by the manufacturer or after it. overhaul. Engine break-in, as a rule, lasts 2-3 thousand kilometers.

Compliance with the engine break-in mode is necessary due to the fact that new parts need to be “lapped in”. New engine parts are made using a cutting tool, and even with 100% compliance with their manufacturing technology, it is not possible to obtain absolutely smooth surfaces. Anyway, after processing, when viewed under a microscope, you will see not a smooth surface, but a surface similar to a mountain landscape.

During the "lapping" of parts, microroughness collide with each other and smooth out. This process is accompanied by increased friction, temperature, which is why it is necessary to observe the engine break-in regime and the use of special anti-seize drugs. It is known that the resource of an incorrectly run-in engine is no more than 30% of a normally run-in one, and a well-run engine will serve you for several hundred thousand kilometers.

The main purpose of running-in is to smooth out micro-roughnesses with minimal engine loads.

First engine start after overhaul

1. Please note that the car battery must be 100% charged, otherwise it will not be able to master the first start. crankshaft.
2. Use good quality engine oil, filling it up to the top of the dipstick. After pouring, wait at least 5-10 minutes for the oil to glass into the pan. Do not fill the oil filter with oil to avoid air lock.
3. If the engine is carbureted or diesel, where there is no fuel pump, pump fuel manually.
4 . Start the engine with a starter, controlling the oil pressure (according to dashboard). If after 3-4 seconds the low oil pressure lamp does not go out - urgently turn off the car and eliminate the cause low pressure oils.
Do not press on the accelerator pedal, this is harmful - the load and lack of oil will quickly and irrevocably damage the surfaces of the parts.
5. If the oil pressure is in order, warm up the engine to 85-93 C. Constantly check for possible leaks of technical fluids. You should not worry if there is a smell of burning or a slight smoke, the cause of their occurrence is the process of burnout of assembly lubricants. As the coolant temperature rises, the oil pressure should drop as the oil becomes thinner. Permissible value of oil pressure is within 0.4-0.8 kg/cm2. If this is not the case, then assembly errors were made (the gaps are not correct, oil pump not correct or low quality oils).
6. Stop the engine, wait until the engine temperature is 30-40 degrees, then start the engine again and let it warm up at idle. Such cycles should be carried out 15-20 , then proceed to running in for more high revs.
7. High rpm break-in - hold 1000 rpm for 3 minutes, 1500 rpm for 4 minutes, 2000 rpm for 5 minutes.

Run-in mode after overhaul

8. After that, you can go to the road. At the same time, do not exceed the speed 60-70 km per hour. It is better not to include fifth gear during this period. First 300-500 km most responsible, do not overload the engine. It is normal for blue smoke to come out of the muffler, especially if installed. new kit piston rings. There may also be some volatility. idle move, fine adjustment of which should be done after 500-1000 km run.
9. After 2500-3000 km mileage top speed can be increased to 80-90 km / h.

Preferably after the run 2500 km change oil and filter, because during this period, a lot of wear products appear in the oil.

After changing the oil, do not forget to stretch the available threaded connections(block heads, oil pan, front cover, starter, alternator, etc.), adjust valve clearances, idle speed, timing belt (chain) tension. When extraneous noises and knocks appear, it is imperative to find their source.

These simple operations will allow you to properly break in the engine of your car. The most common break-in mistake is running in high gears and, accordingly, low revs engine - this cannot be done, because the motor is overloaded during this time. insufficient pressure oils.

Signs of improper break-in: oil in the air cleaner, high flow fuel, low power, oil consumption, problems with starting the engine.

As you can see, the running-in process requires precise implementation of the technology. To avoid possible problems With engine break-in, manufacturers use special break-in additives such as WINDIGO ECO-Universal Oil Package. The additive will provide a perfect "grinding in" of surfaces, protect new parts from scuffing, and your investment in overhaul will provide long term overhauled engine service. The use of WINDIGO additives during break-in allows to reduce the break-in time by 2 times, as well as to avoid possible problems with "grinding" and jamming of engine parts. Also, additives eliminate the scratches that have arisen on the surface of parts if the engine was not run in correctly.

