confidential, for internal use only

Assembly instructions of the Injection- Control Unit

Attention:
1.) Every part must be cleaned and degreased before assembly
2.) For Lubrication of all screws only use Neverseez
3.) For Lubrication of the O-Rings use Molykote 33 Medium (black)

Please note that the assembly sequence in this instruction was used for the units of the Genesis engine
(RT-flex58TB) so that the pictures in this instruction are from such an injection-control unit made in
Oberwinterthur Switzerland. For this assembly instruction however, the article numbers and drawing numbers
are changed to the RT-flex60C.

Assembly instruction of the Injection- Controll Unit.xls 1 von 6

 confidential, for internal use only

1. Preparation of the injection control block (Article number: 107.284.025.200)

1.1 Before mounting the injection control block
Nr. Function Article number Procedure Lubricant Features Drawing Number
1.1.1 Insert the screw plug into the 107.013.950.001 a.) Stick with Loctite 648 2-107.284.025
injection control block b.) Torque load ca. 80 Nm
1.1.2 Insert the 5 screw plugs with the 015.401.300.161 a.) Stick on with Loctite 648 2-107.284.025
fluted seal ring in the injection control 107.267.531.004 b.) Torque load ca. 40 Nm
block

1.2 After mounting the Injection Control Block

1.2.1 Shrink fit of the throttle into the screw 107.114.892.001 a.) Chill throttle with liquid nitrogen Do not clog the 3-107.113.889
plug 107.114.891.001 b.) Heat up screw plug to 450°C throttle
1.2.2 Insert the taper pin into the nozzle 107.114.891.001 3-107.113.889
107.113.899.001
1.2.3 Insert the 3 screw plugs with O- 107.114.892.001 a.) Lubricate the thread and the O- ring Neverseez Anti- 2-107.284.025
Rings into the injection control block 107.284.025.200 with grease Seize & Attention: In this
Do not clog the
107.113.920.001 b.) Torque load ca. 80 Nm Lubricating drawing an old version
throttle
Compound is shown
(Pos. code no.: 002)
1.2.4 Insert the screw plugs with fluted seal 015.401.300.141 a.) Stick on with Loctite 648 2-107.284.025
ring 107.267.531.003 b.) Torque load ca. 40 Nm

2. Preparation and mounting of the Valve Block (Article number.: 107.319.222.001)

Nr. Function Article number Procedure Lubricant Features Drawing Number
2.1 Insert the 3 nozzles 107.319.356.001 a.) Stick on with few Loctite Nr.0243 Do not clog the 0-107.319.222
b.) Torque load ca. 12 Nm nozzle holes
2.2 Insert the 3 screw plugs with the 107.315.170.001 a.) Stick on with few Loctite Nr.0243 0-107.319.222
gaskets into the valve block 021.051.001.307 b.) Torque load ca. 12 Nm
2.3 Put the O- rings into the intermediate 021.702.005.305 Lubricate the O- rings with grease Molykote 33 1-107.284.065
rings 107.013.799.001 Medium (black)

2.4 Stick the screws into the valve block 015.251.404.521 Lubricate the thread and the seat of the Neverseez Anti- 1-107.284.065
screw head with grease Seize &
Lubricating
Compound
2.5 Insert the pistons 107.038.749.001 Pay attention to the 3-107.038.749
correct matching of 1-107.012.830
pistons and bores

2.6 Mount the valve block on the a.) Torque load ca. 20 Nm 1-107.284.065
injection control block b.) Tighten the screws crosswise
carefully
2.7 Insert the O- rings in the pre- control 021.501.000.507 Lubricate the O- rings Molykote 33 1-107.284.065
valves 107.038.650.200 Medium
2.8 Mount the pre- control valves 107.038.650.200 a.) Torque load ca. 2,5 Nm 1-107.284.065
015.251.431.091
2.9 Insert the distance pieces 107.315.179.001 1-107.284.065
2.10 Measure the stroke The stroke has to be 1-107.284.065
(Picture Nr. 1) between 3,25 mm
and 3,4 mm

Picture Nr. 1: Measurement of the stroke

Assembly instruction of the Injection- Controll Unit.xls 2 von 6

 confidential, for internal use only

3. Preparation and Mounting of the injection control valve (Picture Nr. 2)

Nr. Function Article number Procedure Lubricant Features Drawing Number

3.1 Insert the compression springs and 107.038.577.200 1-107.284.065
the spring carriers into the flanges 107.038.571.001
107.094.772.200
3.2 Check the spring force with the The distance from -
housing of the injection control valve the ground of the
set vertically top of the spring injection control
(Picture Nr. 3) valve housing to the
surface of flange
has to be between 7
mm and 7,5 mm

