Club Car Precedent Villager 2 Maintenance And Service Manual
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Club Car Precedent Villager 2 Maintenance And Service Manual

Electric vehicle with eric charging system gasoline vehicle with subaru ex40 engine
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2019 Precedent Villager 2
Maintenance and
Service Manual
Electric Vehicle with ERIC Charging System
Gasoline Vehicle with Subaru EX40 Engine
Manual Number 105355116
Edition Code B

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Summary of Contents for Club Car Precedent Villager 2

  • Page 1 2019 Precedent Villager 2 Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Subaru EX40 Engine Manual Number 105355116 Edition Code B...
  • Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258–2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Kick Plate Removal..........................4-10 Kick Plate Installation..........................4-10 Seat Bottom ..............................4-11 Rear Body..............................4-11 Universal Accessory Mounting........................4-11 Seat Back and Structural Accessory Module (SAM) ................... 4-12 Rear Body Components ........................... 4-13 2019 Precedent Villager 2 Maintenance and Service Manual Page iii...
  • Page 6 Control Arm Installation ..........................7-10 Shock Absorber Removal..........................7-11 Shock Absorber Installation ........................7-11 Front Wheel Bearings and Hubs ........................7-14 Front Wheel Free Play Inspection ......................7-14 Front Hub Removal..........................7-14 Hub Installation............................7-14 Page iv 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 7 V min I ..............................11-10 Signed Battery Current..........................11-10 BDI Percent............................11-10 Speed ..............................11-10 Throttle ..............................11-10 Temperature............................11-10 Arm Current ............................11-10 Field Current ............................11-10 Armature PWM............................11-11 2019 Precedent Villager 2 Maintenance and Service Manual Page v...
  • Page 8 Programming ............................. 11-22 Cloning ..............................11-23 Favorites..............................11-23 HHP Settings ............................. 11-23 Plot & Log ..............................11-25 Plot................................ 11-25 Log ................................ 11-25 CDT Troubleshooting ..........................11-26 Connection Tests ............................11-27 Page vi 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 9 Charger Receptacle ............................13-13 Testing the Charger Receptacle.......................13-13 Charger Receptacle Inspection........................13-13 Charger Receptacle Removal........................13-13 Charger Receptacle Installation .......................13-14 SECTION 14 — Electric Vehicle - Batteries ....................... 14-1 General Information ............................. 14-1 2019 Precedent Villager 2 Maintenance and Service Manual Page vii...
  • Page 10 DC Cord and Strain Relief Installation ......................15-20 Handle Removal .............................15-20 Handle Installation ..........................15-21 Foot Removal............................15-21 Foot Installation ............................15-21 SECTION 16 — Electric Vehicle - Motor ......................16-1 General Information ............................. 16-1 External Motor Testing ..........................16-1 Page viii 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 11 Starter/Generator Assembly ........................19-9 Starter/Generator Installation........................19-12 Belt Tension Adjustment for EFI Engines ....................19-13 Voltage Regulator ............................19-15 Voltage Regulator Removal ........................19-15 Voltage Regulator Installation ........................19-16 Engine Control Unit (ECU) ..........................19-17 Engine Control Unit Removal........................19-17 2019 Precedent Villager 2 Maintenance and Service Manual Page ix...
  • Page 12 General Information ............................. 20-1 Before Servicing ............................20-1 Engine Rotation............................20-1 Torque Specifications..........................20-2 Adjustments and Settings......................... 20-2 Engine Oil – Gasoline Vehicle........................20-2 Spark Plug .............................. 20-5 Breather..............................20-6 Page x 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 13 Fuel Tank Storage ..........................21-24 Fuel Tank Installation ..........................21-24 Fuel Filter..............................21-26 General Information ..........................21-26 Fuel Filter Removal..........................21-26 Fuel Filter Installation..........................21-26 Carbon Canister ............................21-27 Carbon Canister Removal ........................21-27 Carbon Canister Installation ........................21-27 2019 Precedent Villager 2 Maintenance and Service Manual Page xi...
  • Page 14 Shifter Cable Removal ..........................24-13 Shifter Cable Installation .........................24-14 Shifter Cable Adjustment.........................24-14 SECTION 25 — Wiring Diagrams........................25-1 General Information ............................. 25-1 Electric: Accessory Wiring Diagram ......................25-3 Index ................................Index-1 Page xii 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 15: Section 1 - Safety

    • A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury. CAUTION • A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage. 2019 Precedent Villager 2 Maintenance and Service Manual Page 1-1...

  • Page 16: General Warnings

    • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.

  • Page 17: Disabling The Vehicle

    Tighten battery terminals to 41 in·lb (4.3 N·m). Coat terminals with Battery Terminal Protector Spray to minimize corrosion. Attach positive terminal cover. Connect the spark plug wire(s) to the spark plug(s). 2019 Precedent Villager 2 Maintenance and Service Manual Page 1-3...

  • Page 18: Disconnecting The Batteries - Electric Vehicles

    Ensure the Tow/Run switch is in the TOW position. Connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in·lb (12.4 N·m). Coat terminals with Battery Terminal Protector Spray to minimize corrosion. Page 1-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 19: Recycling Lead-Acid Batteries

    Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...
  • Page 20 General Warnings SAFETY Pagination Page Page 1-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 21: Section 2 - Vehicle Specifications

    47.25 in. Overall width (120 cm) (120 cm) Overall height (at steering wheel) 48.0 in. (122 cm) 48.0 in. (122 cm) Wheelbase 65.5 in. (166 cm) 65.5 in. (166 cm) 2019 Precedent Villager 2 Maintenance and Service Manual Page 2-1...
  • Page 22 75.5 dBA Test method: EN 12053:2001 Uncertainty: 2 dBA Uncertainty: 4 dBA 0.6 (m/s 0.7 (m/s Vibration at driver's seat Uncertainty: Uncertainty: Test method: EN 13059:2002 0.114 (m/s 0.211 (m/s Page 2-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 23: E.r.i.c. Battery Charger Specifications

    9 ft (274 cm) Weight 6.5 lb (3 kg) MOUNTING CONFIGURATION Mounting: Set on shelf; mount under shelf, on wall or ceiling; or hang securely from ceiling: any orientation. ● 2019 Precedent Villager 2 Maintenance and Service Manual Page 2-3...
  • Page 24 E.R.I.C. Battery Charger Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 25: Section 3 - General Information

    • See General Warnings on page 1-2. Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 26: Safety Committee

    • Maintaining vehicles in a safe driving condition • How various rules are to be enforced. The safety committee should include all these items and such others as the committee feels necessary or appropriate. Page 3-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 27: Storage - Electric Vehicle

    Let the terminals dry and then coat them with Battery Terminal Protector Spray. Tighten all battery cable connections to 110 in·lb (12.4 N·m). 2019 Precedent Villager 2 Maintenance and Service Manual Page 3-3...

  • Page 28: Returning The Stored Electric Vehicle To Service

    • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. Adjust tires to recommended tire pressure. Perform the See Pre-Operation and Daily Safety Checklist on page 10-1. Perform the Performance Inspection on page 10-2. Page 3-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 29: Storage - Gasoline Vehicle

    18 ft·lb (24.5 N·m). Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric and Subaru EX40 on page 2-1. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-8. 2019 Precedent Villager 2 Maintenance and Service Manual Page 3-5...

  • Page 30: Returning The Stored Gasoline Vehicle To Service

    Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric and Subaru EX40 on page 2-1. Perform the Pre-Operation and Daily Safety Checklist on page 10-1 and the Performance Inspection on page 10-2. Page 3-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 31: Section 4 - Body And Trim

    A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has a Surlyn ®...

  • Page 32: Front And Rear Body Repair

    Continue heating and bending the body until the original shape returns. Under no circumstance should the gun be held closer than 6 inches (15 cm) to the body. See preceding CAUTION. Page 4-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 33: Minor Scratches And Surface Blemishes

    Position brow cap (1) to cover the edge of both the brow (5) and the front beauty panel (3). Secure brow cap (1) with four screws (2). Tighten screws to 25 in·lb (2.8 N·m). 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-3...
  • Page 34 Front Body BODY AND TRIM Figure 4-1 Front Body Page 4-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 35: Front Bumper

    The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4). The nuts are tightened to 13.3 ft·lb (18 N·m). Figure 4-2 Bracket and Front Bumper 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-5...

  • Page 36: Headlight Adjustment

    Tighten screws to 66 in·lb (7.5 N·m). While it is possible to add washers with the headlight/bumper assembly mounted to the vehicle, these adjustments may be easier if the headlight/front bumper assembly is unbolted first (Figure 4-3, Page 4-6). Figure 4-3 Headlight Aiming Page 4-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 37: Instrument Panel

    Secure instrument panel to the dash assembly with screws (1 and 2). Tighten screws (1) to 22 in·lb (2.5 N·m). Tighten screw (2) to 7 in·lb (0.8 N·m). 2697 Figure 4-4 Instrument Panel 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-7...

  • Page 38: Floor Mat And Retainers

    Ensure the floor mat is properly positioned beneath the top flange of the retainer and loosely install two screws (2). Install two push rivets (4) at the rear corners of the retainer. Tighten screws (2) to 4.4 ft·lb (6.0 N·m). Page 4-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 39: Kick Plate And Charger Receptacle Bezel - Electric Vehicles

    Install two front screws (3) to secure the rear beauty panel. Tighten screws to 3.7 ft·lb (5 N·m). Install floor mat. See Floor Mat and Retainers on page 4-8. Snap charger bezel (4) in place on the kick plate. Figure 4-6 Kick Plate and Charger Receptacle Bezel 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-9...

  • Page 40: Kick Plate - Efi Gasoline Vehicles

    Install two front screws (3) to secure the rear beauty panel. Tighten screws to 3.7 ft·lb (5 N·m). Install floor mat. See Floor Mat and Retainers on page 4-8. 620a Figure 4-7 Kick Plate – EFI Gasoline Vehicles Page 4-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 41: Seat Bottom

    (Figure 4-9, Page 4-12). These serve as common attachment points (1) for various accessories. Accessories that can be mounted on the SAM include single or dual sand bottles, sand bucket, and the club cleaner. 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-11...

  • Page 42: Seat Back And Structural Accessory Module (Sam)

    The sweater basket (11) is secured to the bag hoop assembly by three screws (12). Tabs on the upper edge of the basket align with holes in the bag hoop (6) for installation purposes. Tighten screws (12) to 31 in·lb (3.5 N·m) for molded-plastic sweater basket (Figure 4-10, Page 4-13). Page 4-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 43: Rear Body Components

    BODY AND TRIM Rear Body 2653 Figure 4-10 Seat Back, Bag Rack and SAM REAR BODY COMPONENTS Rear Beauty Panel Removal Remove SAM. See SAM Removal on page 4-12. 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-13...
  • Page 44 Position rear crossmember (18) on vehicle and secure with bolts (10) (Figure 4-11, Page 4-15). Bolts (10) thread into J-clips (11) attached to the inner-frame rail. Tighten bolts to 56 in·lb (6.35 N·m). Page 4-14 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 45 BODY AND TRIM Rear Body Figure 4-11 Rear Body Components 2019 Precedent Villager 2 Maintenance and Service Manual Page 4-15...
  • Page 46 Rear Body BODY AND TRIM Pagination Page Page 4-16 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 47: Section 5 - Accelerator And Brake Pedal Group

    Remove two screws (2) on the driver side of the pedal group and two screws (1) on the passenger side of the pedal group. Disconnect the wire harness (12) from the MCOR (13). Lift pedal group from vehicle. 2019 Precedent Villager 2 Maintenance and Service Manual Page 5-1...
  • Page 48 Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP 2518 Figure 5-2 Pedal Group – Electric Vehicle Page 5-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 49: Mcor

    Install the floor mat (2) over the pedal group. Make sure tabs on floor mat sides are beneath the sill (3). Tighten screws (1) to 53 in·lb (6 N·m) (Figure 5-1, Page 5-1). Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2019 Precedent Villager 2 Maintenance and Service Manual Page 5-3...

