Long Block Break-in instructions

1998-2024 Precision Plus and Essential Long blocks

Engine Break In Procedure

1998-2024 Precision Plus and Essential Long blocks

Thank you for your purchase of your new D&J Precision Machine Engine. We have created this break in procedure to ensure optimum performance of your new engine.

Every engine comes pre-lubed with 12 quarts of VR1 20W-50 race oil and a filter. We have found this oil works very well with break in.Your engine has been pressure-checked for oil and crankcase leaks. It has also been pressure checked for coolant leaks. Your engine is ready to start putting on your accessories, wiring harness, turbo, and fuel system. There are a few steps we recommend for proper break in.

Step 1: Install engine in truck. Only hook up fuel system, transmission, turbo with oil supply and return, all electrical plug-ins to run the engine. Install radiator and intercooler piping. Do not fill the radiator at this time.  Install an external mechanical oil pressure gauge, crank the engine with the injectors unplugged, and fuel supply pump off (this helps not to build rail pressure and add more load to the starter) until you start to get oil pressure.  Be careful not to overheat your starter; it may take a few minutes to get oil pressure.   Plug everything in and clear codes.

Step 2: Start the engine with no coolant in it. After the engine is running and reading good oil pressure you are going to increase engine RPM to 1,800 rpm and hold it steady for five minutes. Try not to let the engine idle more than necessary. We have found it causes piston rings to glaze and hinders camshaft break in. There will be a little oil residue coming from the exhaust side of the turbo or smoke out the tailpipe depending if your downpipe is hooked up. This is normal. The oil that is used in assembly is burning off or working its way out of the combustion chamber.  It is a good idea to have a friend watch for leaks.

Step 3: After the five minutes run time is complete you can shut off the engine and check for any leaks. This is a good time to make sure all fuel lines are tight and look for any issue with turbo oil lines. If everything looks good, let the engine cool, and fill the engine with coolant. We recommend leaving the heater core hose off the top of the cylinder head as you are filling the radiator with coolant. This allows air to escape the engine as you are filling it. This also allows the cylinder head to be completely filled with coolant and not have any air trapped in the coolant passages. As you are filling the radiator, watch the fitting for coolant. When the coolant starts to come out of the fitting, install the hose, tighten the clamp. Finish filling the radiator. 

Step 4: After the engine is filled with coolant, a 20 minute run at 1,800 rpm can be done. Once again do not let the engine idle for an excessive amount of time. This helps in bringing the engine up to temperature. We recommend stopping every five to ten minutes and checking for leaks or other issues if you are working by yourself. The engine can be left running during these checks. After the 20 minute run, shut off the engine. 

Step 5: Drain oil and change the filter. A hot re-torque can be done at this time. Remove valve cover, injector wiring harness and rocker box. Intake rockers will also need to be removed at this time to re-torque head studs. We recommend removing intake rockers on the stud being tightened then replaced after torquing to help with checking valve lash in the next step. D&J head studs are re-torqued to 125 ft. lbs starting in the center of the engine and working out towards the ends alternating from side to side.   After re-torque intake rockers can be torqued to 26ft/lbs.

 

D&J Precision Machine Engine Limited Warranty 

Engine Warranty Coverage

Our engine limited warranty covers defects in workmanship under normal use for a period of 2 years or 100,000 miles, whichever comes first, from the date of purchase. The Street Performance Series Engines, Performance Series Engines, Predator Engines, and Enforcer 6.7 Cummins Engines have a 90-day warranty coverage period.

Registration

Register your engine within 30 days of purchase.  Failure to do so will void your warranty.  

