Engine Break in Procedure
Congratulations on the purchase of your new Kill Devil Diesel engine. By following this break in procedure, you will help protect your investment, mitigate the risk of engine damage, and help ensure an efficient, hardworking, long lasting power plant for your truck.
Inspect all belts, pulleys and hoses, motor mounts, transmission mounts, radiator, intercooler piping, turbo and fuel system components prior to installation of the engine. Be sure all batteries are fully charged, and all necessary precautions are observed. Note – Automatic transmissions – be sure the torque converter is fully seated in the transmission, failure to do so will cause severe damage to your engine.
-Precheck- Initial Fire-Up-
After the engine is installed in the truck, make sure oil and coolant are filled to the proper level. Use a quality break in oil (KDD recommends Driven Break-In Oil, available through KDD), or any quality non-synthetic oil. DO NOT USE SYNTHETIC OIL DURING ENGINE BREAK IN, PERIOD. Make sure all electrical connectors and sensors are installed correctly. Ensure all belts, hoses and hose clamps are installed correctly. Be sure all wiring and hoses are clear from moving parts such as the fan and serpentine belt, etc. Be sure no tools were left in the engine bay or near moving parts. Be sure no shop rags or plastic plugs were left in the engine or in the intake/turbo piping, etc. If connectors or sensors are broken; if wires are worn, chaffed, exposed or cut, fix them.
Prior to cranking, perform a key on engine off (KOEO) sensor check – place the key in the on/run position, verify all sensors are reading correctly. Failure to address these concerns can result in severe damages to your new Kill Devil Diesel engine, not covered under warranty.
Prime the engine before first fire - we recommend using an air-over-hydraulic priming tank, such as those offered by Melling or Goodson MFG (available from KDD). KDD does not recommend cranking the engine with the starter to prime the engine.
Initial Start-up: After the KOEO sensor check has been done and the engine has been primed with quality break-in oil it is time to start the engine. Use caution when working around a running engine. Crank the engine over, please note -it may take several minutes of cranking to prime the fuel and injection system (be sure there is clean fuel in the tank). Don’t crank for more than 20 seconds at a time and be sure to allow 1-2 minutes between cranking to avoid draining the batteries and overheating the starter (it is recommended to have a battery charger connected to the vehicle during this time). Immediately after initial start-up, check for proper oil pressure, check for hose/coolant leaks, fuel leaks, exhaust leaks, boost leaks, etc. Check for proper belt routing and alignment, listen for odd noises or interference between moving parts, torque converter/flywheel/belt/fan, etc. After a few minutes of run time, shut the engine off, check oil level as it may have changed after start-up. A new engine will require more oil than a typical service oil change. Once oil and coolant levels have been topped off, restart the engine. Verify that the fuel system and all sensors are working correctly, verify that oil pressure, fuel pressure, and injection pressures are correct, recheck for leaks, etc. It may take several minutes of runtime to force all entrained air out of the injection system, the engine may intermittently stumble or run rough during this time. Bring the engine up to operating temp, go for a short drive to verify all systems are working correctly, inspect for coolant or oil leaks, exhaust leaks, boost leaks…verify the serpentine belt system and all accessories are functioning properly, etc.
Recommended Do’s and Don’ts:
DO Initial fire precheck, and verify all sensors are reading correctly before and after startup.
DO Exercise caution when working around a running engine.
DON’T use synthetic oil during break-in period.
DON’T let the engine idle for extended periods of time during the first few hours of operation.
DON’T induce excessive/heavy loads such as heavy towing during the first 3,000 miles of operation
DON’T “baby” the engine either, run the engine moderately, keeping boost between 5 psi and 20 psi
DON’T run the engine excessively hard…we recommend keeping boost under 30 psi, we also suggest a factory ecu calibration if running factory turbo/injectors, or a light ecu calibration if equipped with larger turbo/injectors.
DO operate the engine under moderate loads at varying RPM. The idea is to put the engine through various heat cycles.
DO keep smoke output to a minimum, excessive fuel/smoke washes oil from the cylinder walls and can hinder the break in processes.
DO - Always make sure to let the engine get up to normal operating temps before driving under moderate load, even after the initial break-in period.
DO - Monitor gauges carefully, erring on the side of caution, to ensure engine is not overheated, and to ensure proper oil pressure.
Kill Devil Diesel is not responsible for failure caused by faulty fuel system, cooling system, or installation. We are always more than happy to help answer any questions you may have, if in doubt, ask. 252-725-1222. sales@killdevildiesel.com
Why do engines need break-in?
All engines require some kind of break-in. Although current technology provides the means of manufacturing engine parts with excellent precision, for the best results, a thorough and proper break in is highly recommended.
“Break-in” is the allowance of the machined cylinder and piston ring surfaces to conform to each other’s shape during engine operation. KDD uses a torque plate during machining to ensure the bores are as round as possible. A tight seal is very important because it prevents the escape of unburned fuel and pressurized gasses into the crankcase, while also preventing crankcase oil from getting into the combustion chamber. This is the ultimate goal of a proper break-in. During break-in, small amounts of oil consumption may be experienced, and the engine may run slightly warmer than normal during the first 2-3 hours of operation…but should not overheat. This is perfectly normal and acceptable in new engines. Although acceptable at first, it is important that these undesirable attributes do not continue after the break-in process has been completed. If coolant temp rises above 230 degrees safely pull over and allow the engine to cool to normal operating temperature and shut the engine down. KDD engines are equipped with “heat tabs” that melt when coolant temp reaches over 250 degrees, voiding the warranty. If the engine overheats, carefully inspect the cooling system for proper function of radiator, fan, fan clutch, belt system, etc.
For proper “break-in” to occur, a fair amount of heat, friction, and resulting wear will have to take place before the piston rings will have “mated” with the cylinder walls. Running the engine under very light or no load prevents the oil film on the cylinder wall from being scraped away by the piston rings. Eventually, this leaves a hard deposit on the cylinder wall known as “glaze”. The rings never seat well if they cannot expand from the dynamics and heat that a load produces. One can expect continuous oil consumption, poor mileage, and increased bearing and engine wear for the entire life of the engine.
When new, a modest amount of heat is created merely from the friction of the new rings passing over the freshly honed cylinder wall. While significant, the real heat is created from combustion of the fuel. When the fuel is burned, combustion gasses expand and heat all of the cylinder parts. Loading moderately will introduce more fuel to the cylinder and will add significant amounts of heat and pressure to the cylinder components. A recommended loading of 70% to 80% (of the engine’s power rating) is common. Moderate loading is the key to a proper break-in which usually lasts the first 150 hours, or 5-10k miles. Noticeable improvements in fuel economy or the “character” of the engine are also good indicators.
With any engine, it is not uncommon to see very small particulates in the first one or two oil changes, or in the filter. This is very normal, and to be expected as the bearings, pistons, cylinder walls, and all moving parts fit and conform to their new home. Again, we recommend changing the “first fire” oil after around 30 minutes -2 hours of run time, then changing the break in oil again after 2-3,000 miles.
Your Kill Devil Diesel engine is an investment in a hardworking power plant for your truck. We are proud to use the best parts available, combined with state-of-the-art machining, and the most meticulous care and precautions during the assembly of your engine. Proper break-in mitigates risk of damaging your investment. With proper break-in and proper care and maintenance your engine will provide years of reliable service. Don’t overthink the break-in, drive “normally” - don’t baby it, don’t abuse it. Please don’t hesitate to contact the Kill Devil Diesel Team for any questions you may have, 252-725-1222 or sales@killdevildiesel.com.