CM6D28 国 IV 系列发动机装配技术条 编号：6D28JT-100-2013

CM6D28 30、40 Engine

Assembly Manual

NO：6D28JT-100-2014

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 CM6D28 国 IV 系列发动机装配技术条 编号：6D28JT-100-2013
件

CONTENT

1 range...............................................................................................................3
2 General technical requirements.........................................................................3
3 Technical requirements for assembly of major parts, components and components
4
4 Use of sealant....................................................................................................11
5 Bolt and nut tightening requirements..............................................................12
6 Main fit clearance..........................................................................14
7 Oil sump oil volume......................................................................17
8 Sealing test..................................................................................17

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 CM6D28 国 IV 系列发动机装配技术条 编号：6D28JT-100-2013
件
CM6D28 Engine assembly technical conditions
1 range
1.1 This standard for CM6D28 d i e s e l a s s e m b l y
2 general technical requirements
2.1 Parts used for diesel engine assembly shall comply with the produ
ct drawings and relevant technical documents and shall pass the i
nspection.
2.2 Before assembly, the parts of the diesel engine should be clean
ed and painted as required.

2.3General rules for bolt tightening: Align the two sides symmetric
ally and crosswise from the center. The tightening torque of the ma
in threaded connection is carried out in accordance with 5.3, tight
ening sequence and tightening according to the torque diagram. If t
he tightening torque is not specified, it shall be performed accord
ing to the tightening torque table of 5.4 ordinary bolts and nuts.
2.4In addition to special requirements, the seals and anti-loose
parts of the diesel engine shall be glued according to the regul
ations. For parts that use sealing and anti-slipping materials,
anti-rust oil should be removed before assembly to meet the requ
irements of gluing. After coating, the extruded rubber must be r
emoved.
2.5When pressing the bowl plugs, it should be coated with Loctite 680 o
r similar compound. The end of the bowl plug should not be higher than
the mounting plane. The screw plug should be coated with Loctite 567 or
similar compound and tightened to the specified torque. After the assem
bly is completed, the sealing test shall be carried out in accordance w
 CM6D28 国 IV 系列发动机装配技术条 编号：6D28JT-100-2013
件
ith the drawings.
2.6All surfaces of the moving friction pair parts should be coated wi
th a certain amount of lubricating oil (in which the surface of the b
earing parts should have more lubricating oil), the lubricating oil m
odel should be consistent with the lubricating oil type of the engine.
2.7When the engine is assembled, when the piston of the first cylinde
r is at top dead center, the 0 scale line on the flywheel should be a
ligned with the top dead center pointer “▽” on the flywheel housin
g.

After the completion of the assembly of the diesel engine, the valve c
learance should be adjusted while ensuring the phase of the diesel eng
ine.the correctness of the match.
2.8When installing the silicone oil damper, crankshaft gear and fly
wheel, the silicone oil damper and the crankshaft front surface, th
e crankshaft gear and the rear end of the crankshaft, and the flywh
eel and crankshaft gears are not allowed to be organic.

三 Assembly technical requirements for main parts, components and components

3.1.1 Cylinder block assembly

3.1.2 The oil passages and waterways on the cylinder block shoul
d be clean and unblocked, and there must be no metal shavings, o
il stains or other sundries, and meet the relevant cleanliness r
equirements.
3.1.3 The surface of the outer surface of the cylinder liner that
is in contact with water shall not be coated with anti-rust paint.
 CM6D28 国 IV 系列发动机装配技术条 编号：6D28JT-100-2013
件
The amount of protrusion on the upper surface of each cylinder s
leeve facing the upper surface of the cylinder block is 0.03-0.08
mm, and the difference between the protrusion amounts of the adja
cent two cylinder sleeves is not more than 0.03 mm.
3.1.4 When assembling the main bearing cap, pay attention to the
pairing mark, and do not reverse the front and rear. When installing
the main bearing bolt, the bearing surface and the thread should be
lubricated. Tighten the main bearing caps in the order shown below.
Cycling the main bearing bolts from the center gear to both ends,
allowing all bolts to be tightened at the same time, allowing repeated
use three times.

