Opel Insignia: Break-In Procedure

ENGINE PRE-OILING

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Pre-oil engine prior to operation to prevent engine damage. Lightly oiled oil pump will cavitate unless oil pump cavities are filled with engine oil or petroleum jelly.

Engine pre-oiling can be done using pressure oiler (if available). Connect pressure oiler to cylinder block oil passage such as oil pressure sending unit. Operate pressure oiler long enough to ensure correct amount of oil has filled crankcase. Check oil level while pre-oiling.

If pressure oiler is not available, disconnect ignition system. Remove oil pressure sending unit and replace with oil pressure test gauge. Using starter motor, rotate engine starter until gauge shows normal oil pressure for several seconds. DO NOT crank engine for more than 30 seconds to avoid starter motor damage. Ensure oil pressure has reached the most distant point from the oil pump.

NOTE: If new lifters or camshaft are installed, some manufacturers require that a crankcase conditioner be added to engine oil. The engine should be operated for specified amount of time to aid in lifter break-in procedure.

INITIAL START-UP

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Start engine and operate engine at low speed while checking for coolant, fuel and oil leaks. Stop engine.

Recheck coolant and oil level. Adjust if necessary.

CAMSHAFT

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Break-in procedure is required when new or reground camshaft has been installed. Operate and maintain engine speed between 1500-2500 RPM for approximately 30 minutes. Procedure may vary due to manufacturer's recommendations.

PISTON RINGS

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Piston rings require a break-in procedure to ensure seating of rings to cylinder walls. Serious damage may occur to rings if correct procedures are not followed.

Extremely high piston ring temperatures are obtained during break-in process. If rings are exposed to excessively high RPM or high cylinder pressures, ring damage can occur. Follow piston ring manufacturer's recommended break-in procedure.

FINAL ADJUSTMENTS

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Check or adjust ignition timing and dwell (if applicable). Adjust valves (if necessary). Adjust idle speed and mixture. Retighten cylinder heads (if required). If cylinder head or block is aluminum, retighten bolts when engine is cold. Follow the engine manufacturer's recommended break-in procedure and maintenance schedule for new engines.

NOTE: Some manufacturers require that head bolts be retightened after specified amount of operation. This must be done to prevent head gasket failure.

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