  • Page 50: Pedal Group - Gasoline Vehicle

    Remove two screws (2) on the driver side of the pedal group and two screws (1) on the passenger side of the pedal group. Disconnect six-pin connector (12) from throttle position sensor. Release the end of the accelerator cable (13) from the pedal group. Lift pedal group from vehicle. Page 5-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 51: Throttle Position Sensor

    The throttle position sensor itself is not intended to be replaced. If sensor is determined to need replacing through test procedures found in this manual, the accelerator pedal assembly must be replaced. See Accelerator Pedal Removal on page 5-6. 2019 Precedent Villager 2 Maintenance and Service Manual Page 5-5...

  • Page 52: Pedal Group Installation

    Insert accelerator pedal assembly (7) through bottom of pedal group mounting plate and secure with four screws (13) (Figure 5-5, Page 5-8). Tighten screws (13) to 38 in·lb (4.3 N·m). Install debris shields (4 and 5). Page 5-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 53: Brake Pedal Removal

    Tighten screws (12) to 100 in·lb (11.3 N·m). Install debris shields (4 and 5). Install pedal group in vehicle. See Pedal Group Installation on page 5-3. See Pedal Group Installation on page 5-6. 2019 Precedent Villager 2 Maintenance and Service Manual Page 5-7...
  • Page 54 Brake Pedal Installation ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 55: Section 6 - Wheel Brake Assemblies

    NOTE: When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods, proceed to step 7 to minimize damage to the brake cluster and brake components. 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-1...
  • Page 56 Grasp both brake shoes and pull them, together with the springs, out of the brake assembly as shown (Figure 6-4, Page 6-3). Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-5, Page 6-3). Page 6-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 57: Brake Shoe Removal

    WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 1400-18100-10222 1400-17700-10225 Figure 6-3 Remove Shoe Retainer Clip Figure 6-4 Remove Brake Shoes 1. Slide 2732 2733 Figure 6-5 Remove Adjuster Wheel Figure 6-6 Lubricate Slide 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-3...

  • Page 58: Brake Assembly Cleaning

    (Figure 6-9, Page 6-5). See preceding WARNING. Install the adjuster wheel (1) and two washers (2 and 3) into the adjuster assembly (Figure 6-5, Page 6-3). Page 6-4 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 59 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 2735 2736 Figure 6-9 Apply Grease To Brake Adjuster Figure 6-10 Install Adjuster Wheel, Trailing Shoe 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-5...

  • Page 60: Brake Shoe Installation

    After the shoes are installed, move them together up and down and side to side to make sure that they will easily slide approximately 1/4 to 3/8 inch (6.3 to 9.5 mm) without binding (Figure 6-14, Page 6-7). Page 6-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 61 (5) (Figure 6-18, Page 6-12). Connect the rods using the turnbuckle. Ensure the ends of the brake cables do not slip out of the brake equalizer during this procedure. Adjust brake cable equalizer. See Brake Cable Equalizer Adjustment on page 6-8. 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-7...

  • Page 62: Brake Cable Equalizer Adjustment

    Install the floor mat (2) over the pedal group. Make sure tabs on floor mat sides are beneath the sill (3). Tighten screws (1) to 53 in·lb (6 N·m) (Figure 5-1, Page 5-1). Page 6-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 63: Brake Cluster Removal And Installation

    Remove bow tie locking pin (13) and clevis pin (12) from brake cable (Figure 6-17, Page 6-10). Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle (Figure 6-17, Page 6-10). Remove brake assembly from transaxle. 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-9...

  • Page 64: Brake Cluster Installation

    Tighten nuts to 17 ft·lb (23.0 N·m). If torquing the bolt heads, torque to 30 ft·lb (40.6 N·m). For electric vehicles: Install the axle shaft. For gasoline vehicles: Install the wheel hub assembly. See Rear Hub Installation, Section 24, Page 24-4. Page 6-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 65 Tighten lug nuts on rear wheels, using a crisscross pattern, to 55 ft·lb (74.6 N·m). See Wheel Installation on page 8-1. Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-8. 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-11...

  • Page 66: Brake Cable Removal And Installation

    Using brake cable release tool, compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket (4) and remove the brake cable from the vehicle. Page 6-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 67: Brake Cable Installation

    Place tab (3) on cable housing over the forward leaf spring mounting bolt (2) (Figure 6-20, Page 6-13). Install nut (1). Tighten nut to 18.4 ft·lb (25 N·m). Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-8. 2019 Precedent Villager 2 Maintenance and Service Manual Page 6-13...
  • Page 68 Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 69: Section 7 - Steering And Front Suspension

    Use a 1/2-inch drive air impact wrench to tighten the anvil screw until the steering wheel releases from the steering shaft. 5.5. Remove the steering wheel from the steering column. 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-1...

  • Page 70: Steering Wheel Installation

    Remove the bolt (11) that secures the steering column universal joint to the pinion shaft of the steering gear (Figure 7-3, Page 7-3). Remove the four bolts (10) that secure the steering column (9) to the frame. Remove the steering column from the vehicle. Page 7-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 71: Steering Column Installation

    Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-3...

  • Page 72: Rack And Pinion

    Listen for unusual noises. Replace the rack and pinion as an assembly if any is found. 1383 Figure 7-4 Rack and Pinion Removal Page 7-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 73: Rack And Pinion Removal

    Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Test drive vehicle before returning it to service. 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-5...

  • Page 74: Front Suspension

    See also Figure 7-5, Page 7-7. Tighten the hex nut (8) on the adjustment eccentric (7) to 10 ft·lb (13.5 N·m) (Figure 7-6, Page 7-7). See also Figure 7-11, Page 7-13. Page 7-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 75 Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in. Proper toe-in is 3/8 inch (±1/8) (9.5 mm (±3.2)). If adjustment is necessary, proceed as follows: 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-7...

  • Page 76: Front Suspension Components

    Install tie rod ends (12) into the spindle tabs. Install the retaining nuts (14) (Figure 7-10, Page 7-12). Page 7-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 77: Leaf Spring Removal

    Remove the wave washer (6) and inspect it. If the washer is broken or has a wave bottom to wave crest height dimension of less than 0.040 inch (1 mm), it must be replaced. 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-9...

  • Page 78: Kingpin And Steering Spindle Installation

    Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Page 7-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 79: Shock Absorber Removal

    NOTE: When installing shock absorbers, make sure front shocks have identical part numbers. Install the shock absorber by reversing the removal procedure. Tighten the bolts to 16 ft·lb (21 N·m). 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-11...
  • Page 80 Front Suspension Components STEERING AND FRONT SUSPENSION 1311 Figure 7-10 Upper Front Suspension Assembly Page 7-12 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 81 STEERING AND FRONT SUSPENSION Front Suspension Components 1312 Figure 7-11 Lower Front Suspension Assembly 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-13...

  • Page 82: Front Wheel Bearings And Hubs

    Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Page 7-14 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 83 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-12 Front Wheel Hub 2019 Precedent Villager 2 Maintenance and Service Manual Page 7-15...
  • Page 84 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Pagination Page Page 7-16 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 85: Section 8 - Wheels And Tires

    Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 8-1...

  • Page 86: Tires

    Remove the wheel. See Wheel Removal on page 8-1. Inflate the tire to no more than 20 psig (138 kPa). 1.2. Immerse the tire in water and then mark the point where bubbles are formed by escaping air. 1.3. Determine the cause of the air leak. See following NOTE. Page 8-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 87: Tire Installation

    Adjust air pressure in tire to recommended pressure. Vehicle Specifications – Electric and Subaru EX40 Immerse the wheel and tire assembly in water to make sure there are no leaks. 2019 Precedent Villager 2 Maintenance and Service Manual Page 8-3...
  • Page 88 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 89: Section 9 - Rear Suspension

    To install, reverse the removal procedure. On the upper and lower shock absorber mounting stems, tighten the nuts until the rubber bushing expands to the size of the cup washer. 2019 Precedent Villager 2 Maintenance and Service Manual Page 9-1...

  • Page 90: Leaf Springs

    Remove the nut (2) and bolt (17) attaching the front of the spring to the vehicle frame and remove the spring. Inspect the bushings (4) and sleeves (3) in the spring eyes and replace them if they are worn or damaged. Page 9-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 91: Leaf Spring Installation

    Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 9-3...
  • Page 92 Leaf Springs REAR SUSPENSION 2689 Figure 9-3 Rear Suspension Assembly and Mounting Page 9-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 93: Section 10 - Periodic Maintenance

    Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.

  • Page 94: Performance Inspection

    Use the following checklist in conjunction with the Daily Pre-Operation and Safety Checklist as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.

  • Page 95: Maintenance

    When the pedal is released it should return to the original position. All Club Car vehicles operate at reduced speed in reverse.

  • Page 96: Periodic Service Schedules

    Check air pressure and adjust if necessary. Tires See Vehicle Specifications – Electric and Subaru EX40 on page 2-1. Thoroughly wash vehicle including the General vehicles underside. TABLE CONTINUED ON NEXT PAGE Page 10-4 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 97 Lubricate all rotating joints. See Periodic Pedal group Lubrication Schedules on page 10-8. Check for loose hardware; tighten if necessary. General vehicle Refer to the appropriate maintenance and service manual. 2019 Precedent Villager 2 Maintenance and Service Manual Page 10-5...
  • Page 98 Check brake shoes; replace if necessary. Lubricate brake system per Lubrication Schedule. Brake system Check brake cables for damage; replace if necessary. Check brake cable equalizer adjustment; adjust if necessary. TABLE CONTINUED ON NEXT PAGE Page 10-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 99 Check safety decals. Replace if damaged or Safety decals illegible. Two year service by trained technician only Engine Check and adjust valve lash as needed. (every 200 hours of operation) 2019 Precedent Villager 2 Maintenance and Service Manual Page 10-7...

