Cummins/Onan — Exhaust System Assembly
Repair & overhaul
From a Cummins/Onan service manual — check it applies to your exact model before use.
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Before you start
- Inhalation of exhaust gases might result in severe personal injury or death.
Procedure
- Install exhaust manifold using new gaskets. Tighten four exhaust manifold screws to specified torque.
- Secure exhaust downpipe to manifold using 5/16-18 bolts, lock washers, and nuts. Use new asbestos gasket.
- Attach muffler inlet to downpipe using a 1-5/8 inch automotive U-bolt clamp. Tighten securely.
- Attach tailpipe to muffler outlet and support using a shock mounted support hanger with clamp.
- Run generator set five minutes and check entire exhaust system for leaks or excessive noise.
Tools required
- 1-5/8 inch U-bolt clamp Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Source: Cummins/Onan service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.