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Home›Repair guides›Cummins/Onan›Injectors Installation

Cummins/Onan — Injectors Installation

Repair & overhaul

From a Cummins/Onan owner's manual covering: K1800, K2000E, K38, K50, KT38, KTA38, KTA50, KTTA38, KTTA50, KtA38, KtA50, KttA38. Check it applies to your exact model before use.

Applies to: Cummins/Onan K38, Cummins/Onan K50, Cummins/Onan KTA38, Cummins/Onan KTA50, Cummins/Onan K38 and K50 engine

Before you start

  • Do NOT use a wooden tool to push the injector on the seat.
  • Do not push the injector on the seat until it is correctly aligned.

Procedure

  1. Identify the o-rings for the correct injector groove. O-ring 3010510 has a red dot or stripe.
  2. O-ring 205216 has no markings. O-ring 193736 has a green dot or stripe.
  3. Lubricate the o-rings with vegetable oil and install them on the injector.
  4. Install the proper size seal ring.
  5. Position the injector in the bore and turn it so the screen or top stop screw hole is correctly aligned.
  6. Use a blunt object touching the top stop screw and use a quick, hard push to seat the injector.
  7. Install the hold down clamp and self-locking capscrews; tighten to 16 Nm [145 in-lb].
  8. Install the o-ring on the jumper tube, lubricated with engine oil, and the copper sealing washers.
  9. Install the connector screw and tighten to 25 Nm [20 ft-lb].
  10. Install the rocker lever assembly and STC injector link; torque to 90 Nm [65 ft-lb].
  11. Adjust the rocker levers, then install the rocker lever cover; torque to 40 Nm [30 ft-lb].

Tools required

  • 1-1/4 inch or 27 mm socket Amazon

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

Specs & values

  • Injector hold down capscrew torque: 16 Nm [145 in-lb]
  • Connector screw torque: 25 Nm [20 ft-lb]
  • Rocker lever assembly torque: 90 Nm [65 ft-lb]
  • Rocker lever cover torque: 40 Nm [30 ft-lb]

Full service-parts list: Cummins/Onan K38 →, Cummins/Onan K50 →, Cummins/Onan KTA38 →, Cummins/Onan KTA50 →

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.

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