Cummins/Onan KTA19-M Engine

⚠ The injector plunger is under spring tension. Do not allow the tool to slip. Personal injury can result.

Tools: Injector and Valve Adjustment Kit Part No. 3375004, Dial Indicator Extension Part No. 3376870, Rocker Lever Actuator Part No. 3376869, Torque Wrench Adapter Part No. ST-669, Inch Pound Torque Wrench Part No. 3376592

1. On engines with STC, remove the wire from the terminal on the oil control valve. Operate engine at high idle for 5 minutes, then shut off.
2. Remove the rocker lever cover and related components (Procedure 07-04).
3. Turn the barring device until the 'A' mark on the pulley aligns with the mark cast into the accessory drive seal boss.
4. Determine the cylinder in position for valve set: if mark A check cylinders 2,5; if B check 3,4; if C check 1,6. Set valves on the cylinder where both levers feel loose.
5. Adjust the crossheads first (loosen locknuts, turn adjusting screw out one turn, hold crosshead down, turn screw in until it touches the valve stem top).
6. Tighten the crosshead lock nut to 35/40 N·m as applicable.
7. Adjust the valves using a feeler gauge: Intake 0.36 mm [0.014 in], Exhaust 0.69 mm [0.027 in].
8. Tighten the locknut to 45 N·m [35 ft-lb] with adapter ST-669 or 60 N·m [45 ft-lb] without adapter.
9. Adjust the injector using the injector and valve adjustment kit Part No. 3375004.
10. Reset to the specified travel: 7.72 mm [0.304 in] less STC; 10.24 mm [0.403 in] with STC.
11. Tighten the locknut to 45 N·m [35 ft-lb] with adapter or 60 N·m [45 ft-lb] without adapter.
12. Rotate the engine, align the next mark, and adjust the appropriate valves and injectors until all are correct.

1. Turn the valve on the filter head to the OFF position.
2. Remove the coolant filter.
3. Use engine oil and lubricate the seal on the filter.
4. Install the coolant filter. Turn until the seal touches the filter head, then an additional half to three-fourths of a turn.
5. Turn the valve to the ON position.

⚠ Wait until the temperature is below 50°C before removing the coolant system pressure cap. Failure to do so can cause personal injury from heated coolant spray.

1. Position the vehicle on level ground. Wait until coolant temperature is below 50°C before removing the pressure cap.
2. Remove the radiator cap after the engine is cool.
3. Open the radiator draincock.
4. Remove the lower radiator hose(s).
5. Open the water pump draincock.
6. Open the oil cooler draincock.

⚠ Check the coolant level only when the engine is stopped. Wait until the temperature is below 50°C [120°F] before removing the pressure cap.

⚠ Do not add cold coolant to a hot engine. Allow the engine to cool to below 50°C [120°F] before adding coolant.

1. Close the radiator draincock.
2. Install the lower radiator hose(s). Tighten the hose clamps to 5 N·m [40 in-lb].
3. Close the engine draincock.
4. Close the oil cooler draincock.
5. Fill with a mixture of 50 percent ethylene glycol antifreeze and 50 percent water to the bottom of the fill neck in the radiator fill tank.
6. Install the radiator or fill cap.
7. Operate the engine until coolant reaches 70°C [160°F] and check for leaks.
8. Shut the engine off and allow it to cool; check the coolant level and add if necessary.

⚠ The fan belt idler is under tension. Do not allow your hands to get between the idler and the belt, or the fan hub. Personal injury can result.

⚠ Be sure the fan idler spring tension is released.

Tools: 8-point socket, breaker bar

1. Use an 8-point socket and breaker bar or large wrench. Hold the idler in position against the spring tension and remove the capscrew.
2. Slowly turn the wrench until the spring tension is relieved.
3. Remove the fan belt.
4. Visually inspect the belt for cracks, glazing, tears or cuts.
5. Install the belt.
6. Rotate the idler against the spring tension until the capscrew holes are aligned. Install the capscrew.
7. Tighten the capscrew to 45 N·m [35 ft-lb].
8. Slowly turn the wrench until the idler is against the belt.

⚠ Do not use Fleetguard No. LF 3325 filters on K19 engines. The cannister seam will touch the head before the seal touches the sealing surface. An oil leak will result.

Tools: Oil Filter Wrench Part No. 3375049

1. Use an oil filter wrench, Part No. 3375049, or equivalent. Remove the full flow oil filters.
2. Discard the filters if they are not needed for a failure analysis.
3. Clean the oil filter head surface.
4. Use engine oil to lubricate the gasket surface of the filters.
5. Fill the filters with clean 15W-40 oil. Install the filters on the oil filter head.
6. Turn the filter until the seal contacts the head. Turn an additional three-fourths of a turn to one turn.
7. Operate the engine and check for leaks.

