Club Car Precedent Villager 2 2019 Maintenance And Service Manual
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Club Car Precedent Villager 2 2019 Maintenance And Service Manual

Electric vehicle with eric charging system gasoline vehicle with kohler ech440 engine
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2019 Precedent,
Villager 2 and 4
Maintenance and
Service Manual
Electric Vehicle with ERIC Charging System
Gasoline Vehicle with Kohler ECH440 Engine
Manual Number 86753090002
Edition Code B

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Summary of Contents for Club Car Precedent Villager 2 2019

  • Page 1 2019 Precedent, Villager 2 and 4 Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Kohler ECH440 Engine Manual Number 86753090002 Edition Code B...
  • Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (1-800-258-2227), 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 Serial Number Decal 2843B Figure -1 Serial Number Decal © Copyright 2019 Club Car, LLC Club Car is a registered trademark of Club Car, LLC This manual effective July, 2019 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page iii...

  • Page 7: Table Of Contents

    CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 General Warnings............................1-2 Disabling the Vehicle..........................1-3 Disconnect the Battery - Gasoline Vehicles....................1-3 Connect the Battery - Gasoline Vehicles...................... 1-4 Disconnect the Batteries – Electric Vehicles ....................1-4 Connect the Batteries – Electric Vehicles ....................1-5 Recycling Lead-Acid Batteries ........................
  • Page 8 Front Body Installation ..........................4-6 Front Bumper ..............................4-8 Headlight Adjustment............................. 4-9 Aiming the Headlight Beam ........................4-9 Instrument Panel ............................4-10 Instrument Panel Removal ........................4-10 Instrument Panel Installation ........................4-10 Dash Assembly ............................4-11 Dash assembly Removal...........................4-11 Dash Assembly Installation ........................4-11 Floor Mat and Retainers..........................
  • Page 9 SECTION 5 — Accelerator and Brake Pedal Group ..................... 5-1 Pedal Group – Electric Vehicle ........................5-1 Pedal Group Removal..........................5-1 MCOR ..............................5-3 Pedal Group Installation ..........................5-3 Pedal Group – Gasoline Vehicle ........................5-4 Pedal Group Removal..........................5-4 Throttle Position Sensor ..........................
  • Page 10 SECTION 8 — Wheels and Tires ........................8-1 General Information ............................8-1 Wheels ................................. 8-1 Wheel Removal ............................8-1 Wheel Installation ............................8-1 Tires ................................8-2 Tire Removal............................. 8-2 Tire Repair ..............................8-2 Tire Installation ............................8-3 SECTION 9 — Rear Suspension ........................9-1 General Information ............................
  • Page 11 SM Version ..............................11-5 VCL App Version ............................11-5 Parameters ..............................11-6 Settings ..............................11-6 Amp Hours...............................11-8 Access Codes ............................11-8 Vehicle ID ..............................11-9 Monitor Menu ...............................11-9 Batt Voltage............................11-10 V min I ..............................11-10 Signed Battery Current..........................11-10 BDI Percent............................11-10 Speed ..............................11-10 Throttle ..............................
  • Page 12 Current Sense Fault..........................11-21 M– Shorted ............................11-21 FLD (Field) Missing..........................11-22 HW Failsafe ............................11-22 Fault History............................11-22 Clear Fault History ..........................11-22 Programming ............................. 11-22 Cloning ..............................11-23 Favorites..............................11-23 HHP Settings ............................. 11-23 Plot & Log ..............................11-25 Plot................................
  • Page 13 Reverse Buzzer Installation ........................13-9 Electronics Module .............................13-10 Electronics Module Removal ........................13-10 Electronics Module Installation ........................ 13-11 Speed Controller ............................13-12 Testing the Solid State Speed Controller ....................13-12 Speed Controller Removal ........................13-12 Speed Controller Installation........................13-12 Solenoid..............................13-13 Testing the Solenoid ..........................13-13 Solenoid Removal ..........................13-13 Solenoid Installation..........................13-14 Charger Receptacle ............................13-14 Testing the Charger Receptacle.......................13-14...
  • Page 14 Charger Maintenance ..........................15-13 USB Service Port Cleaning and Care .......................15-13 Charger Troubleshooting..........................15-14 Numbering Vehicles and Chargers......................15-14 USB Service Port............................15-14 Incoming AC Service ..........................15-14 Terminal Block Cover ..........................15-15 Resetting Power – External Charger ......................15-15 Resetting Power – Onboard Charger .......................15-15 External Charger Troubleshooting Indicators ....................15-16 Onboard Charger Fault Codes.........................15-18 Test Procedures ............................15-20 External Charger Repairs ..........................15-23...
  • Page 15 Ground Locations ............................ 18-1 Low Oil Warning Light ..........................18-2 Malfunction Indicator Light........................18-2 Troubleshooting Guide ..........................18-2 Gasoline Powertrain ..........................18-3 Fuse And Relay Locations..........................18-5 Electrical System ............................18-6 Test Procedures ............................18-7 Testing Basics ............................18-7 SECTION 19 — Gasoline Vehicle - Electrical Components ................. 19-1 Battery ................................
  • Page 16 Transaxle Limit Switch Installation ......................19-27 Brake Light Relay ............................19-28 Brake Light Relay Removal ........................19-28 Brake Light Relay Installation ........................19-29 Fuel Gauge/Hour Meter ..........................19-29 General Information ..........................19-29 Fuel Gauge/Hour Meter Removal ......................19-30 Fuel Gauge/Hour Meter Installation......................19-30 Headlight Switch............................19-31 Headlight Switch Removal........................19-31 Headlight Switch Installation........................19-31 Key Switch ..............................19-32 Key Switch Removal ..........................19-32...
  • Page 17 General Information ..........................21-17 Fuel Pump Module Removal ........................21-17 Fuel Pump Module Installation.........................21-19 Fuel Tank ..............................21-20 General Information ..........................21-20 Fuel Tank Removal ..........................21-20 Fuel Tank Disposal ..........................21-22 Fuel Tank Storage ..........................21-22 Fuel Tank Installation ..........................21-22 Fuel Filter..............................21-24 General Information ..........................21-24 Fuel Filter Removal..........................21-24 Fuel Filter Installation..........................21-25 SECTION 22 —...
  • Page 18 Forward/Neutral/Reverse Handle Installation ....................24-13 Shifter Cable ..............................24-13 Shifter Cable Removal ..........................24-13 Shifter Cable Installation .........................24-14 Shifter Cable Adjustment.........................24-14 SECTION 25 — Kohler Engine Service Manual ....................25-1 SECTION 26 — Wiring Diagrams........................26-1 General Information ............................. 26-1 Engine Harness Wiring Diagram Table ......................26-2 Index ................................

