First start is a controlled inspection—not the beginning of break-in, road testing or full-load tuning. Procedures vary with the engine, ECU, firmware, trigger system and vehicle. Follow Kassel’s project-specific instructions whenever they differ from this checklist.
Mechanical checks
- Verify oil, coolant and transmission-fluid levels
- Prime the oiling system when required
- Confirm spark-plug type, gap and installation
- Inspect belt routing, fans, hoses and wiring
- Check intake, vacuum and charge connections
- Verify fuel-system assembly and plumbing
- Prime the pumps and inspect for leaks
- Fully charge the battery and use an appropriate support charger
Do not continue if a fuel leak is present.
ECU and sensor checks
- Install only approved firmware.
- Save the existing calibration where applicable.
- Load the Kassel-supplied startup calibration.
- Verify plausible coolant and intake-air temperatures.
- Confirm MAP is reasonable for local atmospheric pressure with the engine stopped.
- Verify throttle movement, fuel pressure, ethanol content and other sensors.
- Review current ECU faults.
Cranking checks without fuel
Disable the fuel system using the project-specific method. Confirm stable ECU communication, engine-speed detection, cranking voltage, oil pressure where instrumented, the expected trigger pattern and ignition output.
Ignition synchronization
Ignition synchronization is safety-critical. Verify it only under Kassel’s instructions with the approved timing-light procedure. Do not assume a generic trigger offset is safe.
First start
- Restore and prime the fuel system using the specified base pressure.
- Start without unnecessary throttle input.
- Watch oil pressure, fuel pressure, lambda, coolant temperature and voltage.
- Shut down immediately for abnormal noise, leaks, pressure loss, overheating or implausible data.
- If normal, keep the first run brief and capture the requested log.
- Shut down, inspect again and send the log and current calibration.
Do not begin driving, break-in or dyno testing until Kassel reviews the initial data and the engine builder’s requirements are satisfied.
