Club Car Carryall 295 Maintenance And Service Manual page 330

16
Diesel Engine
7. Install the clutch outer cover. See Clutch Outer Cover Installation on page 16-37.
8. Using new gasket, slide exhaust system forward and secure the manifold pipe to the exhaust manifold. See
Manifold Pipe Installation on page 16-6.
9. Tighten the hardware that secures the muffler. See Muffler Installation on page 16-6.
10. Attach the air filter outlet hose to the intake manifold. See Air Filter Outlet Hose Installation on page 16-25.
11. Connect the two black ground wires (13) to the engine block and tighten the bolt to 39 ft-lb (53 N·m).
12. Connect the red wires (12) to starter solenoid and tighten the nut and lock washer to 90 in-lb (10.3 N·m).
13. Connect the green wire (10) to the starter solenoid and the blue wire (11) to the white solenoid wire (Figure
16-2, Page 16-2).
14. Connect the oil pressure switch connector (9) to the wire harness.
15. Connect the thermostat switch connector (8) to the wire harness (Figure 16-2, Page 16-2).
16. Connect the fuel solenoid valve three-pin connector (7) to the engine (Figure 16-1, Page 16-2).
17. Connect the accelerator cable sheath (6) to the engine bracket (Figure 16-1, Page 16-2).
18. Connect the accelerator cable (5) to the throttle lever.
19. Remove the plug and secure the fuel return line (4) to the engine relief valve with a new clamp (Figure 16-1,
Page 16-2). See following DANGER.
DANGER
• Diesel fuel! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle
and service area.
• To prevent fuel from siphoning, keep the fuel supply line above the fuel level in the fuel tank when
removing the plug.
20. Remove the plug and secure the fuel supply line (3) to the fuel injector assembly (vehicles with electric fuel pump)
or the engine mounted fuel pump (vehicles with mechanical fuel pump) with a new clamp (Figure 16-1, Page
16-2). See previous DANGER.
21. Bleed air from the fuel system, if necessary, and check for leaks. See Bleeding Air From Fuel System on
page 16-9.
22. Attach the overflow/bypass hose (2) to the thermostat cover and secure with new clamp.
23. Attach the upper (1) and lower radiator hoses to the engine and secure with new clamps.
24. Refill the engine and radiator coolant system. See Engine Coolant Change, Section 18, Page 18-1.
25. Install seat frame and lower ROPS (Roll Over Protection Structure). See Seat Support Installation, Section 4,
Page 4-10.
26. Install the upper ROPS frame. See ROPS Installation, Section 4, Page 4-8.
27. Install the cargo bed. See Cargo Bed Installation, Section 4, Page 4-14.
28. Check the engine oil level. See Engine Oil Level Check on page 10-9.
29. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4.
30. Adjust the engine RPM setting if required. See Engine RPM Adjustment on page 16-19.
31. Install both seats.
32. Test-drive the vehicle to ensure all systems are functional and adjusted correctly.
Page 16-4 2008-2012 All-Wheel Drive Maintenance and Service Manual
DIESEL ENGINE, MUFFLER, FUEL SYSTEM,
AND CLUTCHES