2.8.1
2.8.2
2.8.3
2.8.4
2.8.5
2.8.6
2.8.7
2.8.8

3.1.5 When the front end cover, the gear chamber and the cylinder b
lock are assembled, the difference between the lower plane of the f
 CM6D28 国 IV 系列发动机装配技术条 编号：6D28JT-100-2013
件
ront end cover and the lower plane of the cylinder block shall not
exceed 0.18 mm; the lower plane of the gear chamber shall be lower
than the lower plane of the cylinder block, and the drop shall not
be greater than 0.24 mm.
3.1.6 When the gear chamber is assembled with the cylinder block, t
he upper plane of the gear chamber is lower than the upper plane of
the cylinder block, and the drop difference shall not be greater th
an 0.34 mm.
3.1.7 After assembling the piston rod assembly, the piston cooling
nozzle assembly is assembled. After the piston cooling nozzle asse
mbly is installed in the cylinder block, the nozzle direction must
be aligned with the corresponding oil hole of the piston.

3.1.8 The sealing ring is placed around the oil pan, and it is
required to be flat and tight, and the oil pan bolts are tightened
evenly from the middle to the ends.

3.1.9Heat shield bolts, exhaust manifold bolts, studs (connected to t

he supercharger, connected to the exhaust pipe of the vehicle), and t
he anti-bite agent applied to the joints of the front, rear and middl
e sections of the exhaust manifold.
3.2 Piston connecting rod assembly

3.2.1 When installing the piston ring, it is not allowed to scr

atch the piston surface and the piston ring plating, and strictly
ensure that the first ring and the second ring have the TOP mark
facing up, and must not be reversed. After each piston ring is in
stalled in the ring groove, it should be free to rotate. The oil
ring opening is offset from the piston pin by 30° in the axial d
irection. When the cylinder ring is installed, the ring openings
are shifted by 120° from each other. It should be noted that the
oil rings must be assembled in groups, and the inner and outer ri
ngs cannot be misaligned. And the spring lap and the piston ring
opening must be in a 180° relative position.

3.2.2The quality of the piston rod assembly shall not exceed 45g on
the same diesel engine.

3.2.3 When the piston rod assembly is assembled, the connecting

rod FRONT mark and the piston top surface arrow point to the fr
ee end of the crankshaft.
3.2.4 The connecting rod bolts can be reused twice.

3.2.5 After the connecting rod bolts are installed, the clearance betwe
en the two sides of the connecting rod and the crankshaft opening is pe
rformed according to the 6.3 connecting rod axial clearance table.
3.2.6 In order to prevent the cooling nozzle from being damaged duri
ng engine assembly and disassembly. When assembling the engine, firs
t assemble the piston rod assembly and then install the piston cooli
ng nozzle. When disassembling the engine, first remove the cooling n
ozzle and then remove the piston rod assembly.
3.3 Crankshaft assembly
3.3.1 The axial clearance of the crankshaft is performed in accordance w
ith the 6.2 Crankshaft Axial Clearance Table.

3.3.2 After the crankshaft assembly is installed in the cylinder b

lock, tighten the main bearing cap bolts of each gear, install the
piston connecting rod assembly in each cylinder bore, and tighten
the crankshaft return torque after tightening the connecting rod b
olts. The crankshaft reloading torque must not exceed 78.4N.m.。
3.3.4 After the preheating of the oil pump drive gear, it is quick
ly placed on the journal with which it is fitted. The preheating t
emperature is not more than 175 °C, and other reference drawings
are required.
3.3.5 The front and rear oil seals of the crankshaft must use speci
al tools and must not be hammered in! No damage or distortion is al
lowed on the assembled front and rear oil seals.