To restore the former performance characteristics the engine may require a major overhaul, involving the replacement individual parts or whole nodes. After a thorough intervention, it is not recommended to use the vehicle in the usual mode until the car has undergone a phased run-in in compliance with all the rules and recommendations.

Running in the engine after overhaul is extremely necessary measure to extend the working life of the engine and reach the level of indicators embedded in it. Neglecting the rules and recommendations for running in will lead to a decrease in the working potential of a repaired car by at least 25%, and sometimes by 60-70%, while the right approach will create a long-term margin of safety.

Engine break-in is a gentle operation of a new or overhauled engine. Running-in is necessary since new parts require mutual running-in of rubbing surfaces, on which microroughnesses and minimal disproportions are possible.

The usual duration of the first stage of the break-in run is about 3 thousand km, and only after that is a gradual increase in loads allowed. Full lapping of parts is completed no earlier than 10-15 thousand kilometers. During this time, when using the recommended oils and controlling the loads, the likelihood of significant scuffing and melting in the places of microroughnesses on the replaced parts is completely leveled. During the break-in period, the engine load and crankshaft speed should be reduced to 60% of the nominal values.

Even the availability of high-quality components does not allow you to do without running. There are several main reasons for this:

• it is impossible to provide factory conditions at the service station, as a result of which the build quality will suffer to some extent;
• due to the service life, the condition of the elements that do not need to be replaced differs from the original;
• new parts are made with a cutting tool and even after fine processing, they often do not fully meet the required parameters.

First engine start after overhaul

Before running in, the engine must be started correctly for the first time. This moment is extremely important, so everything must be done so that the modules, environments and systems provide maximum support for the reanimated engine at the initial stage after the overhaul.

• The battery is fully charged, otherwise its resource for a heavy crankshaft stroke may not be enough.
• The starter is checked for proper operation.
• Fill with oil up to the top level. To simplify, it is better to immediately measure the desired volume and add as it gradually fills. To avoid airlock, the oil filter must not be filled prior to installation.
• Fuel is supplied manually or by a pump until the float chamber is filled.
• If there is no automatic drive, the air damper is closed in accordance with the outside temperature. In cold weather, the oil can be heated and the engine block brought to a positive temperature.
• The starter starts the engine and the pressure gauge should almost immediately reflect the oil pressure in the range of 3.5 - 4 kg / cm 2. If this does not happen after 3-4 seconds of idle operation, the engine is urgently turned off to eliminate the causes. The appearance of smoke from under the hood when the engine is warming up indicates the combustion of oil that got inside during assembly or installation. This should not cause concern, since the smoke soon passes and does not recur.
• Under normal oil pressure, idle warm-up engine to the recommended temperature, typically 85-93℃ at 750-800rpm, and check for any leaks.
• Next, the radiator fan starts, and after its operation, the engine should be turned off. After waiting until the engine cools down to a warm state (30-40 ℃), the warm-up cycle is repeated and so on up to 15-20 times, after which the actual running-in begins.

It is advisable to first familiarize yourself with the recommendations for observing the speed limit during the break-in period, contained in the instructions for the car. Break-in on the move is preceded by a break-in at medium speed with the control of any sounds that are unacceptable:

• 1000 rpm - 3-4 min;
• 1500 rpm - 3-4 min;
• 2000 rpm - 5 min.

The speed during the break-in period with a light load should not exceed 60-70 km / h, excluding the use of overdrive. During the first 500 km, the appearance of blue exhaust and the manifestation of some instability of revolutions in idle mode, which requires additional debugging. You can fine-tune the speed after 1000 km of run.

As the mileage approaches the mark of 3000 km, it is allowed to raise the speed to 90 km / h. A further increase in speed requires caution and reaches a maximum not earlier than reaching the mileage threshold of 10-15 thousand km.

Running after a major overhaul affects the seals, leads to a slight subsidence of the gaskets, due to which the threaded connections are somewhat loosened. That is why it is necessary to monitor the degree of heating of the engine and periodically tighten the fasteners.

