Fuel Pump Installation - Club Car 2005 FE290 Maintenance Service Supplement

FUEL SYSTEM
4. Install the gasket (29), clear impulse diaphragm (28), and the paper impulse gasket (27) to the pumping
chamber (30).
5. Install the front cover and then the lock washers (25) and four screws (24) on the assembly
(Figure 14-12, Page 14-20). Be sure the arrows on the front cover point from the fuel inlet to the fuel out-
let (Figure 14-13, Page 14-20). Tighten the screws to 26 in-lb (3.0 N·m).

FUEL PUMP INSTALLATION

1. Connect to the fuel pump the fuel line (2) that comes from the primary fuel filter (17). Install a new clamp
(16). Route the fuel lines as shown (Figure 14-11, Page 14-18).
NOTE: Be sure to connect the fuel line (2), that comes from the primary fuel filter (17), to the inlet nipple
on the pump. Direction of fuel flow is indicated by the arrows on the fuel pump (Figure 14-11,
Page 14-18). See also Figure 14-13, Page 14-20.
2. Connect to the output side of the fuel pump, the fuel line (3) that goes to the secondary fuel filter
(Figure 14-11, Page 14-18).
3. Connect the impulse line (7) to the bottom nipple on the fuel pump. Use a new clamp (16).
4. Install the fuel pump:
• For DS or Villager 4 vehicles, install the fuel pump on the frame and tighten the mounting bolts (26) and
lock nuts (25) to 60 in-lb (6.8 N·m) (Figure 14-11, Page 14-18).
• For Carryall vehicles, install the fuel pump onto the mounting bracket with two thread-rolling screws
and tighten to 40 in-lb (4.5 N·m).
5. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m).
See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/
N 1014305) to minimize corrosion
6. Turn the fuel shut-off valve on top of the fuel tank to the open position (Figure 14-17, Page 14-26).
7. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and place the neutral
lockout cam in the SERVICE (MAINTENANCE) position. Start the engine and check for fuel leaks. If the
fuel pump leaks, a rebuild kit must be installed to replace all gaskets and diaphragms. See following
DANGER.
ý
DANGER
• Repair all fuel leaks before operating the vehicle.
8. Place the neutral lockout cam in the OPERATE position.
2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
14
Fuel Pump
A
Page 14-21