  • Page 19: Section 1 - Safety

    SECTION 1 — SAFETY SAFETY DETAILS Safety WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.

  • Page 20: 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 21: Disabling The Vehicle

    SAFETY General Warnings WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. Electric vehicles only: • Place Run/Tow switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning could result in a battery explosion or severe personal injury.

  • Page 22: Connect The Battery - Gasoline Vehicles

    General Warnings SAFETY CONNECT THE BATTERY - GASOLINE VEHICLES Connect the positive (+) cable (2) (Figure 1-1, Page 1-3). Connect the negative (-) cable (1). Tighten the hardware to 41 lb·in (4.3 N·m). Apply battery terminal protector spray to the battery terminals. DISCONNECT THE BATTERIES –...

  • Page 23: Connect The Batteries - Electric Vehicles

    SAFETY General Warnings CONNECT THE BATTERIES – ELECTRIC VEHICLES DANGER • Batteries disconnected or connected with the Run/Tow switch set to RUN can cause a battery explosion and serious personal injury. Set the Run/Tow switch to TOW before the batteries are disconnected or connected.

  • Page 24: 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 25: Section 2 - Vehicle Specifications

    SECTION 2 — VEHICLE SPECIFICATIONS ELECTRIC - VEHICLE SPECIFICATIONS Vehicle Specifications DIMENSIONS DESCRIPTION 2 PASSENGER VILLAGER 2 VILLAGER 4 Length 91.5 in (232 cm) 91.5 in (232 cm) 104 in. (264 cm) Width 47.25 in (120 cm) 47.25 in (120 cm) 47.25 in (120 cm) Height - at steering wheel 48.0 in (122 cm)

  • Page 26: Batteries

    Electric - Vehicle Specifications VEHICLE SPECIFICATIONS BATTERIES DESCRIPTION 2 PASSENGER VILLAGER 2 VILLAGER 4 Battery Type: 8V high capacity deep cycle flooded lead acid ● ● ● Battery Quantity: 6 ● ● ● NOISE AND VIBRATION DESCRIPTION 2 PASSENGER VILLAGER 2 VILLAGER 4 Drive-by Noise Level To Operator 68.5 dBA (±...

  • Page 27: Gasoline - Vehicle Specifications

    Cargo Capacity The cargo capacity includes the weight of optional equipment. Maximum Towing The maximum towing weight is the maximum weight the vehicle can tow with a Club Car approved tow kit. Weight Trailer Tongue Weight The trailer tongue weight is the maximum permitted weight applied by the trailer tongue onto the trailer hitch.