3.3.6 After the crankshaft oil seal is installed, the A size sh

own in the figure below, the front oil seal of the crankshaft should
be 1.0mm ± 0.1mm, and the oil seal behind the crankshaft should be
1.5mm ± 0.1mm.
3.4 Cylinder head assembly

3.4.1 The oil passages, waterways and air passages on the cylinder
head shall be clean and unobstructed, and shall not contain metal
chips, oil or other debris, and meet the relevant cleanliness requ
irements.
3.4.2 Before installing the injector spacer, apply Loctite 648 or s
imilar compound to the flange surface of the thread and mating surf
ace.
3.4.3 The cylinder head assembly is fastened to the cylinder block,
and the cylinder head bolts should be evenly tightened twice in t
he order shown in the figure below. When the cylinder head bolts a
re installed, the bearing surface and the threads should be lubric
ated. When tightening, tighten them evenly from the middle to the
sides. The main bearing bolts are allowed to be reused three times.

3.4.4 As the cylinder seal corrugation is pressed once, the coati

ng on the steel plate will fall off. Therefore, the cylinder head
gasket can only be used once and cannot be reused. .
3.4.5 Pay attention to the pairing mark when assembling the camshaft
support, and do not install the reverse.

3.4.6 When the camshaft gear is hot-sleeve, the heating temperat

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ure is 190 °C, and the end face of the gear should fit complete
ly with the shoulder surface. When assembling the camshaft assem
bly, the camshaft gear meshes with the mark "●" and the adjustm
ent gear's engagement mark "●
●”
3.4.7 When assembling the valve oil seal, use 80-350N thrust on the fra
me (avoid contact with the top rubber and spring of the oil seal). Push
the valve oil seal (≤200mm/min) at low speed and push the valve oil se
al until it touches the cylinder head. Due to the elasticity of the rub
ber, the maximum rebound is allowed to be 0.5 mm.
3.4.8 The amount of valve sinking is performed according to the 6.7 valv
e sinking scale.

3.4.9 The cylinder cover seal is removed and installed no more than 3 t
imes.

3.5 In-cylinder brake assembly

3.5.1 When installing the exhaust valve valve bridge, be careful th

at the actuator pin is close to the camshaft side and cannot be rever
se mounted.

3.5.2 Adjust the brake clearance: adjust the adjustment screw in th

e brake rocker arm to ensure the clearance between the adjustment s
crew and the execution pin in the exhaust valve bridge. When adjust
ing, ensure that the contact position between the exhaust cam and t
he brake cam and the corresponding rocker arm roller are at the bas
e circle. position.
3.6 Fuel injection pump assembly

3.6.1 The fuel injection pump is not allowed to hold the plastic conn
ector part during transportation and installation.

3.6.2 The fuel injection pump is pre-assembled first, and the connect
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ing flange, O-ring and transmission gear are installed, and at O

Apply Vaseline to the seal.

3.6.3 When installing the gear, first remove the grease on the oi
l pump drive shaft and gear hole surface. The tightening torque of
the gear nut is performed according to the tightening torque table
of 5.3 main threaded joints.
3.6.4 The flywheel is rotated to place the crankshaft into the firs
t cylinder compression top dead center position, and the camshaft g
ear is also at the top dead center position of the cylinder. Turn t
he oil pump transmission gear so that the groove between the marks
“●” and “●” on the transmission gear is aligned with the
“●” groove on the oil pump idler gear. Align the flange of the f
uel pump flange mounting bolt with the mounting hole on the gear ch
amber, and gently push the oil pump in (if the gear can not be mesh
ed smoothly, adjust the left and right for fine rotation) and tight
en the flange mounting bolt.

3.6.5 After the diesel engine is assembled, before the factory test s
tarts, remove the screw plug of the oil pump oil supply port, add 200
ml of the cleaning oil that meets the requirements, and then tighten
the screw plug. The tightening torque refers to the tightening torque
table of the main threaded connecting piece.

3.7 Gear assembly

3.7.1 When assembling the camshaft idler gear, the center of the up
per hole of the camshaft timing gear is aligned with the center of
the sight hole on the cylinder head, and the special bolt is used t
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 o lock to determine the position of the 1 cylinder at the top dead
center.
3.7.2 The meshing clearance between the camshaft idler gear and the adjustme
nt gear is performed in accordance with the 6.8 Gear Engagement Gap Table.

