Rebuilt Engine Break in recommendations

pmddouglas

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Joined
May 31, 2003
Messages
14
Somebody please give me some recommendations to break in my new rebuilt engine. The boat is a 20' 1976 I.M.P. Aztec Cuddy Cabin. It is a Mercruiser 888 with Ford 302, 351 heads, and 2bbl carb. Outdrive is model 1. All new exhaust risers, manifolds, end caps etc and engine waterpump. Also new exhaust shutters and I rebuilt the supply water pump. We plan on putting in the distributor(After priming motor by turning oil pump drive shaft) and battery in real soon and plan on hooking up the muffs and starting the motor. Really want to break this in properly, so I don't have to do it all over again for awhile. <br /><br />Thanks,<br /><br />Paul
 

Blk-n-Blu

Master Chief Petty Officer
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May 12, 2004
Messages
821
Re: Rebuilt Engine Break in recommendations

Paul, If you must know, here is an article from a pro ( George Van Parys ) hope it helps;<br /><br />Breaking in a New or Rebuilt Engine<br /><br />Whenever an engine's piston rings are replaced whether in part or in entirety it is necessary to break in the engine. Piston rings are replaced at a complete engine overhaul or repair, top overhaul or single cylinder overhaul or repair.<br /><br />When we refer to engine or cylinder break in, we are talking about the physical mating of the engine's piston rings to it's corresponding cylinder wall. That is, we want to physically wear the new piston rings into the cylinder wall until a compatible seal between the two is achieved.<br /><br />Proper engine break in will produce an engine that achieves maximum power output with the least amount of oil consumption due to the fact that the piston rings have seated properly to the cylinder wall. When the piston rings are broken in or seated, they do not allow combustion gases to escape the combustion chamber past the piston rings into the crankcase section of the engine. This lack of "blow-by" keeps your engine running cleaner and cooler by preventing hot combustion gases and by-products from entering the crankcase section of the engine. Excessive "blow-by" will cause the crankcase section of the engine to become pressurized and contaminated with combustion gases, which in turn will force normal oil vapors out of the engine's breather, causing the engine to consume excessive amounts of oil. In addition to sealing combustion gases in the combustion chamber, piston rings must also manage the amount of oil present on the cylinder walls for lubrication. If the rings do not seat properly, they cannot perform this function and will allow excessive amounts of oil to accumulate on the cylinder wall surfaces. This oil is burned each and every time the cylinder fires. The burning of this oil, coupled with "blow-by" induced engine breathing, are reasons that an engine that hasn't been broken in will consume more than its share of oil.<br /><br />When a cylinder is overhauled or repaired the surface of it's walls are honed with abrasive stones to produce a rough surface that will help wear the piston rings in. This roughing up of the surface is known as "cross-hatching". A cylinder wall that has been properly "cross hatched" has a series of minute peaks and valleys cut into its surface. The face or portion of the piston ring that interfaces with the cross hatched cylinder wall is tapered to allow only a small portion of the ring to contact the honed cylinder wall. When the engine is operated, the tapered portion of the face of the piston ring rubs against the coarse surface of the cylinder wall causing wear on both objects. At the point where the top of the peaks produced by the honing operation become smooth and the tapered portion of the piston ring wears flat break in has occurred.<br /><br />When the engine is operating, a force known as Break Mean Effective Pressure or B.M.E.P is generated within the combustion chamber. B.M.E.P. is the resultant force produced from the controlled burning of the fuel air mixture that the engine runs on. The higher the power setting the engine is running at, the higher the B.M.E.P. is and conversely as the power setting is lowered the B.M.E.P. becomes less.<br /><br />B.M.E.P is an important part of the break in process. When the engine is running, B.M.E.P. is present in the cylinder behind the piston rings and it's force pushes the piston ring outward against the coarse honed cylinder wall. The higher the B.M.E.P, the harder the piston ring is pushed against the wall. The surface temperature at the piston ring face and cylinder wall interface will be greater with high B.M.E.P. than with low B.M.E.P. This is because we are pushing the ring harder against the rough cylinder wall surface causing high amounts of friction and thus heat. The primary deterrent of break in is this heat. Allowing to much heat to build up at the ring to cylinder wall interface will cause the lubricating oil that is present to break down and glaze the cylinder wall surface. This glaze will prevent any further seating of the piston rings. If glazing is allowed to happen break in will never occur. We must achieve a happy medium where we are pushing on the ring hard enough to wear it in but not hard enough to generate enough heat to cause glazing. If glazing should occur, the only remedy is to remove the effected cylinder, re-hone it and replace the piston rings and start the whole process over again.<br /><br />Understanding what happens in the engine during break in allows us to comprehend the ideas behind how we should operate the engine after piston rings have been changed.<br /><br />The break in process may take as long as 20 hours of operation to complete. You are in control of engine break in for 98 % of the time that it takes to occur. This is a serious responsibility when you consider the expense and aggravation of having to remove, re-hone and re-ring cylinders that have glazed and not broken in.<br /><br />Use regular oil, not synthetic, during break-in.<br /><br />When you first start it up, let it COMPLETELY warm up, not just kinda warm, all the way warm. Liquid cooled engines require that the engine be brought gradually to normal operating temperature to avoid cold seizure resulting from pistons expanding faster than the cylinder liner.<br /><br />Allow 1 hour at idle speed only for break-in of new pistons or rings.<br /><br />While it's still hot, check and see if the head needs to be retorqued.<br /><br />Check the timing again, as well as the valve adjustment.<br /><br />DO NOT RUN ENGINE AT CONSTANT RPM FOR PROLONGED PERIODS OF TIME.<br /><br />After gradually bringing engine to normal operating temp., operate engine in gear at approx. 1500 RPM for 20 minutes.<br /><br />Operate in gear at no more than 2000 RPM for the next 60 minutes.<br /><br />Cruise at 3/4 throttle or less for the next 4 hours.<br /><br />Occasionally reduce throttle to idle speed for a cooling period.<br /><br />Use only enough throttle to plane your vessel and then throttle back to ~3000 RPM.<br /><br />Avoid operating in the 2000-3000 RPM range at all times during the 10 hour break-in period.<br /><br />• During the 6th hour of break-in, plane boat quickly and then throttle back to maintain minimum plane speed.<br /><br />• During this 6th hour, you can throttle up to 3/4 throttle for 1-2 minutes, then return to minimum planing speed.<br /><br />During the final hours of break-in you can operate at full throttle for periods of 2 minutes or less.<br /><br />Avoid continuous full throttle operation for the first 10 hours of operation.<br /><br />Change the oil after 10 hours. Still just the regular oil.<br /><br />Change the oil again after 20 hours. Still just the regular oil.<br /><br />Change the oil again (50 hours). Now you can use the expensive synthetics if you want to.<br /><br />After that, the motor is pretty much broken in, so go run the dang thing to see how fast it is!!!!
 

