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Engine installation and initial start-up

checklist for avoiding consequential faults
Is the engine not working after the repair? What damage may occur when the engine is started for the first time? What mistakes can be made during the engine
repair? And how can consequential faults be avoided? You will find an exact description of what to do in this article.

Table of Contents +

SITUATION

Engine mechanics

Before starting the new engine

Electronic components

Test run/finishing work/final inspection

SITUATION
Severe damage often occurs following an engine repair. Faults that are not
resolved in the periphery of the engine, whether mechanical or electrical, can lead
to costly consequential faults. With the following checklist, the majority of possible
sources of trouble can be eliminated during engine installation.

Engine mechanics
 Components Activity Background

Intake system Check, clean There may still be fragments, metal chips or other soiling in the intake system from engine damage.
If these are not removed, they can cause more engine damage or premature wear.

Charge air cooler Clean or Following engine damage, there are often large quantities of engine oil in the charge air cooler.
replace If a new engine is connected, this can lead directly to engine damage.

Turbocharger Check, clean, Supply and return lines are blocked with carbon due to thermal influences, the resulting inadequate oil
connecting lines replace supply leads to turbocharger damage. Mechanically clean the lines (with a metal brush), or replace them.
Blowing out lines with compressed air is not recommended.

Turbocharger Check, replace The turbine and compressor impellers must be in impeccable condition, they must not be deformed or
cracked, or have ground against the housing.

Oil filter, oil cooler and Clean or Metal chips resulting from engine damage can be flushed to the clean side of the oil filter. Thoroughly
oil lines replace wash out and clean the oil cooler and filter housing. Blowing out lines with compressed air is not
recommended. The oil cooler and connecting lines should be replaced completely.

Oil system Fill After you have connected it to all components supplied with pressure oil (oil cooler, turbocharger,
hydraulic pumps, etc.), fill the engine with pressure oil to prevent dry running and damage to bearings.
This process is described in detail in Service Information SI 1639.

Exhaust system Check, clean, As a result of engine damage, fragments of pistons, valves and the turbocharger, as well as fuel and oil,
replace enter the exhaust system and cause further damage on the catalytic converter or particulate filter.

Fuel filter and filter Check, clean Injectors and high-pressure pumps in diesel engines are extremely sensitive to fuel contamination.
housing It is therefore advisable to also check these following engine reconditioning and to clean or replace them
if necessary.

Fuel/ Check, replace Filling the tank with the incorrect fuel frequently leads to engine damage. If there is any uncertainty
contents of the fuel if necessary regarding the composition of the existing contents of the tank, empty the tank completely and fill with the
tank specified fuel.

Cooling system Clean Before installing the engine, rinse cooling system components remaining in the vehicle with clean water.

Coolant agent Replace Only use specified coolant agent in the correct dilution. Do not start up the engine, even briefly, without
filling the cooling system. If the water pump runs dry, the sliding ring seal burns immediately and the
pump starts to leak.

Before starting the new engine

Components Activity Background

Electric Check Check correct connections using a circuit diagram of all vacuum lines and electrical plug-in connections.
Cables and hose This also applies to earth cables between the engine and the body/starter battery. This prevents damage
connections to electrical components and cables due to overstressing.

Engine Start Before starting up the engine, oil pressure must be built up. If necessary, take suitable action to ensure
that the engine does not start up before oil pressure has built up.

Engine After start-up After start-up, do not damage the engine through repeated early acceleration. The oil system needs some
time until it has vented completely and all components are supplied with fresh oil.

Electronic components
Components Activity Background

Engine control unit(s) Fault check Read out the fault code memory, note the diagnostic trouble codes and then delete the fault code
memory.
 Engine electronics with Actuator test The actuator test is used to check the function of the relevant components.
components This is helpful for flagging up interchanged plugs and faulty actuators, for example.

Carry out Adapt, teach in Today, many components have to be adapted following replacement. These include, for example:
adaptation Air mass sensors, stepper motors, throttle valves, regulating throttles and EGR valves.
Also see Pierbug Service Information SI 0090 and SI 0092.

Common rail injectors Programming After being swapped or replaced, common rail injectors must be programmed in the control unit
separately for each cylinder. This is essential in order to compensate for manufacturing tolerances. To
this aim, a code is printed on every injector, which must be saved/entered in the control unit using a
diagnostic tester.
The injectors from some manufacturers do not have a code, and programming is not necessary. These
injectors program themselves via an installed invariable resistor. They can be identified via a 4-pin plug
and the lack of an imprint.

Test run/finishing work/final inspection

Components Activity Background

Test run Note OBD The test run should incorporate a cold start, warm-up, urban traffic, driving on a highway and a
driving cycle motorway.
In addition, please bear in mind that in passenger cars, for example, some components are no longer
monitored by the OBD at velocities in excess of 120 km/h.

Fault code memory Check, delete Always check and delete the fault code memory before and after the test run, even if the MIL (malfunction
indicator lamp) does not light up during or after the test run. With OBD systems, the malfunction indicator
lamp is often only activated after a fault has occurred twice. However, a diagnostic trouble code is stored
in the fault code memory the first time this fault occurs.

Keywords :
oil pump , water pump , piston , piston ring , piston ring set , piston pin, Gudgeon pin , piston pin boss

Product group :
Pistons and components , Air supply , Engine control , Oil supply , Pumps , Engine block

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Contact
MS Motorservice International GmbH
Wilhelm-Maybach-Straße 14-18
74196 Neuenstadt
Germany

Phone: +49 (0) 7139 / 9376 - 33 33

Fax: +49 (0) 7139 / 9376 - 28 64

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For technical personnel only. All content including pictures and diagrams is subject to change. For assignment and replacement, refer to the current catalogues or systems based on
TecAlliance.