Air Box Removal; Air Box Installation; Intake Duct Removal - Club Car FE350 2005 Maintenance Service Supplement

FUEL SYSTEM

AIR BOX REMOVAL

1. Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the
NEUTRAL position, and chock the wheels.
2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 10, Page 10-1.
3. Remove the air intake box from the vehicle by removing intake hose (16) and three screws (23) and
washers (22) that mount the intake box to the vehicle (Figure 14-8, Page 14-13 or Figure 14-9,
Page 14-14).

AIR BOX INSTALLATION

NOTE: The intake duct must be in place before the air box can be installed.
1. Check to be sure the intake seal (14) is seated correctly (Figure 14-8, Page 14-13 or Figure 14-9,
Page 14-14). The seal fits tightly onto the bottom side of the air box. If seal is not in place, moisture will
enter the air intake system.
2. Place the air box assembly into vehicle and install three flat washers (22) and screws (23) from underside
of air box mounting plate into air box (Figure 14-8, Page 14-13 or Figure 14-9, Page 14-14). Tighten to
33 in-lb (3.7 N·m).
3. Place hose onto air box and secure with wire clamp.
4. Attach the choke cable to the air box top. See Choke Cable Installation on page 14-12.
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. Test choke for proper operation.

INTAKE DUCT REMOVAL

Turf 2, Carryall 2 and Carryall 2 Plus:
1. Remove the front body. See Section 4 – Body and Trim in the appropriate maintenance and service
manual.
2. Remove the front left wheel. See Section 8 – Wheels and Tires in the appropriate maintenance and
service manual.
3. Remove the steering joint assembly (Figure 14-10, Page 14-16).
4. Drill out the pop rivet (31) securing the bottom of the air duct shield (30) to the floorboard (Figure 14-8,
Page 14-13).
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 (25) securing the intake duct to the floorboard.
7. Remove three screws (23) and flat washers (22) 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.
2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
Choke and Air Intake System
Page 14-15
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