  • Page 100: Periodic Lubrication Schedules

    Annually by trained technician SF, or SG Oil (or higher) only (every 100 hours of Dupont™ Performance Dry Multi-Use operation) Pedal group (as required) Lubricant Figure 10-1 Lubrication Points – Electric Vehicles Page 10-8 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 101 200 Change engine oil or higher. hours of operation or annually, See also Figure 20-3, Page 20-5. whichever comes first 3117 Figure 10-2 Lubrication Points – Gasoline Vehicles 2019 Precedent Villager 2 Maintenance and Service Manual Page 10-9...
  • Page 102 Periodic Lubrication Schedules PERIODIC MAINTENANCE Pagination Page Page 10-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 103: Section 11 - Controller Diagnostic Tool (Cdt)

    6. Main Menu Button 10. Power Button 3. “+” Key 7. System Port 11. Arrow Keys 4. “–” Key 8. USB Port 12. SD-card Slot 3115 Figure 11-1 CDT Overview 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-1...

  • Page 104: General Information

    SD cards can be used to deliver software upgrades, and can be used in multiple programmers to install identical software. • Softkeys: Three versatile softkeys provide multiple functions, depending on context. • Update: The handheld programmer can update its own software. Page 11-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 105: Plugging The Cdt Into The Vehicle

    In the event that the handset does not display any information, or the screen is difficult to read, refer to the CDT troubleshooting procedures. See CDT Troubleshooting on page 11-26. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-3...

  • Page 106: Quick Reference Guide - Excel With Eric Charging System

    Sonic weld(s) in Tow switch circuit failed (wire harnesses vary; see wiring schematic for that model car) The Tow circuit has failed. Check Tow switch, 16-pin connector, and The controller has failed. wire harness. Page 11-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 107: System Info

    SM VERSION Displays the version number of the Start Manager software in the controller. VCL APP VERSION Displays the version number of the Vehicle Control Language application software in the controller. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-5...

  • Page 108: Parameters

    Program menu, regardless of Pedal Up Mode setting (0,1, or 2). See Speed Setting on page 11-6. Page 11-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 109 • 3 = Deterrent Demo Mode: Uses maximum speeds defined by the deterrent demo setting to demonstrate the automatic speed control features of Guardian and UpLink. See Deterrent Demo on page 11-8. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-7...

  • Page 110: Amp Hours

    The code entries are used to place the vehicle in “private speed mode”, speed setting code 4. Each vehicle has a unique code for placing the vehicle in this mode. A vehicle programmed for “private speed mode”, speed setting 4, Page 11-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 111: Vehicle Id

    Forward/Reverse switch is activated, etc. See following NOTE. NOTE: Values appearing in these menus represent approximate measurements made by the controller and may differ from measurements made by external instruments. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-9...

  • Page 112: Batt Voltage

    This higher current increases the temperature of the speed controller heatsink. ARM CURRENT Displays the motor armature current (in amperes). FIELD CURRENT Displays the motor field current (in amperes). Page 11-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 113: Armature Pwm

    When pin 11 is activated, power is provided to the light and the handset indicates that the LED Driver is ON. When pin 11 is not activated, the handset indicates that the LED Driver is OFF. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-11...

  • Page 114: Password Tries (Oem Access Level Only)

    “private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8.

  • Page 115: Amp Hours Display

    The Fault Count Odometers indicate the odometer reading associated with the last occurrence of each fault type. Will indicate 0.0 (miles) if the fault occurred before the last clearing of fault history. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-13...

  • Page 116: Diagnostics Menu

    Fault History folder. Each detected fault is listed only once, even if the fault has occurred multiple times. You can clear the entire contents of this folder to allow a fresh Fault History to be started. Page 11-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 117: Causes Of Faults

    • H. Limits vehicle speed per Anti-Tamper setting • J. Adds the occurrence to the fault counter • K. Activates a warning device • L. Locks out Private Speed Mode 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-15...
  • Page 118 A, B, C Vehicle comes to a stop ANTI-TAMPER Top speed is reduced HIGH SPEED WALKAWAY J, K Vehicle beeps LOCKOUT FAULT None LOW SOC J, K Charge indicator light ON Page 11-16 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 119: Fault Recovery

    CURRENT SENSE FAULT Within controller M– SHORTED When key switch is cycled ANTI-TAMPER When condition clears HIGH SPEED WALKAWAY When condition clears LOCKOUT FAULT When condition clears LOW SOC When condition clears 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-17...

  • Page 120: Fault Descriptions

    The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8. See also Password Tries (OEM Access Level Only) on page 11-12.

  • Page 121: Thermal Cutback

    LOW SOC If the controller sees that the battery pack has reached a low state of charge (SOC), the controller registers a low SOC fault. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-19...

  • Page 122: Main Welded

    B- side of the solenoid coil, a broken coil wire inside the solenoid which would result in zero ohms resistance reading, a defective coil which could result in very low coil resistance (usually less than 40 ohms; Page 11-20 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 123: Main Dropout (1 Or 2)

    If the fault remains in System Faults or Fault History after clearing and the car will not operate, replace the controller. M– SHORTED If an uncontrolled current path is detected from the motor to B- (bypassing the MOSFETs), an M- shorted fault is detected. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-21...

  • Page 124: Fld (Field) Missing

    CDT or SD card is connected to a PC. For information on how to save and restore these files, refer to the manual supplied with the CDT. Page 11-22 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 125: Cloning

    Backlight Here you can set the brightness of the programmer’s LCD display—from 100% to 20%, in 5% increments. TABLE CONTINUED ON NEXT PAGE 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-23...
  • Page 126 This folder contains information about the programmer similar to what is shown in the System Info menu for each of the modules in the control system: model number, software version, hardware version, serial number, etc. Page 11-24 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 127: Plot & Log

    Log, indicating that logging is in progress. To stop logging, press the right-arrow key, and then in the “Stop Logging” screen, press the “OK” softkey. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-25...

  • Page 128: Cdt Troubleshooting

    Test Procedure 2 – Handset Cord Adaptor on Intermittent handset cord adaptor failure page 11-27 Loose vehicle wire harness connections Test Procedure 3 – CDT Ports on page 11-28 TABLE CONTINUED ON NEXT PAGE Page 11-26 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 129: Connection Tests

    The procedure for testing the handset cord adaptor is similar to the cord test. Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter with the square plug. 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-27...
  • Page 130 Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. 4.2. Remove electronics module cover. See Speed Controller Removal, Section 13, Page 13-11. 4.3. Connect CDT to controller. Page 11-28 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 131 See Test Procedure 2 – Handset Cord Adaptor on page 11-27. Section 12 — Electric Vehicle - Excel System Troubleshooting 4.4. Replace electronics module cover. See Speed Controller Installation, Section 13, Page 13-11. Figure 11-4 CDT Connector On Controller 2019 Precedent Villager 2 Maintenance and Service Manual Page 11-29...
  • Page 132 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Pagination Page Page 11-30 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 133: Section 12 - Electric Vehicle - Excel System Troubleshooting

    There are two features of the Excel electrical system that will activate the motor braking function: Walk Away Braking and Motor Braking (adjustable with the CDT handset). 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-1...
  • Page 134 The vehicle will not move until the accelerator is released and pressed again. When this situation arises, a HPD fault is recorded by the speed controller and will be displayed on an CDT handset in the Diagnostic History menu. See HPD on page 11-19. Page 12-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 135: Battery Wiring Diagram

    ELECTRIC VEHICLE - EXCEL SYSTEM TROUBLESHOOTING Battery Wiring Diagram BATTERY WIRING DIAGRAM WD_6x8V_Batteries_ERIC_Charging Figure 12-1 Battery Wiring Diagram 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-3...

  • Page 136: Sonic Weld, Fuse, And 10K Ohm Resistor Locations

    ELECTRIC VEHICLE - EXCEL SYSTEM Sonic Weld, Fuse, and 10k Ohm Resistor Locations TROUBLESHOOTING SONIC WELD, FUSE, AND 10K OHM RESISTOR LOCATIONS 2783 Figure 12-2 Sonic Weld and 10k Ohm Resistor Locations (Approximate) Page 12-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 137: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. See Controller Diagnostic Tool (CDT) on page 11-1 for operating instructions.
  • Page 138 Test Procedure 5 – Key Switch and MCOR Failed key switch Limit Switch Circuit on page 12-16 TABLE CONTINUED ON NEXT PAGE Page 12-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 139 Train operators to use the brake to hold the Diagnostic Menu – MOTOR STALL fault code Operator error vehicle on a hill, rather than holding the vehicle on a hill using the accelerator pedal 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-7...

  • Page 140: Troubleshooting Guide 2

    TROUBLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, use Troubleshooting Guide 2. If an CDT handset is unavailable, use Troubleshooting Guide 2. Page 12-8 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 141 Controller Removal on page 13-11. Motor – motor connections Check for loose or disconnected wires Speed controller – Motor and power Check for loose or disconnected wires connections TABLE CONTINUED ON NEXT PAGE 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-9...
  • Page 142 Battery charger connections – loose plug or Check wire connections and tighten if charge batteries wires at charger, receptacle or batteries necessary. Section 15 — Electric Vehicle - Battery Battery charger Charger Page 12-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 143: Test Procedures

    • The term “back-probe” refers to probing the side of a connector that the wire enters. This is usually done when the connector must remain connected to a device. See following CAUTION. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-11...
  • Page 144 The battery voltage can be displayed with the CDT handset. If an CDT handset is not available, proceed to Batteries / Voltage Check without the CDT Handset. Batteries / Voltage Check with the CDT Handset Connect the CDT to the vehicle. Page 12-12 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 145 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 6 (Figure 12-4, Page 12-14). 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-13...
  • Page 146 If the CDT display screen remains blank, the CDT port has failed. In this case, disconnect the CDT from the port and connect it directly to the controller (Figure 11-4, Page 11-29). Page 12-14 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 147 With the Tow/Run switch in the RUN position: 3.1. Probe the two, small metal contacts on the top of the fuse (Figure 12-5, Page 12-15). 3.2. Each contact should show BPV. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-15...
  • Page 148 See WARNING “Lift only one end...” in General Warnings on page 1-2. Place the Tow/Run switch in the RUN position and the Forward/Reverse switch in the NEUTRAL position. Page 12-16 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 149 Access the Monitor menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The CDT should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-17...
  • Page 150 When installing the Forward/Reverse switch into its housing, orient the three wire terminals towards the front of the vehicle (i.e. biased closer to the front of the switch housing and farther from the rear body). Page 12-18 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 151 Measure resistance between the two large posts of the solenoid. The reading should be approx. 250 Ohms. If not, replace the pre-charge resistor using most of the steps found in Solenoid Removal on page 13-12. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-19...
  • Page 152 Place the Tow/Run switch in the RUN position, turn the key switch to the ON position, place the Forward/Reverse rocker switch in the FORWARD position, and press the accelerator pedal. The rear tire should rotate and Page 12-20 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 153 If the meter does not indicate continuity, check and repair related connections, Tow/Run switch and wiring. If necessary, replace affected wire harness, charger receptacle or Tow/Run switch. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-21...
  • Page 154 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame rails just forward of each spring mount. See WARNING “Lift only one end...” in General Warnings on page 1-2. See also following WARNING. Page 12-22 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 155 NOTE: Observe closely to see if voltage randomly or sporadically fluctuates with pedal at rest, during pedal travel and with pedal fully pressed. If it fluctuates, the MCOR is defective and must be replaced. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-23...
  • Page 156 If the continuity is correct, replace the speed controller. Check voltage at the red motor speed sensor wire: Page 12-24 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 157 (white wire) and connect the red (+) probe to the A1 (green wire) motor terminal. With Tow/Run switch in the RUN position, place the Forward/Reverse switch in the FORWARD position, turn key switch to the ON position and slowly press accelerator pedal. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-25...
  • Page 158 – Continuity of the 6-gauge red wire from the positive post of battery no. 1 to the solenoid. If the reading is less than BPV, inspect related wiring and connections for tightness, damage and corrosion. Page 12-26 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 159 A procedure is provided for testing each of the wires in the 16-pin connector. For testing, wires have been grouped together based on purpose as either controller input or controller output. Tests vary whether the 16-pin must be connected or disconnected from the controller to get the appropriate result. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-27...
  • Page 160 Pin 6 – Green be ON) REVERSE BUZZER INPUT BPV from Reverse Buzzer with Tow/Run Pin 7 – Orange/White switch in RUN (Key switch either ON or OFF) TABLE CONTINUED ON NEXT PAGE Page 12-28 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 161 Supplies approximately 15 to 16 volts to (Key switch either ON or OFF) the motor speed sensor. TEST PROCEDURE 16 – Reverse Buzzer See General Warnings on page 1-2. NOTE: This is a voltage test. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-29...
  • Page 162 If the CDT quickly displays ON but the charge indicator light still does not flash, check the following items: – Condition of the blue/yellow wire terminal in the 16-pin connector. Page 12-30 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 163 If pin 4 has no voltage, the controllers LIN (Local Interconnect bus) may have failed. The vehicle can be driven if it is not used with Guardian or Visage and will not show any symptoms. Otherwise, Guardian or Visage will disable the vehicle until communication is restored. 2019 Precedent Villager 2 Maintenance and Service Manual Page 12-31...
  • Page 164 ELECTRIC VEHICLE - EXCEL SYSTEM Test Procedures TROUBLESHOOTING Pagination Page Page 12-32 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 165: Section 13 - Electric Vehicle - Electrical Components