pmddouglas

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Joined
May 31, 2003
Messages
14
Re: Rebuilt Engine Break in recommendations

Thanks for the response. That is the type of information I was looking for. Very detailed. I have a question though. According to the article I am to breakin the piston rings by idling for 1 hour. But down below it indicates in Bold letters, do not operate engine for prolong periods at constant RPM. That contradicts the 1 hour at idle. Was the intent to not run at constant RPM for extended periods after the rings have been broken in?<br /><br />And do you believe it will be acceptable to run at idle for one hour with muffs on? Then pull the valve covers, check the head bolt torques, timing etc. (I don't believe there is a valve adjustment for my particular heads).<br /><br />Then will it be OK, to follow up at a later date in the water to break in the rest of the engine? This sure is a lengthy process, but I sure want to get it right and be happy in the end.<br /><br />Thanks,<br /><br />Paul
 

ron7000

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Jul 10, 2004
Messages
498
Re: Rebuilt Engine Break in recommendations

Originally posted by pandjdouglas:<br /> According to the article I am to breakin the piston rings by idling for 1 hour. But down below it indicates in Bold letters, do not operate engine for prolong periods at constant RPM. That contradicts the 1 hour at idle.
if you idle a new/rebuilt engine which has new piston rings, it'll become an oil burner! If you idle a motor with a new cam and/or new lifters, the cam and lifters won't develop the proper wear pattern and they'll eat each other!<br /><br />what do you mean by new rebuilt? I'm assuming that it's basically a new motor, with new pistons, piston rings, cam, and hydraulic lifters. I doubt you have hydraulic roller lifters, in which case you'll have flat tappet hydraulic (same as me). What you need to do when you first fire up the motor, is get it to 2000-2200 rpms, in neutral gear, and run it there for about 20 minutes. What this does is breaks in the cam. You need this rpm so there's adequate oil pressure and flow to the cam and lifters, and so that the lifter will spin in it's bore and develop a good wear pattern on the cam lobe. If you just idle it, the lifter won't get good oil and won't spin. Do not idle it for 5 minutes to warm it up the first time you start it. Start it, make sure timing is correct as quick as possible, then get it to 2000 rpms. After that, just don't run it wide open for the first 10 or so hours. And don't go on a long cruise for like 30 minutes at a constant rpm. Avoid idling in neutral or in gear and try to stay above 1500 rpm. This ensures good oil flow. When you start the engine cold, idle it up to 1200-1500 rpm for only a minute or two to warm it up so that the choke will open and then it'll idle smoothly and you can get it in gear. It's important to get it in gear and put a load on the motor as soon as possible, this is was seats the piston rings. Avoid high rpms, like above 2500, until the motor water temp has reached 140/160F.<br /><br />Use a name brand 30 weight oil and change it after the first 10 hours, and then at 20 hours.<br />Trust me, I've been there with my 351w and have 400 hours on the motor since 1993. Who is George Van Parys?
 