Tools: Seal driver Part No. 3375411, mallet

1. Open the draincock and remove the lower radiator hose to drain the cooling system.
2. Remove both upper radiator hoses and the vent line from the thermostat housing.
3. Remove by-pass tube clamp. Loosen both hose clamps and remove the by-pass tube.
4. Remove the (5) long capscrews and (1) short capscrew.
5. Remove the thermostat housing and gasket.
6. Remove the thermostats and seals.
7. Use a mallet and seal driver Part No. 3375411 to install the seal (no more than 0.51 mm [0.020] below the top of the cast edge).
8. Install the thermostat by pushing on the outer rim.
9. Install a new gasket, thermostat housing and capscrews; tighten to 45 N·m [35 ft-lb].
10. Install the by-pass tube, retainer and capscrew; tighten to 45 N·m [35 ft-lb] and hose clamps to 5.6 N·m [50 in-lb].
11. Install the two upper radiator hoses and tighten clamps to 5.6 N·m [50 in-lb].
12. Fill the cooling system and operate the engine to 70°C [160°F]; check for leaks.

⚠ This assembly weighs more than 23 kg [50 lb]. Handle securely to avoid dropping.

⚠ Do not tighten any capscrews until the support bracket is aligned.

1. Drain the cooling system (01-06).
2. Disconnect the coolant lines from the air compressor.
3. Remove the air inlet and outlet connections.
4. Remove the fuel pump (05-11).
5. Remove the air compressor support mounting capscrews.
6. Remove the four capscrews and nuts; remove the air compressor and spline coupling; discard the gasket.
7. Install the spline coupling, gasket and compressor.
8. Install the four capscrews and two nuts; keep capscrew loose.
9. Install the two bracket capscrews; the support bracket must be flat against the block.
10. Tighten the compressor to accessory drive capscrews to 45 N·m [35 ft-lb] and bracket to block capscrews to 45 N·m [35 ft-lb].
11. Tighten the bracket to compressor capscrew to 45 N·m [35 ft-lb].
12. Install the fuel pump, air inlet/outlet connections, coolant lines, fill the cooling system and check for leaks.

1. Clean the fuel pump and surrounding area.
2. Disconnect the battery cables.
3. Remove the wire to the fuel shutoff valve.
4. Remove the linkage from the throttle lever.
5. On STC engines, remove the STC fuel rail switch.
6. Remove the fuel tubing and air hose (fuel drain, gear pump cooling drain, gear pump suction, AFC fuel drain, fuel supply to injectors, AFC supply hose, tachometer cable).
7. Remove the four mounting capscrews and the fuel pump; remove the drive coupling and discard the gasket.
8. Install the drive coupling, gasket, fuel pump and four capscrews; tighten to 45 N·m [35 ft-lb].
9. Install the fuel tubing and air hose; install the STC pressure switch, electric wire, linkage and battery cables.
10. Operate the engine to normal operating temperature and check for leaks.

⚠ Do not let the STC tappet fall out of the injector. Damage can result.

⚠ Do not use a wooden tool to push the injector on the seat.

Tools: Injector Puller Part No. 3376497, Injector Puller Part No. 3376000

1. Remove the rocker lever cover (07-04), Jacobs engine brake (07-07), and rocker lever assembly (07-09).
2. On STC engines, remove the STC banjo connector mounting screw and banjo connector; discard sealing washers and o-ring.
3. Remove the injector hold down capscrews and the clamp.
4. For top stop injectors use injector puller Part No. 3376497; for standard injectors use Part No. 3376000 or 3376497 with slide hammer.
5. Remove and identify the o-rings (1 red dot, 2 no markings, 3 green dot) and the sealing ring.
6. Clean and inspect the injector; check the orifice screen and clean if debris is present.
7. Install the proper size seal ring and lubricate o-rings with vegetable oil.
8. Position the injector in the bore with the screen pointing toward the hold-down capscrew hole.
9. Seat the injector with a quick, hard push (a single snapping sound will be heard).
10. Install the hold-down clamp and self-locking capscrews; tighten to 16.2 N·m [145 in-lb].
11. Install the jumper tube, copper sealing washers and connector screw; tighten to 25 N·m [20 ft-lb].
12. Install the rocker lever assembly, Jacobs engine brake, adjust the brake and rocker levers, and install the cover.

⚠ This assembly weighs more than 23 kg [50 lb]. Personal injury can result.

⚠ These parts are a safety-related item. Be sure the parts are clamped correctly to prevent fretting.

1. Remove the intake and exhaust pipes from the turbocharger.
2. Remove the turbocharger air crossover; remove retaining straps and capscrews; discard o-rings and dust seal.
3. Disconnect the oil drain hose.
4. Remove the mounting nuts, washers and the turbocharger; discard the gasket.
5. Install the gasket (word OUT towards turbocharger), turbocharger, washers and nuts; tighten to 35 N·m [25 ft-lb].
6. Position the turbocharger drain tube within 35 degrees of vertical.
7. Install the oil drain tube; tighten capscrews to 45 N·m [35 ft-lb].
8. Pour 50 to 60 cc of clean engine oil into the oil supply fitting.
9. Connect the oil supply hose (AiResearch 45 N·m [35 ft-lb]; Holset 20 N·m [15 ft-lb]).
10. Check and adjust air crossover to turbocharger alignment.
11. Connect the exhaust piping; tighten V band clamp to 4.0 N·m [35 in-lb].