Terms and Conditions

This engine warranty is valid only if:
- The engine is installed by a D&J Precision Machine approved technician.
- Regular maintenance is performed according to our schedule.
- Exclusions apply for misuse, unauthorized modifications, lack of proper maintenance, abuse, neglect, overloading, overheating, fuel system failures, or tuning. D&J Precision Machine can only cover workmanship-style errors.
- Proper break-in procedures must be followed as outlined in our break-in procedure documentation.
- If an engine is misdiagnosed by the shop, D&J Precision Machine will not be responsible for any costs associated with the misdiagnosis. The customer and/or shop will be responsible for D&J Precision Machine's time, materials, and shipping if misdiagnosed.

Claim Process

  1. Contact Us: Report issues to our customer service at 740-297-7223 or warranty@djprecisionmachine.com.
    2. Submit Documentation: Provide proof of purchase, registration, maintenance records, and pictures and/or video of the issue. No warranty claims will be approved without photos and/or video documentation.
    3. Inspection: Have the engine inspected by an authorized dealer.
    4. Estimate: Provide an estimate before any work is performed. If any work is performed before approval from D&J Precision Machine, we will not pay for the work.
    5. Approval: Receive written approval or denial of the claim.

Repair or Replacement

Approved claims will result in repair or replacement of defective parts or the engine. Labor costs up to $100 per hour using flat rate, and shipping will be covered for approved claims. 

Customer Responsibilities

Maintain your engine according to the provided maintenance schedule and keep detailed records.  Maintain proper fluid levels.  If an oil, or coolant leak causes a more extensive failure that will not be covered.

Limitations

Our liability is limited to repair or replacement. We are not liable for consequential or incidental damages.

Contact Information

For engine warranty claims, contact:
- Phone: 740-297-7223
- Email: warranty@djprecisionmachine.com
- Mailing Address: D&J Precision Machine, 706 Woodlawn Avenue, Cambridge, OH, 43725

Engines Covered by the Warranty

Engine Model Warranty Period Coverage
Essential Reman Engines 2 years / 100,000 miles Parts & Labor
Precision Plus Reman Engines 2 years / 100,000 miles Parts & Labor
Heavy Hauler Engines 2 years / 100,000 miles Parts & Labor
Street Performance Series Engines 90 days Parts & Labor
Performance Series Engines 90 days Parts & Labor
Predator Engines 90 days Parts & Labor
Enforcer 6.7 Cummins Engines 90 days Parts & Labor

Additional Exclusions for Essential Reman Engines:

  • We cannot cover oil leaks except for the timing gear housing to block.
  • Since there are many factors out of our control that need to be completed by the end user or the shop doing the install, we cannot cover any failures related to oil contamination or failures due to lack of oil pressure on start-up.

Step 6: We also recommend rechecking valve lash at this time. Valve lash needs to be checked at top dead center on number one or number six cylinder. Bring the top dead center mark on the harmonic balancer to the 12:00 o'clock position. If both number one cylinder rocker levers are loose, continue to the next step. If both number one cylinder rocker levers are not loose, rotate the crankshaft 360 degrees.
With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5  . Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Valve lash should be .010” on intake and .020” on exhaust. If the measurement falls within  the limits, adjustment/resetting is not necessary. If measurement finds the lash outside  of the limits, adjustment/resetting is required.

 If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained. Tighten the lock nut to 24 Nm (18 ft. lbs.) and re-check the valve lash. Using the crankshaft barring tool, rotate the crankshaft   one revolution (360°) to align the damper TDC mark to the 12 o'clock position. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6  . Use the same method as above for determining whether valve adjustment is necessary, and adjust those that are found to be outside of the limits.

  If everything checks out you can reinstall rocker box, injector harness, and valve cover.

Step 7: Re-fill engine with oil. We recommend using Hot Shot Secret Green or Blue Diamond full synthetic 15w-40. We have seen good results with these oils. We recommend changing your oil based on usage and horsepower. The more horsepower means more frequent oil change intervals. We have seen oil quality can affect the amount of blow-by an engine can have and ring retention.  Always check engine oil level and also for how clean the oil is. If the oil stains your skin black then it is overdue to be changed. This means the oil is full of soot from combustion and is not going to be as effective in lubricating or cleaning.