  • Page 28: Performance

    Gasoline - Vehicle Specifications VEHICLE SPECIFICATIONS PERFORMANCE DESCRIPTION 2 PASSENGER VILLAGER VILLAGER 4 12 to 15 mph 12 to 15 mph (19 to 24 km/h) (19 to 24 km/h) Forward speed (On Level Ground) - factory setting 19 mph (30.6 km/h) - factory setting 19 mph (30.6 km/h) 19 mph (30.6 km/h)

  • Page 29: Vehicle Weights And Load Capacities

    Cargo Capacity The cargo capacity includes the weight of optional equipment. Maximum Towing The maximum towing weight is the maximum weight the vehicle can tow with a Club Car approved tow kit. Weight Trailer Tongue Weight The trailer tongue weight is the maximum permitted weight applied by the trailer tongue onto the trailer hitch.
  • Page 30 Gasoline - Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 31: Section 3 - Extended Storage

    SECTION 3 — EXTENDED STORAGE DANGER Extended Storage • See General Warnings on page 1-2. DANGER • Fuel is flammable and explosive. Do not attempt to drain fuel when the engine is hot or while it is running. • Fuel is flammable and explosive. Do not operate the vehicle when fuel is spilled. Correctly clean the spilled fuel.

  • Page 32: Return To Service From Extended Storage - Electric

    Electric Vehicle Extended Storage EXTENDED STORAGE Set the Forward/Neutral/Reverse control (FNR) to N. Turn the key to OFF. Remove the key. Keep the key in a safe area. Put chocks against the wheels. NOTE: Do not engage the park brake. Remove all cargo and personal items.
  • Page 33 EXTENDED STORAGE Electric Vehicle Extended Storage Have a trained technician lubricate the vehicle. Do a daily pre-operation safety checklist. Do a vehicle performance inspection. 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 3-3...

  • Page 34: Gasoline Vehicle Extended Storage

    Gasoline Vehicle Extended Storage EXTENDED STORAGE GASOLINE VEHICLE EXTENDED STORAGE See General Warnings on page 1-2. EXTENDED STORAGE PREPARATION - GASOLINE Examine the battery state of charge (SOC) condition. If the SOC is weak, charge the battery. NOTE: Use an automotive-type 12-volt battery charger rated at 10-amps or less. Turn off all accessories.

  • Page 35: Return To Service From Extended Storage - Gasoline

    EXTENDED STORAGE Gasoline Vehicle Extended Storage Prepare the engine for extended storage: 14.1. Disconnect the spark plug wire (1) (Figure 3-2, Page 3-5). Figure 3-2 Spark Plug Wire 14.2. Use a spark plug socket to remove the spark plug. 14.3. Put 0.5 fl-oz (14.2 ml) of SAE 10 weight oil into the spark plug hole.
  • Page 36 Gasoline Vehicle Extended Storage EXTENDED STORAGE Figure 3-3 Fuel Tank Vent Nipple WARNING • Fuel is flammable and explosive. Make sure that the fuel tube is fully connected. 2.2. Connect the vent tube to the fuel tank vent nipple. Connect the battery. Set the Forward / Neutral / Reverse control (FNR) to N.

  • Page 37: Section 4 - Body And Trim

    SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. CLEANING THE WINDSHIELD CAUTION • Do not use a household window cleaner. Use a soft towel and water to clean the windshield. Use mild soap as necessary. CLEANING THE VEHICLE EXTERIOR CAUTION •...

  • Page 38: Cleaning The Vehicle Interior

    Cleaning the Vehicle Interior BODY AND TRIM CLEANING THE VEHICLE INTERIOR CAUTION • Moisture will cause electrical component damage. Do not use a pressure washer or steam cleaner to clean the vehicle. • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first.

  • Page 39: Minor Scratches And Surface Blemishes

    BODY AND TRIM Body Repair CAUTION • Holding the heat gun too close to the body could melt the body or damage the finish. Do not hold the heat gun closer than 6 inches (15 cm) to the body. Continue heating and bending the body until the original shape returns. Do not hold the gun closer than 6 inches (15 cm) to the body.

  • Page 40: Seat Hinge

    Seat Hinge BODY AND TRIM SEAT HINGE The seat bottom (1) is attached to the vehicle with two hinges (3) that hook into slots in the body. Figure 4-1 Seat Bottom Hinge SEAT HINGE REMOVAL Remove the seat bottom (1) from the vehicle (Figure 4-1). Remove the screws (2).

  • Page 41: Hip Restraint

    BODY AND TRIM Hip Restraint HIP RESTRAINT Figure 4-2 Hip Restraint HIP RESTRAINT REMOVAL Remove the seat bottom (1) from the vehicle (Figure 4-2). Remove the screws (2). Remove the hip restraint (3). HIP RESTRAINT INSTALLATION Align the hip restraint (3) onto the seat bottom (1) (Figure 4-2). Install the screws (2).