3.7.3 When assembling the gears, ensure that the meshing marks “●”
“●” and “●” (large marking points) are aligned with each other, as
shown in the gear arrangement diagram below.
3.7.4 The gear train has a two-layer structure and is arranged as
shown below.

第一层轮系 第二层轮系

3.7.5 During the installation of the injector, it is forbidden to carry

the injector on the solenoid valve part of the upper part of the injecto
r. Pay attention to protect the terminal of the magnetic valve part and
the information piece of the upper end. The copper gasket of the injecto
r can only be used once. The relevant bolt torque of the oil is to be ca
rried out according to the tightening torque table of the main threaded
connection of 5.3.
3.7.6 It is only allowed to remove the high and low pressure fuel pip
第 13 页/共 17
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e dust caps during installation. The relevant bolt torques for instal
ling high and low pressure fuel pipes are performed according to the
tightening torque table of 5.3 main threaded joints. The tubing pipe
clamps should be evenly distributed. The high-pressure tubing and pip
e clamps are arranged as shown below.

3.7.7 The valve clearance adjustment value is executed according to the

6.6 valve clearance table.

3.7.8 Concentricity tolerance of the inner circle of the groov

e on the flywheel housing with the clutch housing and the cent
er of the crankshaft 0.20.

3.7.9 The flywheel bolts are tightened in a diagonal sequence and

the tightening torque is performed according to the tightening tor
que table of 5.3 Main Threaded Connections, allowing repeated use
twice.
3.7.10 The exhaust pipe fastening bolts shall be sintered with ant
i-sintering agent and symmetrically tightened according to the tig
htening torque table of 5.3 main threaded joints.
3.7.11 Fill the oil filter with oil, apply a small amount of oil
to the seal, turn the filter until the seal contacts the mountin
g surface, continue tightening 3/4 turn or tighten the torque ac
cording to the tightening torque table of 5.3 main threaded conn
ection .

第 14 页/共 17
页
3.7.12 The tightening torque of the front wheel train related parts i
s performed according to the tightening torque table of 5.3 main threa

ded joints. The front wheel train has a two-layer structure, and the b
elt winding direction is as shown below.

第一层轮系 第二层轮系

第 15 页/共 17
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 3.8 Replace the air conditioner compressor and remove the air conditi
oning compressor back pipe

3.8.1 When replacing the air conditioner compressor, system oil qu

antity control must be performed and the O-ring must be replaced.
The air volume compressor system oil quantity control method is: a
pour out the oil in the new compressor; b pour out and measure the
amount of oil in the old compressor; c add the same amount to the
new compressor as the old compressor plus 10 -20ml of fresh frozen
oil.
3.8.2 To remove the rear end of the air
conditioner compressor, the system must
be blocked. If the air conditioning refr
igerant system has been exposed to the a
tmosphere for more than 4 hours, or if t
he air conditioning refrigerant oil is a
lready contaminated, the desiccant must
be replaced. Failure to replace the desi
ccant will result in damage to the air c
onditioning refrigerant system.
3.8.3 When the system does not have enough
refrigerant charge, the compressor should ne
ver work at high speed or for a long time.

4.Use of sealant
4.1 All parts that need to be kept firm after assembly and are not di
sassembled under normal use and maintenance conditions

(such as studs, etc.) should be used to tighten the sealant, where th

e area sealed with a copper gasket is not allowed to be sealed with a
sealant.
4.2 Where there is no gasket between the joint surfaces, it is necessary to
seal the joint surface of oil, water or gas after assembly. Silicone rubber
flat sealant must be used.
4.2.1 The gear chamber and the cylinder block sealing surface are co
ated with Loctite 518 or similar rubber. No breakpoint is required.
It should not be too much to block the oil passage. The sealant coat
ing method is shown in the following figure:

4.2.2 The flywheel shell and the gear chamber sealing surface are coa
ted with Loctite 5910 or similar rubber, requiring no breakpoints, no
t

Too much to block the oil passage, the sealant coating method is show
n below:
 4.2.3 The front end cover of the cylinder block and the sealing su
rface of the cylinder block are coated with Loctite 5910 or similar
rubber, and no break point is required. The sealant coating method i
s shown in the following figure:

4.2.4 All sealed bowls are coated with Loctite 926 sealant. Sealed oil
bowl plugs are not allowed to apply sealant.

5 Bolt and nut tightening requirements

5.1 For all bolts that are tightened by the corner method, oil or mol
ybdenum disulfide must be applied to the threaded surface and the low
er end of the flange during installation.