These seven steps should ensure a proper break in procedure for your new engine. If you have any further questions, don’t hesitate to call. We will be happy to answer any questions you might have. Thank  you for your purchase.

Engine Break In Procedure

2003-2024 Heavy Hauler, Street Performance, Performance Series, Predator, and Enforcer

Thank you for your purchase of your new D&J Precision Machine Engine. We have created this break in procedure to ensure optimum performance of your new engine.

Every engine comes pre-lubed with 12 quarts of VR1 20W-50 race oil and a filter. We have found this oil works very well with break in.Your engine has been pressure checked for oil and crankcase leaks. It has also been pressure checked for coolant leaks. Your engine is ready to start putting on your accessories, wiring harness, turbo, and fuel system. There are a few steps we recommend for proper break in.

Step 1: Install engine in truck. Only hook up fuel system, transmission, turbo with oil supply and return, all electrical plug-ins to run the engine. Install radiator and intercooler piping. Do not fill the radiator at this time.  Install an external mechanical oil pressure gauge, crank the engine with the injectors unplugged, and fuel supply pump off (this helps not to build rail pressure and add more load to the starter) until you start to get oil pressure.  Be careful not to overheat your starter; it may take a few minutes to get oil pressure.   Plug everything in and clear codes.

Step 2: Start the engine with no coolant in it. After the engine is running and reading good oil pressure you are going to increase engine RPM to 1,800 rpm and hold it steady for five minutes. Try not to let the engine idle more than necessary. We have found it causes piston rings to glaze and hinders camshaft break in. There will be a little oil residue coming from the exhaust side of the turbo or smoke out the tailpipe depending if your downpipe is hooked up. This is normal. The oil that is used in assembly is burning off or working its way out of the combustion chamber.  It is a good idea to have a friend watch for leaks.

Step 3: After the five minutes run time is complete you can shut off the engine and check for any leaks. This is a good time to make sure all fuel lines are tight and look for any issue with turbo oil lines. If everything looks good, let the engine cool, and fill the engine with coolant. We recommend leaving the heater core hose off the top of the cylinder head as you are filling the radiator with coolant. This allows air to escape the engine as you are filling it. This also allows the cylinder head to be completely filled with coolant and not have any air trapped in the coolant passages. As you are filling the radiator, watch the fitting for coolant. When the coolant starts to come out of the fitting, install the hose, tighten the clamp. Finish filling the radiator. 

Step 4: After the engine is filled with coolant, a 20 minute run at 1,800 rpm can be done. Once again do not let the engine idle for an excessive amount of time. This helps in bringing the engine up to temperature. We recommend stopping every five to ten minutes and checking for leaks or other issues if you are working by yourself. The engine can be left running during these checks. After the 20 minute run, shut off the engine. 

Step 5: Drain oil and change the filter. A hot re-torque can be done at this time. Remove valve cover, injector wiring harness and rocker box. Intake rockers will also need to be removed at this time to re-torque head studs. We recommend removing intake rockers on the stud being tightened then replaced after torquing to help with checking valve lash in the next step. D&J 9/16” head studs are re-torqued to 175 ft. lbs starting in the center of the engine and working out towards the ends alternating from side to side.  If your engine has been built with a different stud use their torque spec.  After re-torque intake rockers can be torqued to 26ft/lbs.

 

D&J Precision Machine Engine Limited Warranty 

Engine Warranty Coverage

Our engine limited warranty covers defects in workmanship under normal use for a period of 2 years or 100,000 miles, whichever comes first, from the date of purchase. The Street Performance Series Engines, Performance Series Engines, Predator Engines, and Enforcer 6.7 Cummins Engines have a 90-day warranty coverage period.

Registration

Register your engine within 30 days of purchase.  Failure to do so will void your warranty.  

