Running a Diesel engine in properly

I found this many moons ago somewhere on the great big wide internet and have posted it here for the sake of posterity – enjoy.

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.

First 1,000 miles

Keep rpms below 3,800. Avoid steady rpms. Frequent firm application of power is strongly recomended up to 3,800 rpm. Avoid the use of cruise control so that you naturally fluctuate the power with your foot.

1,000-5,000 miles

Use the full 5,100 rpm power range. Avoid steady rpms. Avoid the use of cruise control. Frequent application of full throttle is recomended to help seat the rings. City driving is ideal for breaking in a TDI due to frequent stops and acceleration. Once you get to 5,000 miles change the oil and perform your first service per the manual

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.

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 550psi. For the most part once you get to 10,000 miles your compression will be around 510psi meaning that most of the break in has occured.

60,000-the life of the motor

The engines I have seen so far using a 5w40 oil are maintaining 550 psi of compression pressure with over 200,000 miles on the odometer. 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.