3.3 Insert the parallel pins into the 017.024.006.063 0-107.284.026

injection control block
3.4 Insert the parallel pins into the 017.024.006.063 2-107.094.772
flanges
3.5 Insert the screws into the flanges 015.251.410.741 Lubricate the thread and the seat of the Neverseez Anti- 1-107.284.065
107.094.772.200 screw head with grease Seize &
Lubricating
Compound
3.6 Insert the O- ring in the housing of 021.700.006.645 Lubricate the O- rings Molykote 33 1-107.284.065
the injection control valve and stick Medium
the housing on the parallel pins in the
injection control block.
3.7 Mount the flanges a.) first tighten the screws crosswise with 1-107.284.065
40 Nm
b.) then tighten the screws crosswise
with 80 Nm

Picture Nr. 2: Different stages of mounting

Picture Nr. 3: Checking of the spring force

Assembly instruction of the Injection- Controll Unit.xls 3 von 6

 confidential, for internal use only

4. Preparation and Mounting of the control piston

Nr. Function Article number Procedure Lubricant Features Drawing Number
4.1 Stick the push rod with the guide into 107.319.152.200 Lubricate the threat and the seat of the Neverseez Anti- 1-107.319.157
the intermediate flange and secure it 107.012.830.200 screw head with grease Seize &
with the screw plug against twisting 107.319.206.001 Lubricating
Compound
4.2 Insert the hexagon nut and secure it 107.319.155.001 only tighten by hand 1-107.319.157
with the spring dowel pin 017.026.204.071

4.3 Mount the intermediate flange with a.) Lubricate the threat and the seat of Neverseez Anti- At all times the 1-107.319.157
the injection control block the screw head with grease Seize & push rod must be
b.) first tighten the screws with 80 Nm, Lubricating easily moveable
then with 140 Nm and finaly with 200 Compound
from one stop to
Nm. Use the sequence shown in the
sketch the other

Sequence of tightening the screws

3 1

7 5

9 10

2 4
6 8

Nr. Function Article number Procedure Lubricant Features Drawing Number

4.4 Insert the screw plug 107.319.205.001 a.) Torque load ca. 500 Nm Neverseez Anti- 1-107.319.157
possibly remove the
b.) Lubricate the threat and the seat of Seize &
other screw plug
the screw head with grease Lubricating
before
Compound
4.5 Final mount of the screw plug 107.319.206.001 a.) Torque load ca. 125 Nm Neverseez Anti- 1-107.319.157
b.) Lubricate the threat and the seat of Seize &
the screw head with grease Lubricating
Compound
4.6 Stroke measurement a.) move the injection control piston to 1-107.319.157
the back stop and measure the distance
Picture Nr. 4
between piston rod and intermediate
flange
b.) move the injection control piston to
the front stop and measure the distance
between piston rod and intermediate
Picture Nr. 5
flange

Picture Nr. 4: Measurement 4.6a

Assembly instruction of the Injection- Controll Unit.xls 4 von 6

 confidential, for internal use only

Picture Nr. 5: Measurement 4.6b

Nr. Function Article number Procedure Lubricant Features Drawing Number

4.7 Put on the cup springs 017.941.302.973 1-107.319.157
4.8 Put on the clamping sleeve 107.319.153.001 1-107.319.157
4.9 Insert the snap ring 107.014.341.001 1-107.319.157
4.10 Pull the clamping sleeve with the 107.319.156.001 Lubricate the snap ring Neverseez Anti- 1-107.319.158
connecting element over the snap Seize &
ring Lubricating
Compound
4.11 Release the connecting element and 1-107.319.159
check the correct seat of the snap
ring

4.12 Stroke measurement Move the injection control piston to the 1-107.319.160
back stop (to the cup springs) and
Picture Nr.6
measure the distance between piston
rod and intermediate flange

Picture Nr. 6: Measurement 4.12

Assembly instruction of the Injection- Controll Unit.xls 5 von 6

 confidential, for internal use only

4.13 Final mount of the connecting Stick on with Loctite 648 1-107.319.157
element

4.14 Check the correct positioning of the Rotate the control piston (when it is at
connecting element the back stop) and measure the round The out of round
at the end of the aluminium pipe with a must be less than
dial gauge 0.9 mm
(Picture Nr.7)

4.15 Mount the housing on the 107.319.710.001 a.) Lubricate the O- ring with Molykote Molykote 33 1-107.319.157
intermediate flange 021.501.003.605 b.) Lubricate the thread and the seat of Medium +
015.251.405.341 the screw heads with Neverseez Neverseez Anti-
c.) Torque load ca. 48 Nm Seize &
Lubricating
Compound
4.16 Mount the control piston position 107.319.710.001 a.) Lubricate the O- ring with Molykote Molykote 33 1-107.319.157
sensor on the housing 021.702.004.105 b.) Lubricate the thread and the seat of Medium +
015.251.404.241 the screw heads with Neverseez Neverseez Anti- check the correct
c.) Torque load ca. 20 Nm Seize & positioning of the
Lubricating position sensor
Compound

< 0.9 mm

Picture Nr. 7: Measurement 4.14

Assembly instruction of the Injection- Controll Unit.xls 6 von 6