Change of oil

At the initial stage of break-in (about 3000 km), it is recommended to change the oil filter and oil up to three times. The lapping of parts during this period is especially hard, which causes the appearance of numerous superfine chip particles.

Ideally, you should change the oil after 500, 1000 and 2000 km of run, using only a high quality product recommended by the manufacturer. At the end of the break-in, another oil change is made and the engine is flushed. Now nothing prevents the use of synthetic oils.

Important Warnings

There are a number of undesirable conditions that can create new difficulties for the car owner, which is why it is not recommended to allow the following:

• use the car without preheat on idling;
• increase speed to 2000 rpm;
• load cars to capacity with passengers and use a trailer;
• change drastically speed mode;
• use one operating mode of the engine for a long time, without alternating driving in upshifts and downshifts within reasonable limits.

It is important to remember that a car overhaul will only benefit if proper break-in and timely service.

Every car owner of a used car at least once in his life faced with the procedure for overhauling the engine. After update power unit replacement required engine oil. Overhaul implies the presence in the engine of new parts, instead of worn ones. Factory "pieces of iron" have their own microscopic roughness, which must be rubbed in during the operation of the unit. To do this, the machine undergoes a run-in, during which the updated equipment begins to function in a balanced way. You will have to run the car in a gentle mode, this means reducing the speed limit to 60 km per hour, smooth movement when starting off, fuel quality control and engine oil change. The run-in lasts from 500 km to 4000 km, depending on the complexity of the repair.

The oil is changed after the overhaul of the engine from one to four times. Quantity is directly related to the work performed. The first time the oil is changed after the car will pass the first 500 km, the second change will be required after 1000 km of run, and so every 500 km, an engine oil change follows. The longer the break-in is needed, the more new engine oil will have to be used up. The oil must be High Quality and match technical specifications this car. Type motor lubricant must be specified in the instruction manual. vehicle, in the same place where you can read about the brand of recommended gasoline and its probable consumption. Do not experiment with types of oil not provided by the manufacturer.

In order to independently replace the engine oil in a car whose engine has been overhauled, it must be driven onto a flyover. Everything will be more convenient there. necessary work. The car is placed on hand brake or in parking mode for automatic box gear so it doesn't roll. After the engine has cooled down, you need to open the filler cap to fill the oil. Then go down under the car and unscrew the lid of the pan, after substituting a container for the spent mixture under it, which should all flow out. When the tray is empty, screw the lid back on. Now the system needs to be filled flushing oil. In order not to overfill it, you need to control the level with a dipstick.

Container filled with flushing oil filler neck plug it in and start the car. The engine should run for as long as indicated on the instructions that came with the engine oil. Then the washing mixture is drained in the same way as the previous one. The pallet is closed with a new stopper. If the time has come to change the oil filter, then it must be removed at this stage. With help special fixture the filter must be replaced with a new one. Don't forget to treat the rubber seal ring with used oil. The engine is ready to accept new engine oil. When the oil level reaches the required proportion, the filler cap is closed. The car is ready for further operation.

When the first oil change after the overhaul has already been done, you will need to change the oil filter. During engine break-in, the filter may become clogged with metal chips generated by the friction of new parts. In addition to replacing the filter, you will need to adjust the valve clearances, belt or chain tension, and adjust the timing drive. If the engine does not start, the cause may be incomplete injection of engine oil into lubrication system, which prevents the hydraulic compensator from working. Then you need to manually add oil to the oil pump and pump up fuel. Consumption oil lubrication in the engine must be constantly monitored. During break-in, oil is consumed more intensively - an average of 300 g per 1000 km of run.

Overhaul of the engine violates the established unity of the "weary" elements. Boring of the cylinder block and installation of new elements piston group change the performance of the vehicle. Often, the power is reduced by almost half of that specified by the designers.

In order to restore the original characteristics, it is necessary for the power plant to go through a break-in mode. Such an engine break-in after overhaul is usually performed for a set operating time or mileage.

On average, engine break-in modern cars ranges from 2 to 3 thousand kilometers. Full grinding does not occur during such a period, but it becomes possible to operate the machine in more aggressive modes, with increased load.

