Cummins/Onan — Injector - Remove and Install (STC)
Repair & overhaul
From a Cummins/Onan owner's manual covering: M11, M1i Series Engines, ps200da. Check it applies to your exact model before use.
Applies to: Cummins/Onan M11 engine
Before you start
- Be sure to place the instrument used to install the injectors on the top cap of the injector, not on the plunger or link. The plungers will be damaged.
Procedure
- Remove the hose from the crankcase breather.
- Remove the 16 capscrews, isolators and spacers from the rocker lever cover assembly.
- Remove the cover and gasket.
- Loosen the locknut and turn out the adjusting screw on each injector and valve rocker lever.
- Rotate the crankshaft clockwise with the accessory drive pulley to relieve spring tension.
- Loosen each adjusting screw and remove the push rod; mark the position of the push rods.
- Rotate the injector and valve rocker levers up on each cylinder.
- Remove and mark the crossheads.
- Loosen the injector hold down capscrew and remove the hold down.
- Use injector puller, Part No. 3823024, to remove the injectors.
- Clean carbon from the injector copper sleeves with a clean wooden stick and cloth.
- Install three new o-rings on the injector and lubricate with clean 15W-40 oil.
- Install the injector into the cylinder head bore and seat it with a clean blunt instrument.
- Install the injector hold down and capscrew; install crossheads, push rods, rocker levers and adjust valves and injectors.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Injector hold down capscrew torque: 75 Nm [55 ft-lb]
- Rocker lever cover capscrew torque: 15 Nm [130 in-lb]
Source: Cummins/Onan owner's 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.