5.2 Cylinder head bolts, connecting rod bolts, main bearing bolts, flywhe
el bolts and damper bolts shall be marked for the number of bolts used af
ter each use.主要螺纹连接件的拧紧力矩，见下表：
Item Name grade 1st step 2nd step 3rd step remark

1 Main bearing bolt M18X2.0 10.9 225±12Nm 60±5° 180±5° Corner

method
2 Connecting rod cover bolt M14 10.9 105±5Nm 60±5° 60±5° Corner
X1.5 method
3 Shock absorber boltM14X1.5 10.9 85±4Nm 60±5° Corner
method
4 Flywheel bolt M16X1.5 10.9 155±8Nm 90±5° 90±5° Corner
method
5 Cylinder head bolt M16X2.0 10.9 155±8Nm 90±5° 180±5° Corner
method
6 Exhaust pipe bolt M10X1.5 55±5Nm

7 Supercharger nutM10X1.5 65±5Nm

8 Supercharger stud M10X1.5 45±4Nm

9 Heat shield bolt M8X1.25 22±2Nm

10 Intake pipe bolt M8X1.25 8.8 18±3Nm

11 Oil filter 30Nm

High and low pressure oil pipe

12 Oil rail return pipe hinge bo 35±3 Nm

lt M14X1.5
13 Injector return pipe hinge bo 80±5Nm
lt M16X1.5
14 Oil pump lubrication machine 10-15Nm
oil inlet pipe hinge bolt
15 Oil pump end and rail end hig 25-35Nm
h pressure tubing nut
16 Injector end high pressure tu 25-28Nm
bing nut
Front wheel

17 Automatic tensioner bolt 50±5Nm

18 Idler 1 bolt M12X1.75 105±5Nm

19 Idler 2 bolt M10X1. 5 45±5Nm

21 Double gear fixing bolt 10.9 50±10N.m 90°±5 30°±5°

22 Air compressor self-locking n 340 N.m

ut
Engine brake

23 Compression spring bracket bo 19-22Nm

lt M8
24 Solenoid valve connecting bol 11-14Nm
t M6
25 Solenoid valve wiring bolt M4 0.9-1.5Nm
x0.7
26 Adjustment screw nut M8 19-22Nm

Fuel pump

27 Oil pump oil filler plug 35±5Nm

Fuel injection pump

28 Injector platen bolt M7X1.0 10Nm Pre-tig

htening
29 High pressure connection pipe 15-20 Nm Pre-
joint M22x1.5 tighten
ing
30 Injector platen boltM7X1.0 17Nm 90° Corner
method
31 High pressure connection pipe 50-55Nm
joint M22x1.5
32 Injector terminal stud 1.25-1.75Nm

33 Gear nut 250-300 Nm

sensor

34 Intake air temperature sensor 8.8 2.5±1Nm

M6X1.0
35 Water temperature sensor bolt 8.8 23±2Nm
M12X1.5
36 Oil pressure sensor thread M6 8.8 10.5±1Nm
X1.0
37 Speed sensor bolt M6X1.0 8,8 8±2Nm

Inlet/exhaust rocker arm

38 Inlet/exhaust rocker adjustme 8,8 46±7 Nm

nt nut

ATTN：1、When using galvanized threads, the tightening torque shoul

d be reduced by 10%.

