Grille Installation; Front Bumper And Side Fender Removal; Front Bumper And Side Fender Installation - Club Car Carryall 550 2019 Maintenance And Service Manual

4
Front Body

GRILLE INSTALLATION

1. Connect the charger receptacle or connector (quick connect).
2. Install, but do not tighten upper M6 screws. (Do not tighten screws until plastic bumper is installed).
3. Lower grille holes are shared with the front bumper, ensure lower bumper screws are attached first then install
grille.
4. Line up upper and lower bolt holes.
5. Install and tighten upper bolts, then lower right and left side bolts. Tighten to 44 in·lb (5 N·m).
6. Connect the batteries.See Connect the Batteries – Electric Vehicles, Section 1, Page 1-5.

FRONT BUMPER AND SIDE FENDER REMOVAL

1. Park the vehicle, chock tires.
2. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
3. Remove HD bumper, (if equipped). See Brushguard Removal on page 4-4.
4. Remove cowl. See Front Cowl on page 4-6.
5. Remove the grille. See Grille Removal on page 4-6.
6. Loosen and remove the two upper and lower bolts (7) that attach the bumper to the vehicle frame. Push down
and rearward on front fenders near the bumper (Figure 4-3, Page 4-7).
7. Remove front bumper (6).
8. Loosen and remove the inner screws, nuts, and spacers (1, 2, 3, and 4) that attach the side fender to the
frame (repeat procedure on opposite side).
9. Unsnap body clips and remove side fenders (5).

FRONT BUMPER AND SIDE FENDER INSTALLATION

1. Install side fenders (5) by snapping in body clips.
2. Install inner screws, nuts, and spacers (1, 2, 3, and 4) that attach the side fender to the frame.
3. Install front bumper (6).
4. Install the two upper and lower bolts (7) that attach the bumper to the vehicle frame. Push down and rearward on
front fenders near the bumper to install.
5. Install the grille. See Grille Installation, Section 4, Page 4-8.
6. Install the front cowl. See Cowl Installation, Section 4, Page 4-5.
7. Install HD bumper (if equipped). See Brushguard Installation, Section 4, Page 4-4.
8. Connect the batteries.See Connect the Batteries – Electric Vehicles, Section 1, Page 1-5.
9. Remove tire chocks.
Page 4-8 2019 Carryall 550 Maintenance and Service Manual
BODY AND TRIM