When starting the engine for the first time after completing its repair, it is imperative to have a class B fire extinguisher on hand!
After installing the power unit on the vehicle, check the engine oil and coolant levels. Once again, make sure that all communication lines (cables, hoses and wiring) connected and properly secured. Remove all tools, rags and other foreign objects from the engine compartment.
Petrol models
1. De-energize the ignition system by disconnecting the wiring from the ignition module (see Chapter Engine electrical equipment). Remove the spark plugs.
2. Remove the fuel pump relay from the mounting block located in the engine compartment (see Chapter Power and exhaust systems).
3. With the spark plugs removed and the ignition and power supply systems temporarily disconnected, turn the engine over, raising the oil pressure in it so much that the corresponding indicator lamp on the vehicle's instrument panel comes on.
4. Screw in the spark plugs, connect the high-voltage wiring and restore the functioning of the ignition and power supply systems.
Diesel models
1. Turn on the ignition and immediately, without waiting for the glow plugs to warm up, begin turning the engine with the starter until the oil pressure warning light goes out.
All models
1. Start the engine in the normal way. Starting may occur with a slight delay, necessary for the fuel pressure to rise, but there should be no particular difficulties.
If flashes occur in the throttle body, check that the valve clearances are adjusted correctly (where required) and ignition timing (see Chapter Engine electrical equipment).
2. After starting, warm up the engine at idle speed to normal operating temperature, checking for signs of oil, coolant and transmission fluid/ATF leaks during warming up. Allow the engine to idle for 15 minutes, which is especially important after replacing connecting rod bearings.
There is no need to worry if a burning smell or slight smoke appears, the cause of which is inevitably the process of burning out assembly lubricants.
The first few minutes the engine will not idle very stably, which is explained by the electronic control module (ECM) selecting the optimal algorithm for the operation of the control systems (see Chapter Power and exhaust systems).
3. After waiting for the upper radiator hose to warm up, turn off the engine and let it cool down.
4. Recheck the oil and coolant levels. On diesel models equipped with a 1.7L SOHC engine, tighten the cylinder head mounting bolts to the required angles (see Specifications).
5. Now you can begin road tests and engine break-in. Take the car to an area where traffic is minimal and accelerate it sharply to 50-80 km/h (30-50 mph). Then reduce the speed to 30 km/h by closing the throttle completely. Repeat the procedure 10-12 times - the resulting cyclic loads will help the piston rings settle in relation to the cylinder walls. Check the engine again for leaks.
6. For the first 800 km (500 miles) of driving, try to operate the engine in a gentle mode, regularly and often checking the engine oil level. Increased oil consumption during the engine break-in period is normal.
7. After approximately 800-1000 km (500-600 miles), change the engine oil and oil filter.
8. The next few hundred kilometers of mileage the car can be operated in normal mode.
9. After 3200 km (2000 miles), change the engine oil and oil filter again. The engine can now be considered completely broken in.
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