Cummins/Onan — Injection Pump Installation
Installation
From a Cummins/Onan service manual covering: 2.5A, 2.5L, 2.7 AJ, 4.0CCK, 6.0CCKB, 6.5 NH, JC - 3CR / 96 T. Check it applies to your exact model before use.
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Before you start
- Do not change the pump mounting shims' total thickness.
Procedure
- Put No. 1 cylinder on compression stroke.
- Turn flywheel to port closing mark on front cylinder compression stroke.
- Remove timing hole screw on pump mounting flange and insert a 1/8-inch diameter wire.
- Rotate pump face gear until wire slips into place, locking gear.
- Mount pump on crankcase with shims in place and secure with screws.
- Remove the 1/8-inch wire.
- Time pump if not yet timed, using Method 2.
- Connect flexible fuel inlet line, fuel return line, and each fuel outlet line to proper pump outlet.
- Connect linkage to governor, run engine and adjust governor maximum stop.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Torque mounting screws 18-21 ft-lb (24.4 to 28.5 Nm)
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.