Terms and Conditions

This engine warranty is valid only if:
- The engine is installed by a D&J Precision Machine approved technician.
- Regular maintenance is performed according to our schedule.
- Exclusions apply for misuse, unauthorized modifications, lack of proper maintenance, abuse, neglect, overloading, overheating, fuel system failures, or tuning. D&J Precision Machine can only cover workmanship-style errors.
- Proper break-in procedures must be followed as outlined in our break-in procedure documentation.
- If an engine is misdiagnosed by the shop, D&J Precision Machine will not be responsible for any costs associated with the misdiagnosis. The customer and/or shop will be responsible for D&J Precision Machine's time, materials, and shipping if misdiagnosed.

Claim Process

  1. Contact Us: Report issues to our customer service at 740-297-7223 or warranty@djprecisionmachine.com.
    2. Submit Documentation: Provide proof of purchase, registration, maintenance records, and pictures and/or video of the issue. No warranty claims will be approved without photos and/or video documentation.
    3. Inspection: Have the engine inspected by an authorized dealer.
    4. Estimate: Provide an estimate before any work is performed. If any work is performed before approval from D&J Precision Machine, we will not pay for the work.
    5. Approval: Receive written approval or denial of the claim.

Repair or Replacement

Approved claims will result in repair or replacement of defective parts or the engine. Labor costs up to $100 per hour using flat rate, and shipping will be covered for approved claims. 

Customer Responsibilities

Maintain your engine according to the provided maintenance schedule and keep detailed records.  Maintain proper fluid levels.  If an oil, or coolant leak causes a more extensive failure that will not be covered.

Limitations

Our liability is limited to repair or replacement. We are not liable for consequential or incidental damages.

Contact Information

For engine warranty claims, contact:
- Phone: 740-297-7223
- Email: warranty@djprecisionmachine.com
- Mailing Address: D&J Precision Machine, 706 Woodlawn Avenue, Cambridge, OH, 43725

Engines Covered by the Warranty

Engine Model Warranty Period Coverage
Essential Reman Engines 2 years / 100,000 miles Parts & Labor
Precision Plus Reman Engines 2 years / 100,000 miles Parts & Labor
Heavy Hauler Engines 2 years / 100,000 miles Parts & Labor
Street Performance Series Engines 90 days Parts & Labor
Performance Series Engines 90 days Parts & Labor
Predator Engines 90 days Parts & Labor
Enforcer 6.7 Cummins Engines 90 days Parts & Labor

Additional Exclusions for Essential Reman Engines:

  • We cannot cover oil leaks except for the timing gear housing to block.
  • Since there are many factors out of our control that need to be completed by the end user or the shop doing the install, we cannot cover any failures related to oil contamination or failures due to lack of oil pressure on start-up.

Step 6: We also recommend rechecking valve lash at this time. Valve lash needs to be checked at top dead center on number one or number six cylinder. Bring the top dead center mark on the harmonic balancer to the 12:00 o'clock position. If both number one cylinder rocker levers are loose, continue to the next step. If both number one cylinder rocker levers are not loose, rotate the crankshaft 360 degrees.
With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5  . Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Valve lash should be .010” on intake and .020” on exhaust. If the measurement falls within  the limits, adjustment/resetting is not necessary. If measurement finds the lash outside  of the limits, adjustment/resetting is required.

 If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained. Tighten the lock nut to 24 Nm (18 ft. lbs.) and re-check the valve lash. Using the crankshaft barring tool, rotate the crankshaft   one revolution (360°) to align the damper TDC mark to the 12 o'clock position. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6  . Use the same method as above for determining whether valve adjustment is necessary, and adjust those that are found to be outside of the limits.

  If everything checks out you can reinstall rocker box, injector harness, and valve cover.