The car reaches its operating parameters by 10-15 thousand kilometers.

When the engine is run-in after a major overhaul, the heating of the rubbing elements increases during grinding. In this regard, power loads on the motor are undesirable, and it is recommended not to raise the speed above 60% of their maximum level during standard operation.

The power plant, after an incorrect break-in, can lose up to 70% of the calculated parameter in power.

At correct operation auto all settings quickly return to scheduled.

Purpose of car break-in

The machined surface of the engine cylinders and newly installed repair units has protrusions and depressions, sometimes pointed traces from the work of the cutter, which were not removed by honing. The task of running-in is to smooth out such defects. Due to this, friction is reduced and the load on all operating units is reduced.

Engine assembly for break-in

The opinion that running in a new engine due to the installation of new components in the motor does not make sense is erroneous.

Each new part has residual microroughnesses, which will be removed during the lapping process. The time required for the entire process depends on the size of such irregularities. After complete grinding, all elements: cylinders, piston rings, the pistons receive a new surface finish on the contacting planes.

There are rules under which the process will lead to the desired results:

1. The oil used during break-in must be on the list recommended by the manufacturer.
2. The oil supply must be carried out no later than 5 seconds after the engine is started in all the necessary components in order to avoid dry friction.
3. When the engine is idling, the oil pressure in the system should be in the range from 0.5 to 1 atmosphere.
4. It is necessary to check the sensors of the measuring equipment for operability.

Before the break-in process, a little preliminary work is also required:

1. The intercooler is flushed and purged, if necessary.
2. changing air filter or oil in an oil bath.
3. Oil change and new oil filters installed.
4. Fuel filters are changed.
5. The coolant level and the presence of fuel in the tank are checked.
6. The fuel pump and injector operation are adjusted according to the manufacturer's recommendation.
7. Air is removed from the fuel system.

Preparation for the first start after repair

The crucial moment after assembling the repaired motor is its first start. If this is done ineptly, then sometimes piston rings can even break. The battery must be fully charged for the first start. The starter must be in good working order.

Wrong car break-in

Unfinished parts will take a lot of power due to the increase in frictional forces between unprocessed nodes.

We fill in a proven company. Oil consumption during engine break-in can be approximately 1 liter for the first 2-3 thousand runs. This option is allowed by experts.

When pouring oil, you need to know that it is not immediately distributed to all nodes. Therefore, you can measure the required volume, so as not to be mistaken, and pour everything into the engine. Oil filter it is not recommended to wet in advance, since such a process does not contribute to the rapid distribution of liquid throughout the system. Rather, on the contrary, it forms airlock degrading the performance of the motor.

It would be preferable to have a forced oil supply through the hole in which the pressure sensor is mounted. At home, for this operation, you can use a tire pump, removing from it check valve and mounting a threaded adapter on the end of the hoses.

Adding oil during break-in

When there is no manual pumping of fuel on the pump, we perform the established sequence of actions: we tightly close the neck fuel tank, remove the inlet hose from the pump, inflate with air a little pressure into fuel system. After that, quickly return the hose to the pump fitting and connect them.

You need to know that excessive pressure in the fuel system can permanently inflate the car's tank.

Due to pressure equalization, some fuel will be poured into the pump. Install air damper to the right position. And getting ready to start the engine.

The first start of the engine for running in

Starting the rotation of the starter, you need to make sure that there is oil pressure in the line. To do this, you need to connect a pressure gauge or use the indicator tips on the panel.

First launch after overhaul

It is urgent to turn off the engine if there is no pressure in the first three or four seconds.

You will need to add oil again to the required level.

When the oil pressure is established at operating parameters of the order of 3-4 kg / cm 2, it is necessary to warm up the engine at idle (700-800 rpm). The temperature should be set at 83-93 degrees. At this time of running-in, you need to carefully consider the appearance of various incomprehensible noises, visible leaks that may appear at the initial stage.

Slight smoke under the hood is normal for a car after a major overhaul.

This is oil that has fallen on the outside of the motor after the temperature rises. power plant burns and smokes a little.

