Club Car Carryall 500 2016 Maintenance And Service Manual page 392

22
Engine Installation
11. Connect air intake hose, fuel line, wire harness connectors, ground cable and governor cable. See Fuel System:
Gasoline Vehicles, Section 23, Page 23-1.
12. If equipped, install air deflector on top of engine.
13. Secure accelerator cable and governor cable P-clamps to engine. Tighten P-clamp bolts to 36 in·lb (4.0 N·m).
14. Check all hardware for proper torque/tightness.
15. Fill engine to proper level with correct type of oil. See Engine Oil – Gasoline Vehicle, Section 22, Page 22-2.
CAUTION
• Do not overfill with oil.
16. Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles,
Section 1, Page 1-5.
See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5.
17. Adjust the engine RPM setting. See Engine RPM Adjustment on page 23-14.
18. Test-drive vehicle to ensure all systems are functional and correctly adjusted.
ENGINE INSTALLATION FROM MID-2016 MODEL YEAR
1. If replacing engine (1), install starter/generator mounting weldment (10) on engine with screws (11), bolts (12),
washers (13), and locknuts (14) (Figure 22-8, Page 22-10). Tighten locknuts (14) only finger-tight at this time.
2. Install oil drain plug and tighten to 18 ft·lb (24.4 N·m).
3. Place engine (1) onto engine pan (9) and secure with mounting hardware (4, 5, and 6). Leave flange nuts (4)
loose at this time.
4. Install clutch plate (8) with bolts (3 and 21). Leave bolts loose at this time.
5. Install bolts (2) through muffler bracket (7) into transaxle but do not tighten.
6. Tighten hardware in the following order:
6.1. Tighten bolts (3) to 27 ft·lb (36 N·m).
6.2. Tighten bolts (21) to 50 ft·lb (68 N·m).
6.3. Tighten bolts (2) to 50 ft·lb (68 N·m).
6.4. Tighten flange nuts (4) to 33 ft·lb (40.6 N·m).
6.5. Tighten locknuts (14) and bolts (15) to 17 ft·lb (23 N·m).
7. Install drive clutch. See Drive Clutch Installation, Section 25, Page 25-11.
8. Install muffler. See Muffler Installation, Section 24, Page 24-1.
9. Install starter/generator and belt. See Starter/Generator Installation, Section 20, Page 20-11.
10. If necessary, install powertrain. See Transaxle Installation, Section 26, Page 26-13.
11. Connect air intake hose, fuel line, wire harness connectors, ground cable and governor cable. See Fuel System:
Gasoline Vehicles, Section 23, Page 23-1.
12. If equipped, install air deflector on top of engine.
13. Secure accelerator cable and governor cable P-clamps to engine. Tighten P-clamp bolts to 36 in·lb (4.0 N·m).
14. Check all hardware for proper torque/tightness.
15. Fill engine to proper level with correct type of oil. See Engine Oil – Gasoline Vehicle, Section 22, Page 22-2.
Page 22-12 2016 Carryall 500 and 700 Maintenance and Service Manual
ENGINE (SUBARU EX40)