pmddouglas

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May 31, 2003
Messages
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Re: Rebuilt Engine Break in recommendations

Well thanks for your reply also Ron7000. I spoke to the machine shop that helped me out, and they pretty much have the same recommendation. He said start the motor and keep at 1500 to 2000 rpm for about 20 minutes to break in the cam and lifters. He said everything else as far as breaking in the lifters and staying below 3/4 throttle is a thing of the past. So to summarize my current thoughts: I will Idle at 1500 to 2000 rpm for 20 minutes. I will not cruise at a constant RPM for 1st 10 hours and will also not go more than 3/4 throttle until I reach 10 hours and will change the oil at 10 hours, then 20 hours. I think I put Rotella 10w-40 in based on Merc recommendation to use 25w-40 for a mercury marine product. I figured 10w would be better for start up. Do you agree? And maybe my engine is not considered a mercury marine product and per Clymers manual use SAE 30 for 32 to 90 degree temps and SAE 40 above 90 deg
 

ron7000

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Jul 10, 2004
Messages
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Re: Rebuilt Engine Break in recommendations

Originally posted by pandjdouglas:<br /> So to summarize my current thoughts: I will Idle at 1500 to 2000 rpm for 20 minutes. I will not cruise at a constant RPM for 1st 10 hours and will also not go more than 3/4 throttle until I reach 10 hours and will change the oil at 10 hours, then 20 hours. I think I put Rotella 10w-40 in based on Merc recommendation to use 25w-40 for a mercury marine product. I figured 10w would be better for start up. Do you agree? And maybe my engine is not considered a mercury marine product and per Clymers manual use SAE 30 for 32 to 90 degree temps and SAE 40 above 90 deg
Not 1500-2000, 2000-2200 for first 20 minutes! Sounds like you got everything else covered well. I think I used castrol 10w-30 for my first 10 hours, and yes a 10W-x would be better for startup, especially for the first few hours. After that, some the best oils to use would be the chevron delo or mobil delvac diesel oils, and the rotella. The chevron 5w-40 synthetic or mobil delvac1 5w-40 synthetic, if you can find them, would be top shelf. Mobil-1 15-50 synthetic is good, although a little on the heavy side but good if you run the motor in the upper rpm range all the time.<br /><br />The merc 25w-40 is not a synthetic oil, is over-priced, and I have oil analysis showing it shearing to a 30-weight oil after 10 hours in my 3.0L. It's rumored to be blended by citgo. Go here to get some good info about oil if you're interested.<br /><br /> http://theoildrop.server101.com/cgi/ultimatebb.cgi
 

pmddouglas

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May 31, 2003
Messages
14
Re: Rebuilt Engine Break in recommendations

Thanks again Ron7000. I spoke to another buddy of mine that knows a little about breaking in motors and he said go about 2000 to 2300 RPM. and that was my plan when I tried to fire up Sunday. But, with my luck here is what happened. Gas was not getting past the water separation filter, looked like it was 80% full of gas and line going to fuel pump was not wet. Tried to pour gas down the carb to see if could get pump pumping with higher rpm, but the roll pin in the starter came out. Thus starter getting rebuilt right now. Hope the end is near to my problems. Plan on pouring gas down inlet and outlet lines to pump with thinking that diaphragm needs to get wet, since motor sat for 4 to 5 years before I rebuilt it.
 

ron7000

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Jul 10, 2004
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Re: Rebuilt Engine Break in recommendations

Originally posted by pandjdouglas:<br /> since motor sat for 4 to 5 years before I rebuilt it.
if you haven't touched the fuel pump in the rebuild, then the pump diaphram (it's mechanical right?) is probably dried out and has torn. Went through the same thing with my 351 when I got the new block, I had to use my old fuel pump... rebuilt that is.<br /><br />A quick way to check the pump is to pull the fuel line exiting the pump. Have someone crank engine and put your finger over the exit port of the fuel pump. You should feel a good puff of air, if not fuel. If you have a fuel pressure guage, the mechanical pump should give at minimum 4 psi, preferably 6-7psi. Also, blow on the inlet fuel line going to the pump, to force air back through the filter and into the tank. You should be able to blow air into the tank, if not then check for obstructions in the tank pickup. Or a closed fuel valve.
 
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