SINOTRUK Genuine Engine Assembly AZ6100004301 – Heavy Duty Truck Engine for HOWO & STEYR Models

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‌SINOTRUK AZ6100004301 Engine Installation Guide‌

‌Preparation‌

1. ‌Clean Components‌

   • Thoroughly degrease and remove contaminants from the cylinder block, crankshaft, and piston assemblies prior to installation.
   • Ensure oil passages are unobstructed using compressed air and lint-free cloths.

2. ‌Alignment Checks‌

   • Verify engine mounting brackets match the chassis specifications (HOWO A7/ZZ1257N3847W models).
   • Confirm bolt hole patterns on the flywheel align with transmission input shaft.

‌Installation Steps‌

‌1. Engine Positioning‌

• Use a hydraulic lift to lower the engine into the chassis bay, ensuring alignment with transmission mounts.
• Temporarily secure with M16 mounting bolts (Grade 10.9) at 50% torque (220N·m).

‌2. Crankshaft Assembly‌

• Apply SAE 15W-40 oil to main bearing journals before placing the crankshaft.
• Install main bearing caps with original matched pairs and torque to 180N·m in cross-sequence.
• Check axial play (0.10-0.35mm) with a dial indicator.

‌3. Piston & Connecting Rod‌

• Position piston rings with gaps staggered 120° apart.
• Lubricate cylinder walls and use ring compressor for insertion.
• Tighten connecting rod bolts diagonally to 120N·m + 90° rotation.

‌4. Cylinder Head Assembly‌

• Install pre-torqued cylinder head bolts (80N·m initial, then 160N·m final in 3 stages).
• Adjust valve clearance to 0.30mm (intake) and 0.35mm (exhaust) after thermal stabilization.

‌5. Auxiliary Systems‌

• Connect fuel lines with anti-leak clamps and torque banjo fittings to 45N·m.
• Route coolant hoses without kinks and bleed air via the highest radiator port.

‌Post-Installation Checks‌

1. ‌Torque Verification‌

   • Re-check all critical fasteners (mounting bolts, bearing caps) after 24 hours.

2. ‌Initial Startup‌

   • Prime the lubrication system by cranking until oil pressure reaches 2.5bar.
   • Monitor coolant temperature and exhaust emissions during 30-minute idle run.

‌Compatibility Notes‌

• Designed for SINOTRUK WD615.96 diesel engines in HOWO A7 6×4 trucks.
• Includes pre-calibrated ECU for Euro III compliance (no remapping required).