SANY Hexagon Screw Plug 160102120008A007 – Precision Port Seal for D12/D09
160102120008A007
Hexagon Screw Plug
Шестигранная заглушка
Tapón roscado hexagonal
🔧 Seal access ports with genuine SANY parts – the OEM threaded plug 160102120008A007 (Hexagon Screw Plug). This precision‑machined hexagon screw plug is a critical sealing component within the SANY Engine Block Group, specifically designed to close access ports and fluid galleries on D12 and D09 heavy‑duty diesel engines. The 160102120008A007 hexagon screw plug prevents oil and coolant leaks where threaded access ports are required for machining or service. When rebuilding your engine or replacing worn sealing plugs, this genuine SANY component guarantees correct thread fit, optimal torque retention, and leak‑free operation in demanding construction, mining, and heavy transport applications.
The 160102120008A007 Hexagon Screw Plug is a precision‑engineered threaded sealing component within the SANY Engine Block Group. According to the SANY Engine Block Group parts catalog, this plug is listed alongside other critical sealing elements such as Corehole plugs (60272566), Pulling Rivets (160102120008A009), Washers (160102120008A008), and Plug, Threaded, Socket Head Cap (60272464).
The 160102120008A007 is specifically used to seal threaded access ports in the engine block, oil galleries, and coolant passages. These ports are necessary for the casting and machining processes but must be sealed during engine assembly to prevent fluid leaks. The hexagon head allows for easy installation and removal using standard wrenches, which is essential during engine overhaul and maintenance.
The SANY D12 engine, jointly developed with DEUTZ, has a displacement of 12.12 liters and six cylinders. It delivers 360 kW (490 hp) at 1,900‑2,100 rpm, with a maximum torque of 2,150 Nm. This high‑output engine requires an exceptionally robust sealing system. The 160102120008A007 plug ensures that oil galleries and coolant passages remain leak‑free under peak cylinder pressures, contributing to the engine’s reliability and durability.
The D12 engine meets Euro VI emission regulations through its 1,800 bar common‑rail injection system. Its low idle speed of 525 rpm reduces component wear and extends service life. The 160102120008A007 screw plug works in conjunction with other sealing components including Corehole plug 16/10 (61000765) and threaded socket head cap plugs (60272464) to ensure complete leak‑proof sealing of all machining passages and fluid galleries.
The 160102120008A007 hexagon screw plug is manufactured from high‑strength, corrosion‑resistant steel. The threads are precision‑rolled to ensure a consistent fit and to prevent galling during installation. The hexagon head is designed to withstand the recommended tightening torque without stripping. A metallic sealing washer or anaerobic thread sealant may be used depending on the specific engine location and SANY service manual recommendations.
The D12 engine has been widely applied in SANY truck mixers, dump trucks, truck‑mounted pumps, compact rollers, excavators, port machinery, and ultra‑high‑pressure pumps. Wherever these engines operate, the reliability of every fluid joint depends on using genuine SANY sealing components. Aftermarket hexagon screw plugs may have incorrect thread pitch, poor material quality, or insufficient hardness, leading to thread damage or fluid leaks.
Why the 160102120008A007 Hexagon Screw Plug Ensures Leak‑Free Sealing
Precision‑Rolled Threads
The 160102120008A007 features precision‑rolled threads that provide a perfect fit with the engine block’s tapped holes. This eliminates thread galling and ensures consistent sealing torque, preventing fluid leaks even after repeated removal and reinstallation during maintenance.
Corrosion‑Resistant Material
The 160102120008A007 is manufactured from corrosion‑resistant steel that withstands engine oil, diesel fuel, and ethylene glycol coolant. This prevents the plug from seizing in the threaded bore, which is a common problem with uncoated steel plugs in harsh engine environments.
Hexagon Head Design
The hexagon head allows for easy installation and removal using standard socket or open-end wrenches. This simplifies engine maintenance and eliminates the need for special tools, reducing service time and the risk of damaging the plug or the engine block.
Genuine SANY Traceability
Each 160102120008A007 hexagon screw plug is part of SANY’s certified parts system, with full material traceability and dimensional verification. Aftermarket plugs may have incorrect thread class or hardness, leading to thread stripping, fluid leaks, or plug blow‑out under pressure.
Technical Specifications – Hexagon Screw Plug 160102120008A007
The role of the hexagon screw plug in the D12 engine sealing system: During the casting and machining of the SANY D12 engine block, various access ports are required for tool access, cleaning, and fluid distribution. Some of these ports are threaded to accept a hexagon screw plug like the 160102120008A007. Unlike expansion corehole plugs that are permanently deformed, the hexagon screw plug can be removed and reinstalled during engine service, allowing access to internal oil or coolant passages. When tightened to the specified torque, the plug’s flat washer face compresses to form a seal directly against the engine block surface, or it may use a separate sealing washer.
Every component within the SANY Engine Block Group, including the 160102120008A007 hexagon screw plug, undergoes rigorous quality control. The threads are inspected for pitch diameter and surface finish; the hardness is verified; and a sample from each batch is torque‑tested. For operators performing major engine overhauls, it is essential to replace any plug that shows thread damage or corrosion. Reusing a damaged plug can lead to thread stripping in the engine block, a costly repair. Replacing it with a genuine SANY 160102120008A007 restores the original sealing integrity and ensures reliable fluid containment.
