COVER 4M8239 - Caterpillar

Distance (X) is 40 mm (1.6 inch). Place Mark (B) onto tube (3) at Distance (X) from the end of tube (3).
Insert tube (3) into the bellows. The tube should be inserted as far as possible without using force. This action will minimize the overall length of the lines group and will help with installation.
Illustration 7 g02211913
Alignment wrap is not shown for photographic purposes.
Prior to installation, position both ball clamp assemblies (2) and (6) onto the lines group.
Position the lines group between the Clean Emissions Module and the turbocharger adapter. Adjust the length of tube (3) in the slip joint at clamp assembly (4) in order to position the lines group. Note: Do not force any of the components into the position.Note: Make sure that you loosely fit all of the parts before the final torquing is started.Note: Failure to reinstall the bellows into the original alignment will result in a failure of the part and a needed replacement.
Illustration 8 g02211953
The photo is a cutaway view of the ball clamp assembly.
Illustration 9 g02211955
The photo is a cutaway view of the ball clamp assembly.
Verify that the cup of the ball joint (E) does not touch the radius of the ball (D). Position ball clamp (2) and loosely tighten ball clamp (2). Note: The ball clamp that is opposite the bellows must always be tightened first. Clamp (2) which can be located at the turbocharger diffuser outlet or the CEM inlet must be tightened first. Refer to Illustration 10 and Illustration 11 for example of the possible placement of clamp (2).
Verify that the ball clamp is centered. Measurement (Y) and measurement (Z) must be within 2 mm (0.07874 inch) of each other. Refer to Illustration 9.
Illustration 10 g02239874
Example of configuration with the bellows located near the turbocharger outlet
Illustration 11 g02239877
Example of configuration with the bellows located near the CEM inlet
Repeat Step 6 and 7 for ball clamp (6).
Verify that Mark (B) is not visible at the slip joint that is positioned near clamp assembly (4). Note: Use hand tools to torque clamps on Steps 10 through 12. Do not use power tools in order to torque clamp assemblies (2), (4), and (6).Note: The ball clamp that is opposite the bellows must always be tightened first. In Illustration 10 the ball clamp that must be tightened first is located at the CEM inlet. In Illustration 11 the ball clamp that must be tightened first is located at the turbocharger diffuser outlet.
Torque ball clamp (2) to a torque of 35 2 N m (26 1 lb ft).
Torque ball clamp (6) to a torque of 35 2 N m (26 1 lb ft).
Torque clamp assembly (4) to a torque of 55 8 N m (41 6 lb ft).
Remove the protective cover that was installed in Step 2 of the removal section. Examples of Possible Misalignment and Results
Illustration 12 g01023261
Example of lateral misalignment
Lateral misalignment is shown in Illustration 12. Lateral misalignment on the exhaust bellows can lead to contact between liner and convolutions. The