Thread: Break-In
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Old July 13th, 2009, 08:17   #1
Drivbiwire
Zehntes Jahr der Veteran
 
Join Date: Oct 1998
Location: Boise, Idaho
Fuel Economy: Who cares, it's a diesel!
Default Break-In

Rules that apply for the life of the car
-When the engine is cold (below the first 3 white marks at the base of the temp gage) rev the engine to at least 2,500 rpms.
-When the engine is warmed up (above the first three white marks) Rev the engine to no less than 3,000 rpms.
The reason for this is to keep the turbo on boost, clear the VNT guide vanes and apply firm pressure to the rings for optimal sealing against blow-by gasses. The rings need the boost to seal since its a turbo charged engine, babying the engine is detrimental and will lead to issues with compression if done so for very long.
-Keep rpms as close to 2000 rpm as possible when driving at a steady speed. This promotes optimum temperatures for the DPF and keeps the engine in the middle of its most efficient rpm range (1800-2200 rpm).
-Allow the DSG or automatic transmission to determine the optimal gear and engine rpm. It knows better than you... Provided you have it trained to be biased to the sport mode the engines shift points will occur at the ideal ranges.


Redline is defined as the maximum rpm allowed by the engine, in the case of all TDI's it is 5,100 rpm. The maximum physical limit of a TDI engine due in part to it's short stroke is approximately 8,800 rpm (this is when you will throw a rod or damage a piston, this rpm is not possible unless you force a downshift into 1st gear while driving 80mph)

The instrument cluster shows a red BAND starting at or around 4600 rpm, most owners will find that very little power resides beyond this point due mostly to the ECU reducing fueling to respect the smoke map.

Adaptive Transmissions, these transmissions learn based on how you apply the power with your foot. Over time they will modify shift patterns with a bias to a "Sport" mode. Train the transmission to shift as close to the recomended rpm ranges below.

When your engine was first produced the motor was placed in a test cell and "Run-in" by a computer run dyno. The motor after the run-in was DRAINED OF ALL ITS FLUIDS (Oil, Coolant etc), the filters were replaced and a unique break-in oil was installed to promote a proper break-in once installed in the car as well as to protect the engine from corrosion during shipping to final assembly.

The "Break-in oil", YES VW does use a specially formulated "Break-In" oil formulated under an internal "TL" specification and produced by Fuchs. The oil is a group IV synthetic 5w30 formulated to comply with the LowSAPS VW507.00 requirements as well as the TL specifications for break-in. The oil is intended to allow a controlled rate of wear while protecting the engine and allowing the internal parts to seat proplerly during the engines first 10,000 road miles.

First 1,000 miles
Keep rpms below 3,800. Avoid steady rpms. Frequent firm (75%) application of power is strongly recomended up to a maximum engine rpm of 3,800. Avoid the use of cruise control so that you naturally fluctuate the power with your foot.
DO NOT CHANGE THE ENGINE OIL UNTIL 10,000 MILES!

1,000-5,000 miles
Use the full 5,100 rpm power range. THIS DOES NOT MEAN DRIVE AROUND AT 5100 RPM! This DOES mean to find the rpm range where your cars best power resides. Most owners will find that the best engine operating range to be between 2000rpm and 4200 rpm for the purpose of acceleration. At all costs avoid using full throttle below 2000 rpm the ECU will attempt to prevent you from applying full power in this range, work with it and don't request it with your foot.
Continue to avoid steady rpms and avoid the use of cruise control. occasional application of full throttle (100%) is recomended to help seat the rings. City driving is ideal for breaking in a TDI due to frequent stops and acceleration. DO NOT CHANGE THE ENGINE OIL UNTIL 10,000 MILES!

5,000-10,000 miles
Use of the cruise control is ok at this point since most of the initial break in has occured. Continue to use occasional full throttle accelerations to continue to seat the rings. You will notice the engine become slightly louder during this phase due to less friction from the engine breaking in (normal for a diesel to become louder under lighter loads). If your going on a long drive and you are using the cruise, every so often step on the peddle to accelerate up about 20 mph then coast back down to your preset speed.

Your first oil change is due at 10,000 miles DO NOT change it early! Oil analysis supports 10,000 miles as being realistic for a first change interval. Wear metals will remain at safe levels during this entire first interval thanks to the initial run-in and flush at the factory before the engine was installed in your car.

10,000-60,000
This is when the rest of the break in occurs. The engine from the factory will check out with about 475psi of compression pressure out of the crate. It will take at least 60,000 miles to reach the peak pressure of 510 psi. For the most part once you get to 10,000 miles your compression will be around 490 psi meaning that most of the break in has occured.

60,000-the life of the motor
The owners have followed the advice above and do not have any oil consumption issues. This also means that with the higher pressure the engine is more efficient returning optimal fuel economy and reduced smoke output. I am still of the opinion that if possible use a LowSAPS 5w40 instead of the 5w30 oils ie Mobil 1 ESP 5w40 formula M (MB229.51, .6 Sulfated Ash)
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Specializing in Injectors for CRI, CR, PD, VE, IDI VW, Audi, MB, SEAT and Skoda Diesel engines.
Offical Importer, Distributor and Installer for Fratelli Bosio, S.R.L. North America
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Last edited by Drivbiwire; July 13th, 2009 at 08:24.
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