An increase in coolant temperature usually goes along with a decrease in oil pressure.. The oil pressure level should not fall below 0.4-0.8 kg / cm 2. It must be understood that a complete drop in oil indicates errors made during engine assembly.

Running in

After a short break-in at idle, the engine is turned off. It should be left alone until the temperature drops to 30-40 degrees. Then start again, wait and turn off again. Approximately 15-20 such pre-running cycles are carried out.

Gentle driving mode

After that, you can gradually increase the speed:

• 3 min - 1000 rpm;
• 4 min - 1500 rpm;
• 5 min - 2000 rpm.

All this time we monitor noise and leaks.

After an idle break-in, this procedure can be carried out with a small load on the go.

While driving, you do not need to exceed the speed limit of more than 60-70 km / h. For the first 300 km, smoke may appear from exhaust pipe especially when installing new rings. The idle speed setting needs to be adjusted regularly.

After a break-in regime of 3 thousand km, the speed can be increased to 90 km / h. At this point, the initial stage of running-in can be considered completed. But up to 10-15 thousand km, it is advisable not to heavily overload the car with aggressive modes.

During long-term operation car, the working elements of the motor are subject to wear and significant overloads, which negatively affects the performance of the power unit. To solve the problem, you need to install a new component. When the usual replacement of nodes is not enough, a major overhaul is carried out diesel engine.

Signs of a need for overhaul

There are a number of indicators that will indicate the need for the procedure:

• increased fuel consumption;
• a significant decrease in the oil level in the engine;
• smoke from the gas and vapor outlet hose;
• withdrawal exhaust gases different shades. For an experienced craftsman, the shade is an indicator of determining the cause of the malfunction;
• interruptions in the operation of the engine at idle;
• extraneous sounds in the exhaust gas mechanism;
• low oil pressure;
• unstable operation of the power unit, overheating;
• appearance extraneous sounds in the internal combustion engine;
• reduction in power performance.

Very important indicator for capital works is the mileage of the car. Usually, the overhaul of a diesel engine is carried out after passing 200 - 250 thousand km. But the mileage varies depending on the model and operating conditions of the vehicle.

Repair frequency table

vehicle type	Mileage before overhaul, thousand km
Cars
With a cubic capacity from 1.2 to 1.8 liters.	150
With a capacity of 1.8 - 3.5 liters.	400
Bus class
extra small, up to 5.0 m long	350
Length from 6 to 7.5 m.	400
Length 8 - 9.5 m.	500
Large, with a length of 10.5 to 12 m.	500
General purpose trucks
lifting capacity up to 1.0t	150
lifting capacity up to 3.0t	175
lifting capacity up to 5.0t	300
Large load capacity
from 5.0 to 6.0t	450
from 6.0 to 8.0t	300
Extra large payload
from 8.0 to 10.0t	300
from 10.0 to 16.0t	300
career transport	200

Overhaul process

Dismantling is a troublesome job that requires special skills and availability special keys and pullers. To perform the work, you can use the services of service centers or do everything yourself.

Stages of engine recovery:

1. Dismantling the power unit. Removal begins with unscrewing the fasteners on the frame and disconnecting the wiring and pipelines from all internal combustion engine components.
2. Inspect the component for damage or wear. The obtained data are verified with the technical documentation. Based on the results of the measurement, the need for repair is determined.

Degree of wear piston-cylinder group determined by the amount of compression. Measurements are taken through the nozzle hole, turning the engine with a starter.

Parameters under which it is necessary to carry out repairs

1. Component troubleshooting:
   • crankshaft: grinding the main and connecting rod journals, checking the journals for hardness, measuring the runout, centering, installing liners in accordance with the repair size;
   • cylinder block: boring to the repair size, abrasive processing of the cylinder mirror, restoration of the mating plane and the crankshaft installation site;
   • oil pan: visual inspection for mechanical damage;
   • cylinder head: removal of carbon deposits from the combustion chamber, replacement of guide bushings, lapping of the valve and seat, troubleshooting of the camshaft, adjustment of the valves;
   • fuel system: torque setting and injection pressure on fuel pump, checking the quality of the nozzle spray, inspecting the seats of the fuel lines for wear or damage.

