808569T02 Mercury POWERHEAD ASSEMBLY

When holding the bellows ensure that no excessive stress is induced on it. The bellows must be supported always when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools to disassemble or assemble any part of the flexible exhaust system.The alignment of the bellows is important. Incorrect alignment may lead to premature failure of the bellows and possible emissions failure. Misalignment can be identified by visually inspecting the uniformity of the spacing between the convolutions on the bellows.Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Illustration 1 g06369006
Typical example
The lateral alignment of the bellows is critical. All the components must be assembled in the same alignment as prior to disassembly. The components that require correct lateral alignment are shown at Positions (A) and (B).
Illustration 2 g06368998
Typical example
Follow Step 2a through Step 2d to remove the flexible exhaust (6) as an assembly from the Clean Emission Module (CEM) and the turbocharger.
Use suitable material to encase exhaust pipe bellows (3). Encasing the exhaust pipe bellows will prevent damage. Encase between Position (C) and Position (D). Use cable straps to retain the suitable material.Note: Ensure that the flexible exhaust pipe is supported always.
Loosen ball clamp (2) from the flexible exhaust pipe assembly.
Loosen the bolt for V-band clamp (4).Note: If V-band clamp (4) remain tight on the flanges, apply releasing fluid on the V-band clamp. Lightly tap the bolt on the V-band clamp with a soft faced hammer to assist removal. Do not use a prybar to remove V-band clamp.
Remove the assembly of the flexible exhaust pipe from the exhaust back pressure valve (5) first and then from CEM (1).Note: Ensure that the assembly of the flexible exhaust pipe is supported as the clamps are removed.Installation Procedure for the Flexible Exhaust Pipe as an Assembly
Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Failure to reinstall the bellows into the original position will result in a failure of the bellows and possible emissions failure.
Check the flexible exhaust pipe assembly for damage. Refer to your Caterpillar dealer for further information.
Illustration 3 g06368998
Typical example
Position a new ball clamp (2) onto the flexible exhaust pipe assembly (6).
Install V-band clamp (4) onto exhaust back pressure valve (5).
Install the assembly of the flexible exhaust pipe first onto CEM (1) and then on the exhaust back pressure valve (5).Note: Ensure that the assembly of the flexible exhaust pipe is supported always and the bellows is not subjected to any undue stress. Ensure correct alignment of all components.
Tighten V-band clamp (4) hand tight.
Tighten ball clamp (2) hand tight.
Illustration 4 g06368998
Typical example
Tighten ball clamp (2) to a torque of 35 N m (26 lb ft).
Tighten V-band clamp (4) to a torque of 12 N m (106 lb in).
Cut cable straps from the suitable material that was encasing the bellows (3) between Position (C) and Position (D). Remove the suitable material from bellows (3).