Intake Duct Installation; Intake Duct Repair - Club Car 2005 FE290 Maintenance Service Supplement

FUEL SYSTEM
Intake Duct Removal, Continued:
4. Drill out the pop rivet (31) securing the bottom of the air duct shield (30) to the floorboard (Figure 14-10,
Page 14-14).
5. Separate the double-sided tape that secures the top of the air duct shield to the frame and remove air
duct shield from vehicle.
6. Drill out the two pop rivets (26) securing the intake duct to the floorboard (Figure 14-10, Page 14-14).
7. Remove three screws (24) and flat washers (23) from the bottom of the air box assembly.
8. Lift air box assembly off the intake duct. Be careful that the intake seal on the bottom of the air box
assembly is not dislodged in the process.
9. Pull the intake duct forward and out of the vehicle.

INTAKE DUCT INSTALLATION

The intake duct assembly is installed from the front of the vehicle.
1. Slide the intake duct between the round crossmember and the floorboard, moving it to the rear along the
underside of the floorboard. Insert the end of the intake duct through the slot in the front of the air box
mounting plate.
2. Secure the front of the duct to the underside of the floorboard with two pop rivets (25) and flat washers
(26) (Figure 14-10, Page 14-14).
3. Install the air duct shield (30).
3.1. Remove any old double-sided tape that may still be adhered to the air duct shield or frame.
3.2. Place a new strip of double-sided tape on the air duct shield. Do not remove backing from exposed
side of tape.
3.3. Secure the bottom of the air duct shield to the floorboard with a rivet (31).
3.4. Remove the backing from the tape and secure top of air duct shield to frame.
4. Install air box. See Air Box Installation on page 14-13.
5. Install steering joint assembly. See following NOTE.
NOTE: Make sure steering wheel and front wheels are properly aligned before installing steering joint.
5.1. Position steering joint assembly (1) on vehicle as shown. Install three lock washers and three bolts
and tighten to 15 ft-lb (20.3 N·m) (Figure 14-10, Page 14-14).
5.2. Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide
the shaft into the upper universal joint. Install the bolt and lock washer on the upper universal joint
and tighten to 15 ft-lb (20 N·m).
6. Install front left wheel. Tighten the wheel rim mounting nuts to 55 ft-lb (75 N·m).
7. Install front body.
8. Check for proper operation.

INTAKE DUCT REPAIR

If the air intake duct has a crack of 1/16 inch (1.5 mm) or less, and does not exceed 11 inches (27.5 cm) in
length, or has a round shaped hole no greater than 1/2 inch (13 mm) in diameter, it may be repairable with an
Air Duct Repair Kit (CCI P/N 101971001). This kit includes repair materials and procedures for small cracks
and holes. If the intake duct is badly torn or has larger holes, it will need to be replaced.
2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
Choke and Air Intake System
Page 14-15
14
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