Step 7: Re-fill engine with oil. We recommend using Hot Shot Secret Blue Diamond full synthetic 15w-40, Black Diamond Outlaw Full Synthetic (non emissions trucks), or Hot Shot’s Secret Adrenaline R4 Full Synthetic (race vehicles) . We have seen good results with these oils. We recommend changing your oil based on usage and horsepower. The more horsepower means more frequent oil change intervals. We have seen oil quality can affect the amount of blow-by an engine can have and ring retention.  Always check engine oil level and also for how clean the oil is. If the oil stains your skin black then it is overdue to be changed. This means the oil is full of soot from combustion and is not going to be as effective in lubricating or cleaning.

These seven steps should ensure a proper break in procedure for your new engine. If you have any further questions, don’t hesitate to call. We will be happy to answer any questions you might have. Thank  you for your purchase.

D&J Engine Warranty

D&J Precision Machine Engine Limited Warranty 

Engine Warranty Coverage

Our engine limited warranty covers defects in workmanship under normal use for a period of 2 years or 100,000 miles, whichever comes first, from the date of purchase. The Street Performance Series Engines, Performance Series Engines, Predator Engines, and Enforcer 6.7 Cummins Engines have a 90-day warranty coverage period.

Registration

Register your engine within 30 days of purchase.  Failure to do so will void your warranty.  

Terms and Conditions

This engine warranty is valid only if:
- The engine is installed by a D&J Precision Machine approved technician.
- Regular maintenance is performed according to our schedule.
- Exclusions apply for misuse, unauthorized modifications, lack of proper maintenance, abuse, neglect, overloading, overheating, fuel system failures, or tuning. D&J Precision Machine can only cover workmanship-style errors.
- Proper break-in procedures must be followed as outlined in our break-in procedure documentation.
- If an engine is misdiagnosed by the shop, D&J Precision Machine will not be responsible for any costs associated with the misdiagnosis. The customer and/or shop will be responsible for D&J Precision Machine's time, materials, and shipping if misdiagnosed.

Claim Process

  1. Contact Us: Report issues to our customer service at 740-297-7223 or warranty@djprecisionmachine.com.
    2. Submit Documentation: Provide proof of purchase, registration, maintenance records, and pictures and/or video of the issue. No warranty claims will be approved without photos and/or video documentation.
    3. Inspection: Have the engine inspected by an authorized dealer.
    4. Estimate: Provide an estimate before any work is performed. If any work is performed before approval from D&J Precision Machine, we will not pay for the work.
    5. Approval: Receive written approval or denial of the claim.

Repair or Replacement

Approved claims will result in repair or replacement of defective parts or the engine. Labor costs up to $100 per hour using flat rate, and shipping will be covered for approved claims. 

Customer Responsibilities

Maintain your engine according to the provided maintenance schedule and keep detailed records.  Maintain proper fluid levels.  If an oil, or coolant leak causes a more extensive failure that will not be covered.

Limitations

Our liability is limited to repair or replacement. We are not liable for consequential or incidental damages.

Contact Information

For engine warranty claims, contact:
- Phone: 740-297-7223
- Email: warranty@djprecisionmachine.com
- Mailing Address: D&J Precision Machine, 706 Woodlawn Avenue, Cambridge, OH, 43725

Engines Covered by the Warranty

Engine Model Warranty Period Coverage
Essential Reman Engines 2 years / 100,000 miles Parts & Labor
Precision Plus Reman Engines 2 years / 100,000 miles Parts & Labor
Heavy Hauler Engines 2 years / 100,000 miles Parts & Labor
Street Performance Series Engines 90 days Parts & Labor
Performance Series Engines 90 days Parts & Labor
Predator Engines 90 days Parts & Labor
Enforcer 6.7 Cummins Engines 90 days Parts & Labor

Additional Exclusions for Essential Reman Engines:

  • We cannot cover oil leaks except for the timing gear housing to block.
  • Since there are many factors out of our control that need to be completed by the end user or the shop doing the install, we cannot cover any failures related to oil contamination or failures due to lack of oil pressure on start-up.

Contact us

D&J Precision Machine 706 Woodlawn Ave. Cambridge, Ohio 43725 (740) 297-7223 info@djprecisionmachine.com