Fuel Tank Installation - Club Car 2005 FE290 Maintenance Service Supplement

14
FUEL SYSTEM
A

FUEL TANK INSTALLATION

1. With the retaining straps correctly positioned, install the fuel tank in the vehicle.
2. Secure the tank with the retaining straps (13 and 18) (Figure 14-11, Page 14-18).
2.1. Position the straps in the indentions on the tank.
2.2. Install the screws (12) into the speed nuts (11). Tighten screws and nuts to 25 in-lb (2.8 N·m)
(Figure 14-11, Page 14-18).
3. Install the rear body on the vehicle if removed. Install seat back support if removed. See Section 4 –
Body and Trim in the appropriate maintenance and service manual.
4. Connect the vent tube (6) to the fuel tank vent (Figure 14-11, Page 14-18).
5. Connect the fuel line (1) to the fuel tank shut-off valve (15). Use a new clamp (Figure 14-11,
Page 14-18).
6. Connect the black wire from the fuel gauge to one of the fuel level sending unit screws. Connect the
orange wire to the center stud and install the flat washer, lock washer, and nut. Tighten to 18 in-lb (2.0
N·m).
7. Slide the rubber boot over the stud (Figure 14-14, Page 14-23).
8. Add fuel to the tank.
9. 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
10. Ensure that the wheels are chocked, the Forward/Reverse handle is in the NEUTRAL position, and that
the neutral lockout cam is in the SERVICE (MAINTENANCE) position.
11. Check to be sure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 14-17,
Page 14-26).
12. Turn the key switch to the ON position and press the accelerator pedal to start the engine. See following
DANGER.
ý
DANGER
• Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.
• After installing the fuel tank and adding fuel, carefully check all fuel lines and connections for
leaks. Repair any fuel leaks before operating the vehicle.
13. Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel.
14. Inspect each fuel line for leaks.
14.1. Check all of the fuel line clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks.
14.2. Inspect each fuel line to ensure that the lines are not cracked, cut, or worn.
Page 14-24 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
Fuel Tank