The overhaul of diesel engines is completed with a run-in.

Diesel engine options

During major works, worn parts are replaced. To operate the engine on full power, it is necessary that all rubbing working elements are perfectly worked out. The lapping of parts and maximum performance is ensured by a proper break-in process.

Engine break-in rules at home

Factory motors run-in process is carried out on special equipment, under the guidance of skilled workers.

For self-fulfillment work is necessary:

1. Check the level and condition of the electrolyte in the battery, if necessary, bring it to the required standards.
2. View starter status. After the overhaul, the diesel engine will be hard to scroll, so the starter must scroll the crankshaft without delay.
3. Replace oil system filter.
4. Using a dipstick, check the oil in the engine crankcase, if necessary, top up to the upper mark. Use only the best quality oil.
5. Further, if there is no electric fuel pump, we fill the fuel system manually.
6. temperature dependent external environment, you need to adjust the damper of the cooling system. IN winter time, you need to heat the crankcase with a heating pad.
7. Start the engine, while monitoring the oil pressure and watching the indicators on the instrument panel. The first start usually takes longer, this is due to the filling of the fuel supply system.
8. The pressure on the pressure gauge should be in the range of 3.5 - 4 kg / cm2. After reaching this mark, continue warming up at idle.
9. Next, we start the radiator cooling fan for a few minutes, and turn off the car.

After cooling the power unit to 40 degrees, we start warming up again. The procedure must be repeated 10-15 times. After fulfilling all the requirements, we begin to run in at medium speeds. To do this, for 3 minutes we hold 1000 revolutions. After, gradually increase to 1500 and 2000 rpm.

At each mark, we linger for 5 minutes. Then you can start running on the go. In the instruction manual specific vehicle, their required speeds are indicated.

Break-in rules

• the speed limit should be within 60-70 km/h. Driving in higher gears is prohibited;
• after 3 km. mileage, you can begin to adjust the speed;
• do not overload the vehicle. Maximum load, acceptable after passing 10 thousand km;
• start driving only on a warm vehicle;
• alternate high speed transmissions. During this period, the formation of efficiency and smooth operation of the motor takes place, therefore driving is prohibited only at high or low speeds;
• do not allow a sharp decrease in speed and speed. Running in is best done outside the city or in the evening;
• on modifications with a turbocharger, it is not recommended to immediately turn off the engine, you need to idle for some time.

Oil change during repair

Since the capital work, the oil has been changed 3-4 times. Together with the oil, wear products of parts are washed out. Therefore, if you ignore this item, the chips get into the bearings, liners, scratch the cylinder, and then you will have to carry out repairs again. For best performance of the power unit and proper grinding of parts, an oil change should be carried out every 500 km. The last replacement is done after 2000 km. run.

After 500 km of run, the following operations are performed:

• replacement of the oil system filter;
• adjustment of the gas distribution mechanism;
• tightening the cylinder head bolts;
• timing drive installation.

Synthetic oil can be filled in only after the break-in period has ended and the engine has been flushed. In winter or summer period oils are applied different viscosity. For summer break-in, the 15W-30 SF / CE and M-10G2k brands are suitable; in winter, M-8G2, M-10DM are used.

Low viscosity oils improve the running-in of parts, while oil with a higher viscosity does not cause surface roughness. installed parts. Manufacturers of some car models fill branded oils, which contain a package of additives to speed up the break-in process.

Cold running on the bench

The best option for running in a diesel engine after a major overhaul is a run-in at the stand. This option is more reliable and eliminates damage to components due to sharp drop temperature regime. Advantages this method in that the specialist can fully control the process.

Work is carried out at a service station or in service center, where there is necessary equipment. To the crankshaft of the engine, through cardan transmission, the electric motor is connected. The rotational speed is controlled by a tachometer. The required revolutions are set special program, which focuses on data from sensors.

Compliance with the thermal regime is ensured by the supply of engine oil or hot water. The duration of the burn-in procedure is about 3 hours.