    Secure instrument panel to the dash assembly with three screws (1). Tighten screws to 1.8 ft·lb (2.5 N·m). Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-1...

  • Page 166: Charge Indicator Light

    CHARGE INDICATOR LIGHT INSTALLATION Install in reverse order of removal. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Page 13-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 167: Forward/Reverse Rocker Switch

    Remove two screws (2) that hold Forward/Reverse rocker switch housing (1) to the vehicle (Figure 13-4, Page 13-4). Remove the three wires from the rocker switch. Press in on the locking tabs on each side of switch (3), and push switch out of housing. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-3...

  • Page 168: Forward/Reverse Rocker Switch Installation

    REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 13-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 169: Electronics Module Cover

    – Do not direct water stream in the area of the cover. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-5...

  • Page 170: Tow/Run Switch

    (Figure 13-6, Page 13-7). Tighten Tow/Run switch boot/hex nut (1) to 16 in·lb (1.8 N·m). Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Page 13-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 171: Motor Controller Output Regulator (Mcor)

    Connect the two-pin and three-pin connectors from the wire harness to the MCOR. Install the pedal group. See Pedal Group Installation on page 5-3. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-7...

  • Page 172: Reverse Buzzer

    Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. (Viewed from underside of instrument panel) A. Pink B. Orange/White Figure 13-7 Reverse Buzzer Page 13-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 173: Electronics Module

    • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate. – Remove plate from vehicle completely. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-9...

  • Page 174: Electronics Module Installation

    Complete connections to the controller (1), the Tow/Run switch (5) and the solenoid (4) per the electrical schematics. Tighten bolts (6) on the controller to 108 in·lb (12.2 N·m). Tighten nuts (7) on the solenoid to 6.4 ft·lb (8.7 N·m). Page 13-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 175: Speed Controller

    Connect the the heavy gauge wires to the controller (1) per the electrical schematics. Tighten terminal screws (6) on the controller to 108 in·lb (12.2 N·m). Return electronics module cover (8) to its original location. See Electronics Module Cover Installation on page 13-5. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-11...

  • Page 176: Solenoid

    Select Program, Vehicle ID, Vehicle Date of Manufacture and enter the number on the model year and week from the vehicle serial number. 7.7. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. 7.8.

  • Page 177: Solenoid Installation

    Disconnect the 10-gauge black wire from the controller B- terminal. Disconnect the light blue wire from main harness at the bullet connector. Remove the three screws (1) that secure the charger receptacle (2) to the bucket. 2019 Precedent Villager 2 Maintenance and Service Manual Page 13-13...

  • Page 178: Charger Receptacle Installation

    Install kick plate. See Kick Plate and Charger Receptacle Bezel – Electric Vehicles on page 4-9. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Page 13-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 179: Section 14 - Electric Vehicle - Batteries

    The electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting, and ignition” (SLI) battery. They should never be substituted for one another. 2019 Precedent Villager 2 Maintenance and Service Manual Page 14-1...

  • Page 180: Battery Testing Basics - 8 Volt

    Cell 1 (Cell with Positive Post) Cell 2 (Cell adjacent to Positive Post) Cell 3 (Cell adjacent to Negative Post) Cell 4 (Cell with Negative Post) 2739 Figure 14-1 Battery Cell Numbering – 8 Volt Page 14-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 181: Battery Testing - 8 Volt

    Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
  • Page 182 Battery Regrouping ELECTRIC VEHICLE - BATTERIES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 183: Battery Replacement

    See preceding CAUTION. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the cells are equalized prior to use. 2019 Precedent Villager 2 Maintenance and Service Manual Page 14-5...

  • Page 184: Battery Care

    See General Warnings on page 1-2. WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries. Club Car is, therefore, placing increased importance on battery water quality. Outlined below are four battery watering procedures, grouped into two categories: Preferred and Alternate methods.

  • Page 185: Battery Care - Vehicles Equipped With The Optional Single-Point Watering System (Spws)

    • The watering interval must adequately maintain the electrolyte level above the top of the plates. See Figure 14-3. • Water the batteries only AFTER charging. NOTE: Bottled distilled water, with the hand pump is recommended for private consumer SPWS applications. 2019 Precedent Villager 2 Maintenance and Service Manual Page 14-7...

  • Page 186: Battery Care - Vehicles Without The Single-Point Watering System (Spws)

    • Do not overfill the batteries. NOTE: A battery watering gun or bottle is available from your authorized Club Car dealer. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.

  • Page 187: Self-Discharge

    For best results, use a battery watering gun to add water to batteries. Check the electrolyte level more frequently in hot weather or when batteries are old. 2019 Precedent Villager 2 Maintenance and Service Manual Page 14-9...

  • Page 188: Vibration Damage

    • Water the batteries only AFTER charging. • Use water that meets the quality standards shown on page 14-6. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications. INITIAL MAINTENANCE OF THE SPWS After six weeks of operation, remove the valves from the batteries and manually check the battery water level to ensure that the SPWS is not leaving any cells dry.

  • Page 189: Battery Storage

    50 to 70 times. If they are excessively discharged early in their life, their effective service life will be shortened. It is advisable to limit the use of any vehicle with new batteries for at least the first four weeks and then gradually increase their range. 2019 Precedent Villager 2 Maintenance and Service Manual Page 14-11...
  • Page 190 Early Excessive Discharging ELECTRIC VEHICLE - BATTERIES Pagination Page Page 14-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 191: Section 15 - Electric Vehicle - Battery Charger

    2%. Make sure proper ventilation is used when charging batteries. WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

  • Page 192: General Information

    General Information ELECTRIC VEHICLE - BATTERY CHARGER Contact your authorized Club Car dealer/distributor with any questions about battery and charger compatibility or algorithm updates. GENERAL INFORMATION NOTE: This charger has no internals to service or repair. It only has a few external repairs that can be performed.

  • Page 193: Usb Service Port

    USB SERVICE PORT The ERIC charger has a USB port for use by Club Car authorized technicians for data transfer, reconfiguration, and updates. Keep the USB port cover in place when the port is not in use. See USB Service Port Cleaning and Care on page 15-11.

  • Page 194: Charger Power Connection Fuse

    NOTE: The number of flashes and beeps can vary depending on the Beep Option setting. See Beep Option, Section 11, Page 11-8. CHARGER STATUS INDICATORS The indicator lights on the charger provides information concerning charger status. Page 15-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 195: Long-Term Storage

    Flashing green Solid blue AC power to charger is present. LONG-TERM STORAGE High-frequency chargers are designed to be left connected with AC power to the charger during off-season or long-term storage. 2019 Precedent Villager 2 Maintenance and Service Manual Page 15-5...

  • Page 196: External Charger Mounting

    When installing charger, incorporate a "drip loop" in the AC cord to prevent water from running down the cord and into the AC cord receptacle on the charger (Figure 15-4, Page 15-7). Page 15-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 197: Ac Power Connection

    NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 198: The Charge Circuit

    THE CHARGE CIRCUIT The charge circuit consists of the charger receptacle, interlock wire, controller, solenoid and battery pack (Figure 15-5, Page 15-8). 2788 Figure 15-5 Charge Circuit – External High-Frequency Charger Page 15-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 199: Charger Operation

    (or) the vehicle receptacle. • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer. Frozen batteries can explode.
  • Page 200 Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (50 to 70 charge cycles). For maximum battery life, Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deeply discharging the batteries.

  • Page 201: Charger Maintenance

    After cleaning, preventative maintenance of the USB port should include applying dielectric grease into the port cavity or applying Corrosion Block ® Corrosion Preventative to help prevent any reoccurance of contamination. 2019 Precedent Villager 2 Maintenance and Service Manual Page 15-11...

  • Page 202: Charger Troubleshooting

    If not, consult your local power company or electrical contractor. TERMINAL BLOCK COVER The terminal block cover prevents water exposure and prevents a short across the terminals, which will blow the 30-amp fuse in the charger receptacle wire harness. Page 15-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 203: Resetting Power - External Charger

    When the blue AC status indicator light comes on, connect the DC cord to the vehicle. If the triangular status indicator light comes on, contact your Club Car dealer. If the light does not come back on, attempt to charge the car as usual.

  • Page 204: Charger Troubleshooting Indicators

    Continuity Test of AC Circuit on page 15-17. Replace cord. See AC Power and Continuity Test 5. Failed AC plug or cord of AC Circuit on page 15-17. TABLE CONTINUED ON NEXT PAGE Page 15-14 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 205 If charge is successful, proceed to step 2. If status occurs again, troubleshoot the AC power supply, vehicle and battery pack. 2. Charger internal fault Replace charger. 2019 Precedent Villager 2 Maintenance and Service Manual Page 15-15...

  • Page 206: Test Procedures

    After a full charge, disconnect the charger DC plug, wait 30 seconds and reconnect the charger DC plug. The battery-shaped status indicator will be green with the upper half flashing at Page 15-16 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 207 NOTE: The positive symbol (+) and negative symbol (–) are molded into the terminal block for easy identification. Install terminal block cover. See Terminal Block Cover Installation on page 15-20. 2019 Precedent Villager 2 Maintenance and Service Manual Page 15-17...
  • Page 208 With a Meter: A clamp meter can be used to measure current in the red battery cable (connected to the positive (+) post of battery no. 1) while charging. Current can reach just over 13-amps at the beginning of a charge session and taper down to approximately 5-amps near the end. Page 15-18 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 209: External Charger Repairs

    TERMINAL BLOCK COVER REMOVAL Disconnect DC cord (1) from vehicle. Disconnect AC cord (2) from AC outlet. Push in mounting tabs (Figure 15-9, Page 15-20) to release cover (3) from terminal block (4). 2019 Precedent Villager 2 Maintenance and Service Manual Page 15-19...

