Facts About Generators
GeneratorsDirectoryCompareRepairEnginesControllersPartsManufacturersGuides
Search models or part #
Home›Repair guides›Cummins/Onan›Injectors - Replace (05-09)

Cummins/Onan — Injectors - Replace (05-09)

Repair & overhaul

From a Cummins/Onan service manual covering: K 19, K19, KTA19, KTA19-M, KTA19G2, KTTA19, Kt19. Check it applies to your exact model before use.

Applies to: Cummins/Onan K 19, Cummins/Onan Kt19, Cummins/Onan K19 engine

Before you start

  • 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.

Procedure

  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.

Tools required

  • Injector Puller Part No. 3376497 Amazon
  • Injector Puller Part No. 3376000 Amazon

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

Specs & values

  • Holder-down capscrews 16.2 N·m [145 in-lb]
  • Connector screw 25 N·m [20 ft-lb]

Full service-parts list: Cummins/Onan K 19 →, Cummins/Onan Kt19 →

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.

More Cummins/Onan repair guides →