2、When the threaded hole material is made of aluminum, the tig

htening torque should be reduced by 10%.
6 Main fit clearance
6.1 Bearing clearance (cold machine)
Bearing Minimum clearance（mm） Max clearance（mm）
Main bearing 0.050 0.114

Connecting rod bearing 0.040 0.106

Connecting rod bushing 0.043 0.069

Double gear bushing 0.040 0.081

Camshaft idler gear 2 bushin 0.030 0.079

g
Camshaft idler gear bushing 0.030 0.079

Fuel injection pump idler bu 0.030 0.079

shing
Air compressor idler gear bu 0.025 0.066
shing
Rocker bushing 0.025 0.066

Camshaft bearing 0.049 0.102

6.2 Crankshaft axial clearance

Min（mm） Max（mm）

Crankshaft axial clearance 0.200 0.420

6.3 connect rod axial clearance

Min（mm） Max（mm）

connect rod axial cle 0.200 0.450

arance
6.4 Camshaft axial clearance
Min（mm） Max（mm）

Camshaft axial clearance 0.150 0.350

 6.5 Piston clearance
Min（mm） Max（mm）

Piston skirt and cylinder liner clearanc 0.111 0.154

e
Piston pin hole and piston pin clearance 0.010 0.026

Clearance between the cylinder head and 0.836 1.724

the top dead center of the piston

Intake valve 0.4mm±0.05mm

Exhaust valve 0.65mm±0.05mm

Braking arm 4.26mm±0.05mm

6.6 Valve clearance

 6.7 Valve sinking
Intake valve 0±0.2mm

Exhaust valve 1±0.2mm

6.8 Gear meshing clearance

Item Part name Max clearance Min clearance Name clearance

Driven ge PTO gear 0.382 0.069 0.2255

ar
Driving g Double gear (pinion gea 0.382 0.069 0.2255
ear r)
Driven ge Power steering oil pump 0.382 0.069 0.2255
ar gear
Driving g Double gear (large gea 0.382 0.069 0.2255
ear r)
Driven ge Double gear (large gea 0.382 0.069 0.2255
ar r)
Driving g Crankshaft gear 0.382 0.069 0.2255
ear
Driven ge Air compressor idler ge 0.382 0.069 0.2255
ar ar
Driving g Crankshaft gear 0.382 0.069 0.2255
ear
Driven ge Air compressor gear 0.349 0.046 0.1975
ar
Driving g Air compressor idler ge 0.349 0.046 0.1975
ear ar
Driven ge Camshaft gear 0.382 0.069 0.2255
ar
Driving g Camshaft idler gear 0.382 0.069 0.2255
ear
Driven ge Camshaft idler gear 0.382 0.069 0.2255
ar
Driving g Adjustment gear 0.382 0.069 0.2255
ear
Driving ge Adjustment gear 0.382 0.069 0.2255
ar
Driving ge Double gear (pinion gea 0.349 0.046 0.1975
ar
 r)
Driven ge Fuel pump gear 0.349 0.046 0.1975
ar
Driving g Fuel pump idler gear 0.349 0.046 0.1975
ear
Driven ge Fuel pump idler gear 0.316 0.022 0.169
ar

Driving Double gear (pinion gea 0.316 0.022 0.169

gear r)
Driven Oil pump gear 0.382 0.069 0.2255
gear
Driving Oil pump idler gear 0.382 0.069 0.2255
gear
7 Oil sump oil volume
generally:

Performance level Suggest :CH-4

Oil sump oil volume

Max volume 38L

Min volume 30L

8.Sealing test

Item Name control parameter

1 Cylinder block oil se 3

2.5bar（20℃）,5 cm /min ，Hold pressure for two minutes
al test
2 Cylinder waterway sea 3
1.5bar（20℃）, 8 cm /min ，Hold pressure for two minutes In
l test
stall the cylinder liner and O-ring;
3 Cylinder head oil pas 3
2.5bar（20℃）,8 cm /min ，Hold pressure for two minutes
sage seal test
4 Cylinder head waterwa 3
1.5bar（20℃）, 12 cm /min ，Hold pressure for two minutes
y seal test
5 Cylinder head fuel pa 3
2.5bar（20℃）,8 cm /min ，Hold pressure for two minutes
ssage seal test