  • Page 210: Terminal Block Cover Installation

    Install terminal block cover (3). See Terminal Block Cover Installation on page 15-20. Secure strain relief (6) to charger with torx screws (5). Tighten screws (5) to 27 in·lb (3.1 N·m). HANDLE REMOVAL Remove torx screws (8) securing handle (9) to charger. Page 15-20 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 211: Handle Installation

    Push foot (10) into hole in charger mounting tab until the barbs come through and secure foot in place. If required, mount charger to shelf or wall. See External Charger Mounting on page 15-6. 2019 Precedent Villager 2 Maintenance and Service Manual Page 15-21...
  • Page 212 External Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Pagination Page Page 15-22 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 213: Section 16 - Electric Vehicle - Motor

    The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in Excel System vehicles. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.
  • Page 214 See Motor Removal on page 16-4. If reading is correct, reconnect the motor wires. See Motor Installation on page 16-15. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Page 16-2 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 215 See Motor Removal on page 16-4. If reading is correct, reconnect the motor wires. See Motor Installation on page 16-15. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-3...

  • Page 216: Motor

    To gain easier access to the motor, lower the transaxle as low as it will go. If more room is needed, remove the jack from beneath the transaxle and allow the springs to rest on the floor (Figure 16-3, Page 16-5). Page 16-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 217: Motor Disassembly

    Figure 16-4 Speed Sensor Magnet Figure 16-5 End Cap MOTOR DISASSEMBLY Before beginning disassembly, place match marks on the motor end cap and motor frame. Remove speed sensor and magnet. 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-5...
  • Page 218 Inspect the brush springs for proper tension. See Motor Brush, Spring, and Terminal Insulator Inspection on page 16-10. Remove the armature from the end cap bearing. See following CAUTION and NOTE. Page 16-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 219 Use an arbor press to remove the bearing from the end cap. Inspect the bearing for wear and damage. See Bearing Inspection on page 16-11. Figure 16-8 Armature Removal Figure 16-9 A1 and A2 Terminals 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-7...

  • Page 220: Motor Component Testing And Inspection

    A dirty or oily commutator should be cleaned and wiped dry. Abnormalities identified during the inspection can help determine original cause of failure. Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper. See following CAUTION and NOTE. Page 16-8 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 221 With a multimeter set to 200 ohms, place one probe on the commutator (1) and the other on the armature core (2). The multimeter should indicate no continuity (Figure 16-12, Page 16-9). If the reading is incorrect, replace the armature. Figure 16-12 Armature Test 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-9...

  • Page 222: Motor Frame And Field Windings Inspection

    Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 16-5. Inspect the insulators (4 and 6) for cracks or other damage (Figure 16-15, Page 16-12). Replace insulators as required. Page 16-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 223 Figure 16-13 Brush Spring Tension Test Figure 16-14 Bearing Inspection Speed Sensor Magnet Inspection Inspect the speed sensor magnet (24) for rust, wear, and cracks (Figure 16-15, Page 16-12). Replace the magnet if necessary. 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-11...
  • Page 224 Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 225: Reconditioning The Motor

    One at a time, push the brushes back until they are completely retracted into their mounting slots and the spring pressure holds them in the retracted position as shown (Figure 16-17, Page 16-14). 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-13...
  • Page 226 Page 16-12). Tighten bolts to 130 in·lb (14.7 N·m). Install the speed sensor magnet (24) with screw (23). Tighten to 65 in·lb (7.3 N·m). Install the speed sensor (10) with screws (25). Tighten to 20 in·lb (2.2 N·m). Page 16-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 227: Motor Installation

    NOTE: The motor coupling and the new molded bumper must be free of grease and debris. 3.2. Ensure that the installed bumper is seated at the bottom of the coupling. 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-15...
  • Page 228 Install the motor wires, making sure they are connected to the correct motor terminals and that the terminal orientation is correct. See page . Hold the bottom nut of stud with wrench and tighten the terminal retaining Page 16-16 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 229 REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 1313 Figure 16-24 EJ8–4001A Motor Mounting Bolts and Tightening Sequence 2019 Precedent Villager 2 Maintenance and Service Manual Page 16-17...
  • Page 230 Motor Installation ELECTRIC VEHICLE - MOTOR Pagination Page Page 16-18 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 231: Section 17 - Electric Vehicle - Transaxle

    NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. Varying rear axle configurations have been installed on vehicles. If replacing axle tubes, take note of individual axle tube lengths to ensure proper fit. 2019 Precedent Villager 2 Maintenance and Service Manual Page 17-1...
  • Page 232 Figure 17-1 Remove Internal Retaining Ring Figure 17-2 Axle Seal and Adapter Ring Removal A. Adapter Ring Lip Figure 17-3 Axle Seal and Adapter Ring Figure 17-4 Axle Seal and Adapter Ring Installation Page 17-2 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 233 ELECTRIC VEHICLE - TRANSAXLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2019 Precedent Villager 2 Maintenance and Service Manual Page 17-3...

  • Page 234: Axle Bearing

    Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly (1 or 2) must be replaced (Figure 17-5, Page 17-3). Page 17-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 235: Transaxle Removal

    Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out. See preceding WARNING. 2019 Precedent Villager 2 Maintenance and Service Manual Page 17-5...
  • Page 236 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. Remove the brake assemblies if required. See Brake Cluster Removal on page 6-9. 1. Villager 2 2. Villager 4 Figure 17-10 Leaf Springs Figure 17-11 Motor Mounting Bolts Page 17-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 237: Transaxle Disassembly, Inspection, And Assembly

    17-5, Page 17-3). See also Figure 17-12, Page 17-7. Press the bearing (18) off the intermediate gear assembly (Figure 17-5, Page 17-3). 1. Press Ram 2. Arbor Figure 17-12 Intermediate Gear Assembly 2019 Precedent Villager 2 Maintenance and Service Manual Page 17-7...
  • Page 238 • Do not reuse bearings after removing them. Replace bearings with new ones. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE. Page 17-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 239: Transaxle Assembly

    Place a 1/4 to 3/8-inch (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated. See following WARNING. 2019 Precedent Villager 2 Maintenance and Service Manual Page 17-9...

  • Page 240: Transaxle Installation

    Inspect the vehicle to check for proper operation. See following WARNING. WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. WARNING CONTINUED ON NEXT PAGE Page 17-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 241 REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2019 Precedent Villager 2 Maintenance and Service Manual Page 17-11...
  • Page 242 Transaxle Installation ELECTRIC VEHICLE - TRANSAXLE Pagination Page Page 17-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 243: Section 18 - Gasoline Vehicle - Troubleshooting And Electrical System

    B– battery terminal. • Between Engine and Battery: The engine and chassis each have a separate lead that connects to the main wire harness and goes to the B– battery terminal. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-1...

  • Page 244: Features Of The Electronic Fuel Injection (Efi) System

    Failure Mode Table – After Ignition Has Been In ON Position (i.e. During Use of Vehicle) DISPLAY MODE CONDITION LAMP CONTROL Blink Code No Failure Step 1: Lamp OFF Detect Failure Step 1: Lamp OFF Four Seconds Step 2: Display Blink Code Page 18-2 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 245 NOTE: If codes 22, 23, and 41 blink in-sequence, the gray plug is disconnected from the ECU. If no codes blink, the black plug is disconnected from the ECU. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-3...

  • Page 246: Gasoline Powertrain

    Fuel pump malfunction; fuel pressure to Section 21 — Gasoline Vehicle - Fuel System throttle body too low TABLE CONTINUED ON NEXT PAGE Page 18-4 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 247 Section 20 — Gasoline Vehicle - Engine Restricted fuel flow Section 21 — Gasoline Vehicle - Fuel System Torque converter is not backshifting properly Section 23 — Gasoline Vehicle - Clutches TABLE CONTINUED ON NEXT PAGE 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-5...
  • Page 248 Components Belt Tension Adjustment for EFI Engines on page 19-13 Voltage regulator failed Test Procedure 13 – Voltage Regulator Battery failed Test Procedure 1 – Battery TABLE CONTINUED ON NEXT PAGE Page 18-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 249 Fuel mixture is too lean; check EFI Section 21 — Gasoline Vehicle - Fuel System Throttle stop screw out of adjustment at Section 21 — Gasoline Vehicle - Fuel System governor arm 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-7...

  • Page 250: Sonic Weld, Fuse, And Diode Locations

    GASOLINE VEHICLE - TROUBLESHOOTING Sonic Weld, Fuse, and Diode Locations AND ELECTRICAL SYSTEM SONIC WELD, FUSE, AND DIODE LOCATIONS Figure 18-1 Sonic Weld and Diode Locations (Approximate) – Villager 2 EFI Page 18-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 251: Electrical System

    Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem. Use the appropriate test procedure to correct the electrical problem. See Test Procedures on page 18-10. For a complete wiring diagram, see . 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-9...

