Volvo 240/740/760/780/940/960 1990-1998

Engine Start-up and Break-in



Now that the engine is installed and every wire and hose is properly connected, go back and double check that all coolant and vacuum hoses are connected. Check that you oil drain plug is installed and properly tightened. If not already done, install a new oil filter onto the engine. Fill the crankcase with the proper amount and grade of engine oil. Fill the cooling system with a 50/50 mixture of coolant/water.

  1. Connect the vehicle battery.
  3. Start the engine. Keep your eye on your oil pressure indicator; if it does not indicate oil pressure within 10 seconds of starting, turn the vehicle off.

Damage to the engine can result if it is allowed to run with no oil pressure. Check the engine oil level to make sure that it is full. Check for any leaks and if found, repair the leaks before continuing. If there is still no indication of oil pressure, you may need to prime the system.

  1. Confirm that there are no fluid leaks (oil or other).
  3. Allow the engine to reach normal operating temperature (the upper radiator hose will be hot to the touch).
  5. If necessary, set the ignition timing.
  7. Install any remaining components such as the air cleaner (if removed for ignition timing) or body panels which were removed.


Make the first miles on the new engine, easy ones. Vary the speed but do not accelerate hard. Most importantly, do not lug the engine, and avoid sustained high speeds until at least 100 miles (161 km). Check the engine oil and coolant levels frequently. Expect the engine to use a little oil until the rings seat. Change the oil and filter at 500 miles (805 km), 1500 miles (2415 km), then every 3000 miles (4830 km) past that.


Now that you have just gone through all of that hard work, keep yourself from doing it all over again by thoroughly maintaining it. Not that you may not have maintained it before, heck you could have had one to two hundred thousand miles on it before doing this. However, you may have bought the vehicle used, and the previous owner did not keep up on maintenance. Which is why you just went through all of that hard work. See-