FAW Russian Cylinder Block Assembly: 30 Essential Parts for Unstoppable Performance

The FAW Russian Cylinder Block Assembly is the robust core of the CA3250P66K24L1TE5Z dump truck, engineered to conquer the freezing Russian tundra. This guide details the 30 specific components that make up this assembly. Mastering these parts is the key to executing precise maintenance and ensuring your fleet operates reliably in the world’s most demanding cold zones.

FAW Russian Cylinder Block Assembly

The Structural Backbone: Block and Liners

The foundation of the entire system is the Cylinder Block Assembly (Part No. 1002015-35E). This is not a standard casting; it is the “Russian Cold Zone” variant, formulated with a high-strength iron alloy designed to resist the thermal shock of starting in -40°C temperatures. The integrity of this block defines the engine’s lifespan. It houses the critical Cylinder Liner (Part No. 1002016-81D), a replaceable wet sleeve that provides the friction surface for the pistons.

In the FAW Russian Cylinder Block Assembly, the sealing of these liners is paramount. We identify 12 units of the O-Ring Rubber Seal (Part No. 1002017-55R) and 6 units of the O-Ring Rubber Seal (Part No. 1002019-55R). These are not ordinary rubber; they are engineered elastomers capable of maintaining flexibility in sub-zero conditions. A failure here would allow coolant to mix with oil, leading to catastrophic bearing failure, making these small seals some of the most vital components in the entire list.

Securing the external accessories to the block are various specialized covers. The Gear Chamber Cover Plate (Part No. 1002076-81D) and the Gear Chamber Cover – Flywheel Housing (Part No. 1002061-1509) shield the timing gears from debris. In the rugged mining environments of Russia, dust ingress is a constant threat. These covers, sealed strictly against the FAW Russian Cylinder Block Assembly, ensure that the precise timing mechanism remains clean and lubricated.

Bearing and Rotating Assembly Dynamics

The FAW Russian Cylinder Block Assembly supports the crankshaft with a robust bearing system. This includes 7 units of the Lower Main Bearing Shell (Part No. 1002032-81D) and 7 units of the Upper Main Bearing Shell (Part No. 1002031-81D). These shells are composed of a tri-metal material designed to withstand the immense downward pressure of the power stroke. Their ability to retain an oil film is critical for preventing metal-on-metal contact during heavy hauling.

Axial movement of the crankshaft is controlled by the Thrust Washer (Part No. 1002036-53D). We find 4 of these units in the assembly. They prevent the crankshaft from shifting forward or backward when the clutch is engaged. In the FAW Russian Cylinder Block Assembly, maintaining this axial tolerance is essential to prevent side-loading on the connecting rods, which could lead to uneven piston wear and reduced compression over time.

Fluid retention at the front of the engine is handled by the Crankshaft Front Oil Seal Seat (Part No. 1002056-81D). This component must be perfectly aligned to ensure the radial seal functions correctly. Leaks here are common in poorly maintained engines, but the precision machining of the seat in the FAW Russian Cylinder Block Assembly ensures a tight, leak-free fit, keeping oil inside the engine where it belongs.

Cooling Systems and Precision Fasteners

To combat the intense heat of combustion, the FAW Russian Cylinder Block Assembly is equipped with 6 units of the Piston Cooling Nozzle Assembly (Part No. 1002210-81D). These nozzles spray oil directly onto the piston undercrowns. This not only cools the pistons but also provides essential lubrication to the wrist pins. Each nozzle is secured by a specialized Bolt – Piston Cooling Nozzle Assembly (Part No. 1002214A53D-S), ensuring they do not vibrate loose during operation.

The assembly is held together by a specific array of fasteners. For instance, we see 9 units of the Hex Flange Bolt Fine Thread R Type (Part No. Q1821055) and 12 units of the Stud (Part No. 1002043-2000). Using the correct fastener is critical; the “R Type” designation often implies a specific tensile strength or thread profile suited for the high-vibration environment of the FAW Russian Cylinder Block Assembly. Substituting these with generic hardware can lead to stripped threads or sheared bolts.

Finally, identification and logistics are covered by the Nameplate (Part No. 1002091-29D) and its securing Label Rivet (Part No. Q541026). While these may seem minor, the nameplate carries the serial number and specification data of the FAW Russian Cylinder Block Assembly. In a fleet environment, being able to identify the exact batch and manufacturing date of a cylinder block is crucial for tracking service history and ordering the correct spare parts.

Complete 30-Point Parts Breakdown

Below is the comprehensive list of the 30 distinct components contained within the FAW Russian Cylinder Block Assembly breakdown. Please reference these English translations and part numbers for accurate procurement.

Proactive Maintenance for Reliability

Maintaining the FAW Russian Cylinder Block Assembly requires a strict adherence to service protocols. The most common oversight is the condition of the Piston Cooling Nozzle Assembly (Part No. 1002210-81D). Over time, carbon deposits can restrict the flow of oil through these nozzles. In the CA3250P66K24L1TE5Z model, a blocked nozzle leads to rapid piston overheating. We recommend inspecting and ultrasonically cleaning these nozzles during every in-frame overhaul.

Another critical check point is the Thrust Washer (Part No. 1002036-53D). These washers control the crankshaft’s end play. If worn beyond specification, the crankshaft can damage the block saddle. Always measure the end play with a dial indicator before closing the bottom end. Additionally, ensure that the O-Ring Rubber Seal (Part No. 1002017-55R) is lubricated with a rubber-compatible grease during installation to prevent tearing, which is a leading cause of coolant leaks in rebuilt engines.

Finally, pay attention to the Double End Stud (Part No. 1002043-2000). These studs are often subjected to corrosion in the salty road conditions of Russia. Before reassembling the components, chase the threads to ensure accurate torque readings. Ignoring corroded fasteners on the FAW Russian Cylinder Block Assembly can result in loose accessories and vibration damage, compromising the entire vehicle’s reliability.

Conclusion

The FAW Russian Cylinder Block Assembly is a complex masterpiece of engineering, comprising 30 distinct components working in unison. From the heavy-duty Cylinder Block Assembly casting to the precision Piston Cooling Nozzle Assembly, every part is essential for operation in extreme cold. By using only genuine parts and following the maintenance guidelines outlined above, fleet operators can ensure their FAW trucks remain operational and profitable, regardless of the weather conditions.