  • Page 252: Test Procedures

    • When testing resistance or continuity, turn off power to the circuit being measured and discharge any capacitor(s). The presence of voltage can cause inaccurate readings. Index of Test Procedures 1 – Battery Page 18-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 253 19 – Battery Test (Under Load) 20 – Fuel Pump 21 – Fuel Level Sending Unit 22 – Fuel Gauge 23 – Hour Meter 24 – 4-Pin Connector (for Connected Car Device) 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-11...
  • Page 254 Read the battery voltage after the load tester has been turned ON for 15 seconds. Compare the battery’s voltage reading with the following table. Make sure you have the correct ambient temperature. Page 18-12 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 255 8.5 V If the battery is found to be good, or if the electrical problem continues after the battery has been replaced with a good one, test the electrical circuits. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-13...
  • Page 256 If neither side of a fuse shows battery voltage, inspect the following locations: – Check condition and connection of large red wires at solenoid. – Check sonic weld_8 in main wire harness. Page 18-14 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 257 The reading should be continuity. If the reading is incorrect, clean and tighten cable connections. If the connections are good and the reading is incorrect, repair or replace the wire or cable. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-15...
  • Page 258 TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-2. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 18-10. Page 18-16 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 259 (+) Terminal Battery Voltage Voltage: ECU Black Pin 1 (Black/White) and ECU Black Black Fuel Pump Input (after pump stops Key ON Pin 10 (Black) running) TABLE CONTINUED ON NEXT PAGE 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-17...
  • Page 260 Continuity: ECU Black Pin 18 (Black) and Ground Meter should beep Key OFF Ground for ECU Black Voltage: ECU Black Pin 18 (Black) and Battery (+) Housing –Battery Voltage Key OFF Terminal Page 18-18 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 261 Connect wires to the key switch. Make sure wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Install dash panel in reverse order of removal. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-19...
  • Page 262 Press the accelerator to engage the starter and engine. With accelerator pedal pressed, the meter should indicate approximately 1.0 volt. If either reading is incorrect, replace the accelerator pedal assembly. See Accelerator Pedal Removal on page 5-6. Page 18-20 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 263 Press the accelerator to engage the starter and engine. With accelerator pedal pressed, the meter should indicate an over limit (no continuity) condition. If either reading is incorrect, replace the accelerator pedal assembly. See Accelerator Pedal Removal on page 5-6. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-21...
  • Page 264 – With accelerator pedal pressed: The solenoid should click and the meter should read battery voltage. 4.3. If the readings are incorrect, replace solenoid. See Solenoid Removal, Section 19, Page 19-21. Page 18-22 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 265 5.2. does work as stated and the MAINTENANCE/OPERATE modes still do not work: – Check the limit switches. – Check continuity of the wires involved. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-23...
  • Page 266 3028 Figure 18-7 Neutral Lockout Limit Switch Test If switch does not work as stated in previous step, replace switch. See Neutral Lockout Limit Switch Removal, Section 19, Page 19-20. Page 18-24 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 267 • Tag the starter/generator wires for identification before disconnecting. • Remove starter/generator wire from one of the “A” terminals and one of the “F” terminals if testing while starter/generator is in vehicle. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-25...
  • Page 268 See Starter/Generator Removal on page 19-1. Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Page 18-26 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 269 See Voltage Regulator Removal, Section 19, Page 19-15. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Voltage Regulator 2. Solenoid 3. Battery 4. 20 VDC Setting Figure 18-10 Voltage Regulator Test 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-27...
  • Page 270 The gap should be set at 0.024 to 0.028 in. (0.6 to 0.7 mm). If the gap is correct, replace the spark plug with a new part and test the engine for proper operation. 1. Ignition Gap Test Tool 2. Chassis Figure 18-11 Ignition Spark Test Page 18-28 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 271 TEST RESULT White Signal Wire to Ground 9 to 11 kOhms White Signal Wire to Spark 17 to 20 kOhms Plug Cap Spark Plug Cap to Ground 8 to 13 kOhms 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-29...
  • Page 272 If battery voltage is present, use a test lead to ground the yellow wire terminal of low oil warning light. Light should illuminate. If not, replace low oil warning light. Page 18-30 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 273 If all of the test results are good and the voltage reading is zero, there may be a broken or damaged heavy-gauge white wire from the solenoid to the starter/generator. See Starter/Generator (Starter Function) on page 18-25. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-31...
  • Page 274 If no voltage, check key switch. See Key Switch (Start Circuit) on page 18-19. Pump If necessary, see Testing Basics on page 18-10. Disconnect battery. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Page 18-32 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 275 If the readings are correct according to the position of the float, but give an incorrect reading on the fuel gauge, test the fuel gauge. See Fuel Gauge on page 18-34. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-33...
  • Page 276 750V ORANGE 200mA WIRE 1000 --- FUSED 750V 18-GAUGE REMOVE BLACK 18-GAUGE WIRE TO ORANGE GROUND WIRE 2429 2430 Figure 18-13 Fuel Gauge Test Figure 18-14 Fuel Gauge Voltage Test Page 18-34 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 277 • Do not operate vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. If the reading does not change after six minutes, then replace the hour meter. 2019 Precedent Villager 2 Maintenance and Service Manual Page 18-35...
  • Page 278 If pin 4 has no voltage, the ECU LIN (Local Interconnect bus) may have failed. The vehicle can be driven if it is not used with Guardian or Visage and will not show any symptoms. Otherwise, Guardian or Visage will disable the vehicle until communication is restored. Page 18-36 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 279: Section 19 - Gasoline Vehicle - Electrical Components

    Remove brush covers (29 and 30), terminal hardware (25), brush springs (28), and brushes (27) (Figure 19-2, Page 19-2). See following NOTE. NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator to Service the Armature/Commutator on page 19-4. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-1...

  • Page 280: Brush Inspection And Replacement

    Using a spring scale, test brush spring tension. If any spring has a tension less than 24 ozf (0.68 kgf), replace all four springs (Figure 19-4, Page 19-3). See following CAUTION. Page 19-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 281: Starter/Generator Assembly

    A2 terminal. Install the remaining three brush covers (29) in the openings in the commutator end cover (23) (Figure 19-2, Page 19-2). 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-3...

  • Page 282: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    Remove the internal retaining ring (32) to release the bearing (35) and armature (33) from the output end cover (36). (Figure 19-6, Page 19-5). Page 19-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 283: Bearing Cleaning And Inspection

    Do not remove the bearings unless they are to be replaced. Figure 19-7 Bearing Play Inspection 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-5...

  • Page 284: Bearing Removal

    • Worn, burned, or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator Page 19-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 285: Commutator Cleaning And Inspection

    Using a micrometer, measure the outside diameter at two points along the commutator. If the commutator outside diameter is less than 1.535 inches (39 mm), replace the armature and bearings (Figure 19-10, Page 19-8). 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-7...

  • Page 286: Armature Ground Test

    Using a multimeter set on 200 ohms, place the positive (+) probe on the commutator bars and the negative (–) probe on the armature core. The reading should be no continuity. If the reading is incorrect, replace the armature and the two bearings (Figure 19-11, Page 19-9). Page 19-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 287: Visual Inspection Of Field Coils

    0.006 to 0.01 ohms Generator field coil resistance 4.5 to 5.5 ohms STARTER/GENERATOR ASSEMBLY Slide the bearing retainer (32) onto the output end of the armature shaft (33) (Figure 19-6, Page 19-5). 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-9...
  • Page 288 NOTE: Secure bottom nut of terminal with wrench before tightening top nut. 9.3. Form wire against starter housing as shown and allow terminal at F1 to self-orient. Tighten nut to 44 in·lb (5 N·m). See preceding NOTE. Page 19-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 289 Starter/Generator 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 19-12 A1 to F1 Terminal Jumper Wire Routing 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-11...

  • Page 290: Starter/Generator Installation

    48 in·lb (5.4 N·m). Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Page 19-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 291: Belt Tension Adjustment For Efi Engines

    Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Access engine compartment. – Remove seat and rear access panel (if equipped). – Raise cargo bed (if equipped). 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-13...
  • Page 292 – Install J-bolt and nut into bracket. 6.3. Remove pry bar. A. Remove 3/8 to 1/2 inch (9.5 to 12.7 mm) 1. Before 2. After 2726 Figure 19-17 Belt Tension Tool Modification (If Necessary) Tension belt. Page 19-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 293: Voltage Regulator

    See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Disconnect the voltage regulator connector (3) from the wire harness (Figure 19-18, Page 19-16). Remove the voltage regulator mounting screw (2) and remove the voltage regulator (1). 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-15...

  • Page 294: Voltage Regulator Installation

    Place Forward/Reverse handle in NEUTRAL and place the neutral lockout cam in the MAINTENANCE position. Start the engine and check regulator for proper functioning as described in the voltage regulator test procedure. See Test Procedure 13 – Voltage Regulator on page 18-27. Page 19-16 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 295: Engine Control Unit (Ecu)

    Mount ECU to plate with bolts and tighten to 60 in·lb (6.8 N·m). Install gray connector to the gray port on the ECU. See preceding WARNING. Install black connector to the black port on the ECU. Connect the battery. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-17...

  • Page 296: Key Switch

    From the back of the instrument panel, push down on the retaining tabs surrounding the key switch (4) and remove the key switch cap (8). Hold the key switch and remove the switch retaining nut (6) from the outside of the instrument panel (Figure 19-20, Page 19-18). Page 19-18 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 297: Key Switch Installation

    Connect the three spade terminals (Figure 18-6, Page 18-23). Make sure groove switch is aligned with tang on bracket and install switch. Tighten maintenance/operate switch boot/hex nut to 16 in·lb (1.8 N·m). Connect the battery. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-19...

  • Page 298: Neutral Lockout Limit Switch

    Connect the 3-wire connector to the neutral lockout limit switch lead. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Test drive the vehicle in both forward and reverse for proper operation. Page 19-20 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 299: Solenoid

    Tighten the hex nuts on the large solenoid posts to 55 in·lb (6.2 N·m). Tighten the nuts on the small solenoid posts to 22 in·lb (2.5 N·m). Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-21...

  • Page 300: Fuse

    ATM Fuse Only: Install the fuse holder cover. ABC Fuse Only: Assemble in-line fuse holder. Connect battery. See Connecting the Battery- Gasoline Vehicles on page 1-3. Page 19-22 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 301: Accelerator Pedal Limit Switch

    Remove the instrument panel. See Key Switch Removal on page 19-18. Disconnect the wires from the reverse warning buzzer (2) (Figure 19-21, Page 19-24). Remove the two mounting screws (3) securing the buzzer to the instrument panel. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-23...

  • Page 302: Reverse Warning Buzzer Installation

    Secure instrument panel to the dash assembly with three screws (1). Tighten screws to 1.8 ft·lb (2.5 N·m). Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Shift the Forward/Reverse handle to the REVERSE position. The buzzer should sound. Page 19-24 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 303: Reverse Buzzer Limit Switch

    Connect the two wire connector to the reverse buzzer limit switch (3). Connect battery and spark plug wire(s). Shift the Forward/Reverse handle to the REVERSE position. The buzzer should sound. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-25...
  • Page 304 GASOLINE VEHICLE - ELECTRICAL Reverse Buzzer Limit Switch COMPONENTS Figure 19-22 Reverse Buzzer Limit Switch Page 19-26 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 305: Low Oil Warning Light

    Secure instrument panel to the dash assembly with three screws (1). Tighten screws to 1.8 ft·lb (2.5 N·m). Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-27...

  • Page 306: Fuel Gauge

    Connect the blue wire from the wire harness to the (I) terminal, the orange wire from the wire harness to the (S) terminal, and the black wire from the wire harness to the (G) terminal. Install the instrument panel. 4.1. Connect the electrical connector (3) (Figure 19-19, Page 19-18). Page 19-28 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 307: Fuel Level Sending Unit

    Install a new hour meter into bracket (3) and secure it by sliding the keeper (4) onto it (Figure 19-25, Page 19-30). Connect wires to the hour meter. Position bracket (3) on the vehicle and secure in place with screw (2). 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-29...

  • Page 308: Oil Level Sensor

    See Test Procedure 18 – Oil Level Sensor on page 18-31. OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 20-12. OIL LEVEL SENSOR INSTALLATION See Oil Level Sensor Installation on page 20-13. Page 19-30 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 309: Battery

    Any frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 41 in·lb (4.3 N·m), coat terminals with Battery Terminal Protector Spray to prevent future corrosion. See preceding WARNINGS and following CAUTION. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-31...

  • Page 310: Self-Discharge

    The acid that is lost reduces the capacity of the battery and cannot be replaced. Page 19-32 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 311: Battery Removal

    N·m) for top-post battery. A loose battery clamp may allow the battery to become damaged from vibration or jarring. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 19-33...

