Engine Installation - Club Car Carryall 300 2018 Maintenance And Service Manual

ENGINE (SUBARU EX40)
2. For some vehicles, the engine (1) can be removed by lifting it up and out of the chassis. For other vehicles, it
is easier to remove the entire powertrain assembly first. If removing powertrain, see Transaxle Removal on
page 26-9.
3. If equipped, remove air deflector from top of engine.
4. Disconnect governor cable and P-clamp, air intake hose, fuel line, wire harness connectors, ground cable, and
accelerator cable P-clamp. See Fuel System: Gasoline Vehicles, Section 23, Page 23-1.
5. Remove starter/generator and belt. See Starter/Generator Removal, Section 20, Page 20-1.
6. Remove drive clutch. See Drive Clutch Removal, Section 25, Page 25-5.
7. Remove muffler. See Muffler Removal, Section 24, Page 24-1.
8. Remove engine mounting hardware (2, 3, 4, 5, and 6) from muffler bracket (7), clutch plate (8), and engine pan
(9) (Figure 22-7, Page 22-8).
9. Lift engine (1) from engine pan (9). See following NOTE.
NOTE: The engine weighs approximately 54 lb (24.5 kg).
10. Remove crankcase oil drain plug and drain all oil from crankcase. Dispose of engine oil properly.
11. If replacing engine (1), remove starter/generator mounting weldment (10) and retain for installation on new
engine. See following NOTE.
NOTE: If replacing engine and throttle body, the ECU must also be replaced. Throttle bodies and ECU's are matched
pairs.

ENGINE INSTALLATION

See General Warnings on page 1-1.
1. If replacing engine (1), install starter/generator mounting weldment (10) on engine with screws (11), bolts (12),
washers (13), and locknuts (14) (Figure 22-7, Page 22-8). 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 20-12.
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).
2018 Carryall 300 Maintenance and Service Manual
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Engine Installation
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