Installation of the 160102120008A007 hexagon screw plug begins with cleaning the threaded hole in the engine block. Remove any old thread sealant, debris, or corrosion using a thread chaser or tap of the correct size. Apply a small amount of SANY‑approved thread sealant or engine oil to the threads as specified in the service manual. Some locations require a sealing washer (such as 160102120008A008) while others rely solely on the plug’s flat face.
Thread the plug into the hole by hand to avoid cross‑threading. Once finger‑tight, use a torque wrench with the correct hex socket to tighten the plug to the specified torque (typically 25 N·m or as indicated in the SANY service manual). Overtightening can strip the threads in the engine block or crack the surrounding casting. Undertightening will cause fluid leaks. After tightening, clean any excess sealant from around the plug head.
Common installation errors include: using the wrong thread size or pitch, failing to clean the threaded hole, applying too much sealant which can contaminate oil galleries, bending or damaging the sealing washer, and using a standard wrench instead of a torque wrench. A correctly installed hexagon screw plug will be flush or slightly recessed and show no signs of leakage after the engine reaches operating temperature.
For SANY equipment operating in severe conditions, inspect the hexagon screw plugs for signs of leakage at every service interval. If oil or coolant weeps from the plug, check the tightening torque. If the torque is correct and leakage persists, replace the plug and its sealing washer. Over time, the plug’s threads may corrode or the seal can degrade. Replacing the plug at major engine overhaul (10,000‑12,000 hours) is a low‑cost preventive measure.
Applications of Hexagon Screw Plug 160102120008A007
- SANY Kingway 435 Heavy Trucks
- SANY SYZ324C-8 / SYZ425C‑8 Dump Trucks
- SANY SYZ432C-8 / SYZ436C‑9S Dump Trucks
- SANY SKT105 Mining Dumpers
- SANY Concrete Mixer Trucks
- SANY SY / SYH Series Excavators
- SANY Truck‑Mounted Pumps
- SANY D12 / D09 / D06 Series Diesel Engines
Hexagon screw plug failure symptoms and replacement criteria: Common signs of a failed or failing plug include visible oil or coolant weeping around the hex head, buildup of dried fluid residue, torque loss when re‑tightening, and stripped or damaged threads on the plug or in the engine block. The 160102120008A007 should be replaced if the hexagon head shows signs of rounding (making it difficult to remove with a wrench), if the threads are damaged, or if the sealing face is pitted or scratched. A plug that will not reach the specified torque without continuing to turn must be removed and inspected for thread damage.
For severe service conditions, inspect the hexagon screw plug at every major service interval. When replacing a plug, always use a genuine SANY part. Aftermarket plugs may have incorrect thread class, insufficient hardness, or poor corrosion resistance, leading to thread galling, seizing, or leakage. After installation, run the engine and inspect for leaks. If any leakage is observed, remove the plug, re‑clean the threads, apply fresh sealant, and re‑torque. If leakage persists, the engine block threads may be damaged and require repair with a thread insert.
To verify authenticity, inspect the 160102120008A007 hexagon screw plug for the SANY logo and part number stamped on the hex head. Genuine SANY plugs have a crisp hex shape, clean thread finish, and uniform coating. Aftermarket plugs often have poorly defined hex corners, rough thread surfaces, or no markings. Always source from authorised SANY parts distributors to ensure warranty coverage and long‑term reliability.
When ordering, provide your engine serial number (ESN). The 160102120008A007 is part of the SANY Engine Block Group and is used as a dedicated sealing plug on D12 and D09 engines. One plug is required per crankcase assembly. Ensure you also purchase the correct sealing washer (160102120008A008) if specified for your engine. Always refer to the SANY parts catalog to confirm the exact application.
- 160102120008A007 – Hexagon Screw Plug (this item)
- 160102120008A008 – Washer (sealing washer for this plug)
- 60272566 – Corehole Plug (companion sealing element)
- 61000765 – Corehole plug 16/10
- 160102120008A009 – Pulling Rivet
- 60272464 – Plug, Threaded, Socket Head Cap
- 160102130004A027 – Crankcase Assembly
- SANY‑approved thread sealant
- Clean threaded hole thoroughly using a thread chaser
- Inspect plug threads for damage or corrosion
- Apply SANY‑approved thread sealant to the plug threads (if required)
- Install new sealing washer (160102120008A008) if specified
- Hand‑thread plug into hole to avoid cross‑threading
- Torque plug to specification using calibrated torque wrench
- Clean excess sealant from around plug head
- After engine run, inspect for leaks and re‑torque if necessary
Genuine SANY 160102120008A007 – Precision Sealing for Engine Block Ports.
Corrosion‑resistant hexagon screw plug with precision‑rolled threads and reliable sealing face. Designed for SANY D12/D09/D06 engines in trucks, dumpers, mixers, and construction equipment. OEM‑certified, 12‑month warranty, full batch traceability.
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