  • Page 312: Battery Storage

    NOTE: Verify that all cables (fuel tank, engine, battery, starter/generator and voltage regulator) are connected securely. TESTING THE GROUND CABLES See Test Procedure 3 – Ground Cables on page 18-15. Page 19-34 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 313: Section 20 - Gasoline Vehicle - Engine

    Anyone attempting engine service should have knowledge and experience in small engine service and repair. ENGINE ROTATION When turning the crankshaft by hand, always turn it counterclockwise as viewed from the clutch side of the engine. 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-1...

  • Page 314: Torque Specifications

    Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (Figure 20-1). See following CAUTION. CAUTION • Do not remove dipstick while engine is running. Page 20-2 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 315 Access the engine compartment and place the Maintenance/Operate switch in the MAINTENANCE position. Disconnect battery and spark plug wire. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Position a pan designed for oil changes under the drain plug (1) (Figure 20-2). 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-3...
  • Page 316 The engine requires 40.5 fl-oz (1.2 L) of oil per change. 10W-30 or 5W-30 grade SE or higher is recommended. Refer to oil viscosity guidelines for selection of oil grade (Figure 20-3). Replace the dipstick. Page 20-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 317: Spark Plug

    • Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle. To avoid ignition of fuel and serious personal injury or death, never try to start the engine with plug removed from engine. 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-5...

  • Page 318: Breather

    Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber. In the rocker chamber most oil separates from the air and drains back to the crankcase. The air passes through a tube and vents to the intake manifold. Page 20-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 319: Valve Clearance Check And Adjustment

    1. Feeler Gauge 2. Lock Nut 3. Adjuster Screw 4. Rocker Arm cylinder head surface. (exhaust) 5. Rocker Arm (intake) 3034 3035 Figure 20-5 Top Dead Center (TDC) – EX40 Engine Figure 20-6 Setting Valve Clearance – EX40 Engine 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-7...

  • Page 320: Engine Removal

    Engine Removal GASOLINE VEHICLE - ENGINE ENGINE REMOVAL ENGINE REMOVAL 3036a Figure 20-7 EX40 Engine and Mounting Brackets Page 20-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 321: Engine Installation

    Install drive clutch. See Drive Clutch Installation, Section 23, Page 23-11. Install muffler. See Muffler Installation, Section 22, Page 22-1. Install starter/generator and belt. See Starter/Generator Installation, Section 19, Page 19-12. 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-9...

  • Page 322: Flywheel

    Adjust the engine RPM setting. See Engine RPM Adjustment on page 21-13. Test-drive vehicle to ensure all systems are functional and correctly adjusted. FLYWHEEL See General Warnings on page 1-2. Page 20-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 323: Flywheel Removal

    Detach flywheel (4) from crankshaft with a large, two-jaw puller. Remove flywheel nut (8) and flywheel (4) from crankshaft. Remove woodruff key (10) from groove in crankshaft. 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-11...

  • Page 324: Flywheel Installation

    Remove bolt (1) securing oil sensor wire clamp (2) to engine. Disconnect oil level sensor wire (3) from wire harness (Figure 20-11, Page 20-13). Remove two bolts (4) securing oil sensor (5) in engine. Page 20-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 325: Oil Level Sensor Installation

    Install flywheel and fan shroud. See Ignition Coil Removal on page 20-14. Fill engine to proper level with correct type of oil. See Engine Oil – Gasoline Vehicle, Section 20, Page 20-2. 3038 Figure 20-11 Oil Level Sensor – EX40 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-13...

  • Page 326: Ignition Coil

    0.012 to 0.020 in. (0.3 to 0.5 mm) (Figure 20-13, Page 20-14). Tighten ignition coil bolts (6) to 71 in·lb (8 N·m). Connect ignition coil primary lead wire (12) to terminal (13) on coil (Figure 20-12, Page 20-14). Page 20-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 327: Snubber

    Slide snubber (2) onto bracket (5) (Figure 20-14, Page 20-15). Install bracket and snubber assembly onto engine pan (1). Tighten lock nuts (4) from 20 to 25 ft·lb (27.1 to 33.9 N·m). 3039 Figure 20-14 Snubber 2019 Precedent Villager 2 Maintenance and Service Manual Page 20-15...
  • Page 328 Snubber GASOLINE VEHICLE - ENGINE Pagination Page Page 20-16 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 329: Section 21 - Gasoline Vehicle - Fuel System

    • Flow: 16 L per hour minimum @ 12-volts/36 psig (250 kPa) • Current draw: 2-amps maximum • Throttle Body Bore: 31 mm diameter • Open-loop system (i.e. oxygen sensor not used) • Separate EFI wire harness • Fail-safe function 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-1...
  • Page 330 GASOLINE VEHICLE - FUEL SYSTEM 1. ECU 2. Fuel Pump 3. Fuel Tank 4. Fuel Injector 5. MAP Sensor 6. Engine Temperature Sensor 7. CDI Ignition Unit 3040 Figure 21-1 EFI System Components Page 21-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 331: Refuel

    • Do not repeatedly attempt to start a vehicle when the fuel pump is dry (no gas in tank). Doing so can damage the fuel pump. Turn the key to OFF. Let the engine cool. Lift the seat bottom. 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-3...

  • Page 332: Relieving Fuel Pressure

    Following these will relieve any pressure in the fuel hose prior to opening the fuel system. TO RELIEVE FUEL PRESSURE • Shut off engine, disconnect battery, and wait 15 minutes or more to allow pressure to dissipate. – or – Page 21-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 333: Throttle Body

    • Carefully drain any fuel into an approved container. Add drained fuel back into fuel tank or dispose of properly. Loosen air intake hose clamp and disconnect air intake hose. 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-5...
  • Page 334 Remove two flange nuts (7) and slide air intake adapter (3), bracket (4), gaskets (8), insulator (9), and throttle body (1) off threaded studs. 3041 Figure 21-3 Throttle Body – Exploded View Page 21-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 335: Throttle Body Installation

    • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 24-1, Page 24-1). Test drive vehicle to ensure proper operation. 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-7...

  • Page 336: Engine Control Linkages

    See following CAUTION. CAUTION • Improper adjustment can result in poor vehicle performance and/or damage to the engine components. 3123 Figure 21-4 Engine Control Linkages – Villager 2 EFI vehicles Page 21-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 337: Ground Speed

    At transaxle: 2.1. Slide bellows off threaded end of cable housing, separate jam nuts and place threaded end into governor bracket (5) (Figure 21-6, Page 21-10). 2.2. Finger-tighten jam nuts. 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-9...

  • Page 338: Accelerator Cable

    Access the pedal group and disconnect accelerator cable clip from the accelerator pedal. See Pedal Group Removal on page 5-4. 4.2. Loosen jam nuts securing accelerator cable to underbody and remove accelerator cable (9) from vehicle (Figure 5-4, Page 5-5). Page 21-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 339 Before tightening the cable jam nuts, make sure the engine RPM adjustment is correct. See Engine RPM Adjustment on page 21-13. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-11...

  • Page 340: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles

    Convert to MPH: Divide 72000 ft/hour by 5280 (number of ft in 1 mile) = 13.64 miles/hour Convert to KPH: Move the decimal point over three places; 21960 m/hour = 21.96 km/hour Page 21-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 341: Engine Rpm Adjustment

    Excessive drive belt and clutch wear can also prevent proper ground speed adjustment. Check them for excessive wear. Section 23 — Gasoline Vehicle - Clutches 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-13...

  • Page 342: Air Intake System

    Pull the yellow tab (1) on the air filter cover (2) away from the air cleaner (Figure 21-10, Page 21-15). Rotate the cover counterclockwise to approximately the 10 o’clock position to release the internal locking tabs. Remove the cover. Page 21-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 343: Air Intake System Removal

    • If air cleaner is extremely dirty, clean thoroughly. • Use only Club Car replacement air filters or equivalent. The use of other air filters could result in engine damage. If the air filter is too small, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.

  • Page 344: Air Intake System Installation

    • Intake hose (3) is made from a special fire retardant neoprene material. Use of any hose that does not meet Club Car, LLC specifications could create a fire hazard. • Improper orientation of the hose clamp (5) may result in fuel tank damage (Figure 21-11, Page 21-16).

  • Page 345: Fuel Line

    NOTE: This EFI gasoline vehicle is equipped with SAEJ30R9 fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.

  • Page 346: Fuel Line Installation

    • Ensure line is connected properly to avoid a leak that can cause a fire. • Make sure fuel line is the correct length and properly routed. Failure to heed this warning could result in damage to fuel line and fire. Page 21-18 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 347: Fuel Pump Module

    The fuel pump module can be disassembled to replace the fuel filter. The EFI gasoline vehicle is equipped with an electric fuel pump. The fuel pump is protected by a filter and pickup screen. 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-19...

  • Page 348: Fuel Pump Module Removal

    Install hold down ring (6) and ground wire (7) with hardware (5) and tighten in a crisscross pattern to 66 in·lb (7.5 N·m). See following WARNING. WARNING • Always install ground wires during reassembly. Tighten fuel tank retaining strap screw (9) to 26.5 in·lb (3 N·m). Page 21-20 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 349 DANGER • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 24-1, Page 24-1). 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-21...
  • Page 350 Fuel Pump Module GASOLINE VEHICLE - FUEL SYSTEM 3125a Figure 21-15 Fuel System (Precedent) – Exploded View Page 21-22 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 351: Fuel Tank

    SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. FUEL TANK REMOVAL Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position.

  • Page 352: Fuel Tank Disposal

    SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. Place fuel tank (10) in vehicle.
  • Page 353 DANGER • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 24-1, Page 24-1). 2019 Precedent Villager 2 Maintenance and Service Manual Page 21-25...

  • Page 354: Fuel Filter

    Start the engine and check for fuel leaks. See following DANGER. DANGER • Repair all fuel leaks before operating the vehicle. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 24-1, Page 24-1). Page 21-26 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 355: Carbon Canister

    CARBON CANISTER WARNING • If the carbon canister is damaged, only use an OEM (Club Car) replacement that is specifically designed and approved for use on this vehicle. Do not attempt to repair it. See the following canister removal procedure.
  • Page 356 Carbon Canister GASOLINE VEHICLE - FUEL SYSTEM Attach hoses (2, 3, and 4) to appropriate locations on carbon canister and secure with hose clamps (1). Install and/or lower seat bottom. Page 21-28 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 357: Section 22 - Gasoline Vehicle - Exhaust System

    Start the engine and check for exhaust leaks and proper engine operation. See following DANGER. DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 2019 Precedent Villager 2 Maintenance and Service Manual Page 22-1...
  • Page 358 Muffler GASOLINE VEHICLE - EXHAUST SYSTEM 3112a Figure 22-1 Exhaust System Page 22-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 359: Section 23 - Gasoline Vehicle - Clutches

    Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation. 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-1...
  • Page 360 1. Drive Clutch Hub Puller 2. Driven Clutch Cam Puller 3. Driven Clutch Cam Press Tool 4. Drive Clutch Holder Tool 5. Driven Clutch Puller Plug 6. Cam Installation Tool 7. Drive Clutch Puller 2963 Figure 23-1 Clutch Tools Page 23-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 361: Drive Belt

    With the belt started onto the driven clutch (1), rotate the driven clutch counterclockwise and roll the belt over the outer, moveable sheave. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-3...

