RE: Engine startup and break in

["Korolyshyn, Dan Mr. DAC DPW ENGR RESOURCE MGMT BR" <Dan.Korolyshyn@xxxxxxxxxxxxxxxxxxxx>]

Ciao Alfisti,

I now have 730 miles on my newly rebuilt/overhauled/upgraded 
"74" Spider 2.0 liter engine.  One of the mechanics who overhauled
the engine, Paolo, did the first 30 or so miles, I did not ask in
detail how he drove, but I gathered that he drove it very easily,
home to lunch the day the work was completed.  After I picked the
car up the next day, I drove it by the book, ie. not over 3500 rpm
for the first 300 miles and now not over 4500 rpm.  I varied the speed
and when I was on a long drive to Val d'Aosta in norther Italy last 
weekend I took the small roads as much as possible and stopped a lot
just to go through the gears not exceeding the limits.  Fortunately 
there was not much traffic so I could drive as I pleased concentrating
on my "rodaggio", break-in rather than the traffic.  Now with the 
730 miles completed, my oil consumed was about .25 quarts, so I presume
that the break-in has been successful thus far.  Hopefully all of the 
bearings and machined surfaces are nicely polished and good for at
least another 100,000 miles.  FWIW, I did use a lead substitute that
is common here in Italy for older cars that require a leaded fuel
which is no longer available and I also used about 2oz. of Marvel
Mystery Oil per tankful of gas just to provide some lubrication for
the valves and valve guides.  I know that there is a lot of controversy
on the use of an upper cylinder lubricant, but during the break-in
I kinda feel that a little is better than not using it at all,
especially for the valve guides.  So if my oil consumption remains
at what it is right now, I will be very happy indeed.  My presumption
is, is that the rings are now seated and the rest of the break-in 
period is for the various moving parts to continue to conform to 
each other develop a smooth mating surface between parts.
One other issue of interest is that while my original owners manual calls
for a head re-torque at 600 miles, something I could not do by the book
as I was on my trip, the mechanics at Alfa maintain that the head
re-torquing
for the Giulia series engines is at 1500 km or about 1000 miles. 
I insisted on setting up an appointment to bring the car in for the
recommended re-torquing as specified in my manual and they just 
shook their heads and laughed.  So since I'm going on leave for the
next week out of country, I will bring the car in when I get back.
Since they installed an original Alfa head gasket, I get a one year 
warranty on parts and labor for that and all dealer bought Alfa parts 
installed.

Ciao,
Dan Korolyshyn




Date: Mon, 14 Jul 2003 13:32:46 -0700
From: alfacybersite <acs@domain.elided>
Subject: Engine startup and break in (long) 

Tom, first, Congratulations on getting Her running! However, I disagree
with a few of your break-in plans.

I've never heard of any great concerns over cam break-in periods. I
heavily coat all moving parts, except piston rings / piston / cylinder
walls, with STP when rebuilding. I add oil to the upper 'reservoirs in
the head before installing the cam cover. True, if one has a warped
head, then yes, there will be cam bearing problems which will be only a
part of a very major problem.

I idle no longer than necessary to make enough adjustments so that it'll
run at least 'okay'. I make a short run and come back to check for
leaks. Fix any. Take a small assortment of tools and fire extinguisher,
then go for a few mile run and return (hopefully).

I Never Ever lug the engine, but concentrate on slowly bringing up the
revs, then backing off the throttle completely. I personally feel a
steep hill is a bit much for a fresh engine - although I'm aware engine
builders have been using them for years (where available).

After twenty or thirty fairly careful miles, I briefly bring the revs up
to 5,000 or so and again back off. My feeling if the engine is built
correctly, everything is going to bed in pretty quickly - even the
rings, if installed dry.

I go 250 miles or so before changing oil. I don't cut the oil filter
open but do sift through the oil with my fingers after it has settled so
that any shavings fall to the bottom. I rarely find any shavings. What I
do find when opening up engines rebuilt by other mechanics is often a
lot of silicone strings clinging to the oil pump inlet.

Best of luck,

Biba
Irwindale, CA USA
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