  • Page 362: Drive Clutch

    7. Drive Clutch Button 16. No Item to Show 8. Drive Clutch Weight 17. Spacer, Idler, Drive 9. Thrust Washer 18. Sheave, Fixed, Drive 2960 Figure 23-3 Drive Clutch – Exploded View Page 23-4 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 363: Drive Clutch Removal

    • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised WARNING CONTINUED ON NEXT PAGE 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-5...

  • Page 364: Drive Clutch Cleaning And Inspection

    23-6, Page 23-7). Make match marks on the drive clutch hub and on the moveable face (Figure 23-6, Page 23-7). Remove the drive clutch hub (5) (Figure 23-3, Page 23-4): Page 23-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 365 Remove the thrust washer (9) from the moveable sheave (13) (Figure 23-3, Page 23-4). Remove the drive buttons (3) by removing the screws (1), flat washers (2), and drive button take-up springs (4) as shown (Figure 23-8, Page 23-8). 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-7...
  • Page 366 NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 23-10, Page 23-9). 5.3. Remove the plastic washers, weights (2 and 3) and wave washer (1) from the pin (4). Retain all parts. Page 23-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 367: Inspection Of Drive Clutch Parts

    Replace the shaft if it is worn, scratched, or damaged. Inspect the thrust washer (9) for wear. If it is worn more than 0.030 in. (0.76 mm), turn it over or replace it with a new one. 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-9...

  • Page 368: Drive Clutch Assembly

    (Figure 23-12, Page 23-10). Figure 23-12 Install White Washers Install the 1/4-20 bolts (1) and washers (2) and tighten them to 10 ft·lb (13 N·m) (Figure 23-9, Page 23-8). See following NOTE. Page 23-10 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 369: Drive Clutch Installation

    Engines, Section 19, Page 19-13. Install the drive belt as instructed. See Drive Belt Installation on page 23-3. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-11...
  • Page 370 Drive Clutch GASOLINE VEHICLE - CLUTCHES Drive the vehicle and check for proper operation. Page 23-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 371: Driven Clutch

    11. Sheave, Fixed, Driven 6. Spring, Driven Clutch, 55 Degree 12. Key, 3/16 in. (4.7 mm) Square X 1.50 in. (38 mm) Long 2961 Figure 23-14 Driven Clutch – Exploded View 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-13...

  • Page 372: Driven Clutch Removal

    (3) from the fixed sheave. Remove the spring (6) (Figure 23-14, Page 23-13). Retain the key (4). Slide the moveable sheave (9) off the fixed sheave (11). Page 23-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 373: Driven Clutch Inspection

    1/4 to 3/8 in. (6.3 to 9.5 mm). 5.1. Press Assembly Process: 5.1.1. Place the clutch assembly in a press and position the cam press tool on the cam (2) as shown (Figure 23-17, Page 23-16). 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-15...
  • Page 374 (Figure 23-17, Page 23-16). 5.2.5. Place the cam press hub (6) onto the cam installation bolt and thread it down onto the cam hub, centering the press hub onto the cam hub. Page 23-16 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 375: Driven Clutch Installation

    NOTE: The bolt (1) must be replaced with a new bolt containing a locking patch that will prevent the bolt from loosening. Tighten the bolt (1) to 18 ft·lb (24.4 N·m). Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 23-17...
  • Page 376 Driven Clutch GASOLINE VEHICLE - CLUTCHES Pagination Page Page 23-18 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 377: Section 24 - Gasoline Vehicle - Transaxle

    With the switch in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position. See following WARNING and NOTE. 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-1...

  • Page 378: Governor System

    WT. API class GL or 80-90 WT. AGMA class 5 EP gear lubricant (or until lubricant begins to run out of the level indicator hole). Install upper plug and gasket and tighten to 17 ft·lb (23 N·m). Page 24-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 379: Tools Required For This Section

    No. 2 phillips-head screwdriver 16-in. rolling head prybar 5/8-in. socket, 3/8- in. drive 1/4-in. nut driver Plastic or rubber mallet Axle seal tool 5/16-in. nut driver Ratchet wrench, 3/8-in. drive 7/16-in. combination wrench 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-3...

  • Page 380: Rear Hubs

    NOTE: If brake shoes are replaced on one side, replace the opposite side also. Clean the splines and threaded portion of the axle shaft. Apply anti-seize compound to both the axle shaft splines and hub (6) splines. See following CAUTION. Page 24-4 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 381 See Connecting the Battery- Gasoline Vehicles on page 1-3. A = 1.49 in. (38 mm) maximum diameter allowable area for cotter pin after deformation. 3057 Figure 24-4 Cotter Pin Deformation 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-5...

  • Page 382: Axle Tubes, Axle Shafts And Wheel Bearings

    Avoiding damage caused by dragging splines across lip of oil seal (7) in transaxle gearcase, carefully pull axle tube (2) and shaft (3) from transaxle. 3058 Figure 24-5 Axle Tube, Shaft, Bearing and Oil Seal Page 24-6 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 383: Axle Tube And Axle Shaft Installation

    The rear axle tubes (2) must be unbolted from the transaxle to replace oil seals (7) (Figure 24-5, Page 24-6). Clean debris from drain plug and area around it at the bottom of the transaxle. Drain oil. Install plug after draining. 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-7...

  • Page 384: Axle Shaft Oil Seal Installation

    Clean end of axle shaft (3) and carefully install axle tube (2) to avoid damaging new oil seal (7) with splines of axle shaft. See Axle Tube and Axle Shaft Installation on page 24-7. Refill transaxle with appropriate type and volume of oil. See Oil Change – Transaxle on page 24-2. Page 24-8 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 385: Transaxle Removal

    Figure 24-6 Governor Arm, Cable and Brackets Figure 24-7 Disconnect Shock Absorbers Disconnect brake cables from brake assemblies. See Wheel Brake Assemblies section. Remove lower shock mounting hardware from both rear shocks (Figure 24-7, Page 24-9). 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-9...
  • Page 386 Grasp ends of leaf springs at rear of vehicle and carefully pull the powertrain until snubber at front of engine pan is free of the chassis. Gently lower front of powertrain to the floor (Figure 24-12, Page 24-11). The powertrain should be completely disconnected from vehicle and resting on floor. Page 24-10 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 387 NOTE: The transaxle weighs approximately 58 lb (26.2 kg). If replacing transaxle, remove leaf springs, wheels, hubs and brake assemblies and retain for installation on new transaxle. See Rear Suspension section. See Wheel Brake Assemblies section. 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-11...

  • Page 388: Transaxle Installation

    Check governor adjustment and correct if necessary. See Governor Cable Installation and Adjustment, Section 21, Page 21-9. Check engine RPM setting. Adjust if necessary. See Engine RPM Adjustment, Section 21, Page 21-13. Page 24-12 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 389: Forward/Reverse Handle

    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. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. 2019 Precedent Villager 2 Maintenance and Service Manual Page 24-13...

  • Page 390: Shifter Cable Installation

    To adjust, the jam nuts (6) at the FNR/accelerator cable bracket must be loosened and moved forward or backward as required (Figure 24-16, Page 24-14). Tighten jam nuts (6) to 22 ft·lb (29.8 N·m). Page 24-14 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 391: Section 25 - Wiring Diagrams

    BLK_WHT Black with White Stripe BLK_YEL Black with Yellow Stripe BLU_WHT Blue with White Stripe BRN_WHT Brown with White Stripe GRN_RED Green with Red Stripe TABLE CONTINUED ON NEXT PAGE 2019 Precedent Villager 2 Maintenance and Service Manual Page 25-1...

  • Page 392: General Information

    ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe Page 25-2 2019 Precedent Villager 2 Maintenance and Service Manual...

  • Page 393: Electric: Accessory Wiring Diagram

    WIRING DIAGRAMS Electric: Accessory Wiring Diagram ELECTRIC: ACCESSORY WIRING DIAGRAM WD1025104E5-L 2019 Precedent Villager 2 Maintenance and Service Manual Page 25-3...
  • Page 394 Electric: Accessory Wiring Diagram WIRING DIAGRAMS WD1025104E5-R Figure 25-2 Electric: Accessory Wiring Diagram (Continued) Page 25-4 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 395 Wiring Diagrams Electric: Main Harness ELECTRIC: MAIN HARNESS...
  • Page 396 (Page intentionally left blank.)
  • Page 397 Wiring Diagrams Electric: Instrument Panel Dash Harness ELECTRIC: INSTRUMENT PANEL DASH HARNESS...
  • Page 398 (Page intentionally left blank.)
  • Page 399 Wiring Diagrams Gasoline: Main Harness GASOLINE: MAIN HARNESS...
  • Page 400 (Page intentionally left blank.)
  • Page 401 Wiring Diagrams Gasoline: Instrument Panel Dash Harness GASOLINE: INSTRUMENT PANEL DASH HARNESS...
  • Page 402 (Page intentionally left blank.)
  • Page 403 Wiring Diagrams Gasoline: Engine Harness GASOLINE: ENGINE HARNESS...
  • Page 404 (Page intentionally left blank.)

  • Page 405: Index

    12-12 battery type............11-8 voltage test (under load) ........ 12-13 code a, code b, and code c ......... 11-8 vibration damage..........14-10 connection tests ..........11-27 battery control mode ............11-7 2019 Precedent Villager 2 Maintenance and Service Manual Index-1...
  • Page 406 6-4 seat ..............4-1 vehicle body............4-1 clutch (torque converter) troubleshooting....23-1 connector, 18-pin clutch, drive see test procedures........18-16 see drive clutch ..........23-4 installation ............19-17 Index-2 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 407 .............. 4-6 front body high pedal detect ........... 12-2 see body, front ............. 4-3 hip restraint ............4-11 front bumper............4-5 hubs fuel hub, rear relieving pressure ..........21-4 installation ............24-4 2019 Precedent Villager 2 Maintenance and Service Manual Index-3...
  • Page 408 ............22-1 testing ............. 18-21 removal ............. 22-1 see also exhaust system........22-1 leaf spring see suspension, front and suspension, rear ... 9-2 low oil warning light neutral lockout............24-1 Index-4 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 409 ........4-3 cleaning ..........19-5–19-6 minor impact damage/deformations....4-2 inspection..........19-5–19-6 minor scratches and surface blemishes ....4-3 removal ............19-6 stress lines or streaks........4-2 2019 Precedent Villager 2 Maintenance and Service Manual Index-5...
  • Page 410 ............... 18-14 removal ............9-2 ground cables ..........18-15 shock absorber ignition coil............18-29 inspection and removal........9-1 iignition spark........... 18-28 installation ............9-1 key switch sweater basket ............4-12 Index-6 2019 Precedent Villager 2 Maintenance and Service Manual...
  • Page 411 ............17-1 oil seal installation ............17-4 removal ............17-1 removal ............. 17-5 troubleshooting CDT handheld programmer........11-26 torque converter ..........23-1 troubleshooting guide 1........12-5 troubleshooting guide 2........12-8 troubleshooting guide 2019 Precedent Villager 2 Maintenance and Service Manual Index-7...
  • Page 412 NOTES...

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