  • Page 42: Front Body Installation

    Front Body BODY AND TRIM Pull the front beauty panel (3) up and away from the brow and fascia assembly (4), disengaging the snap tabs. If the vehicle is equipped with a canopy, loosen the canopy support cover then loosen, but do not remove, the front canopy support bolts.
  • Page 43 BODY AND TRIM Front Body Figure 4-3 Front Body 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 4-7...

  • Page 44: Front Bumper

    Front Bumper BODY AND TRIM FRONT BUMPER The underbody bracket (1) connects the front suspension to the front underbody (Figure 4-4, Page 4-8). Each bracket is secured in place by two taptite screws (2) tightened to 13 ft·lb (17.6 N·m). The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4).

  • Page 45: Headlight Adjustment

    BODY AND TRIM Headlight Adjustment HEADLIGHT ADJUSTMENT Headlights are available as an accessory on this vehicle. To raise or lower the headlight beam, washers can be added to the mounting hardware between the headlight and the bumper assembly. See General Warnings on page 1-2. AIMING THE HEADLIGHT BEAM Park the vehicle on a level surface 5 feet away from, and facing a vertical surface such as a garage door or wall.

  • Page 46: Instrument Panel

    Instrument Panel BODY AND TRIM INSTRUMENT PANEL 2697B Figure 4-6 Instrument Panel INSTRUMENT PANEL REMOVAL Remove the screws (1) (Figure 4-6). Tilt instrument panel (2) up to release it from the dash assembly (3). Disconnect the electrical connector (4) on the passenger side. INSTRUMENT PANEL INSTALLATION Connect the electrical connector (4) on the passenger side (Figure 4-6).

  • Page 47: Dash Assembly

    BODY AND TRIM Dash Assembly DASH ASSEMBLY 2697C Figure 4-7 Dash Assembly DASH ASSEMBLY REMOVAL Remove the instrument panel (1) (Figure 4-7). Remove the screws (2). Disconnect the USB receptacle. Remove the dash assembly (3). DASH ASSEMBLY INSTALLATION Put the dash assembly (3) on vehicle (Figure 4-7). Make sure tabs on the forward edge engage to front underbody.

  • Page 48: Floor Mat And Retainers

    Floor Mat and Retainers BODY AND TRIM FLOOR MAT AND RETAINERS 1382 Figure 4-8 Floor Mat And Retainers FLOOR MAT REMOVAL Remove the screws (2) (Figure 4-8). Remove the floor mat (3) from under the floor mat retainers (1). FLOOR MAT INSTALLATION Install the floor mat (3) under the floor mat retainers (Figure 4-8).
  • Page 49 BODY AND TRIM Floor Mat and Retainers Install the push rivets (4) (Figure 4-8, Page 4-12). Tighten the two screws (2) to 4.4 lb·ft (6.0 N·m). 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 4-13...

  • Page 50: Kick Plate And Charger Receptacle Bezel - Electric Vehicles

    Kick Plate and Charger Receptacle Bezel – Electric Vehicles BODY AND TRIM KICK PLATE AND CHARGER RECEPTACLE BEZEL – ELECTRIC VEHICLES KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL Special Tools Needed Charger Bezel Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. Figure 4-9 Kick Plate and Charger Receptacle Bezel Removal Use the charger bezel tool to remove charger receptacle bezel (1) from the kick plate (2) (Figure 4-9, Page 4-14).

  • Page 51: Kick Plate And Charger Receptacle Bezel Installation

    Kick Plate and Charger Receptacle Bezel BODY AND TRIM – Electric Vehicles Raise the forward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate. Remove the kick plate from vehicle. KICK PLATE AND CHARGER RECEPTACLE BEZEL INSTALLATION Figure 4-10 Kick Plate and Charger Receptacle Bezel Installation Install the kick plate (3).

  • Page 52: Kick Plate - Gasoline Vehicles

    Kick Plate – Gasoline Vehicles BODY AND TRIM KICK PLATE – GASOLINE VEHICLES Figure 4-11 Kick Plate – Gasoline Vehicles KICK PLATE REMOVAL Remove the floor mat. Remove the three screws (1) and washers (2). Remove the two front screws (4). Raise the forward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate.

  • Page 53: Access Panel

    BODY AND TRIM Access Panel ACCESS PANEL Figure 4-12 Access Panel ACCESS PANEL REMOVAL Remove the two push rivets (1) (Figure 4-12). Remove the access panel (2). ACCESS PANEL INSTALLATION Install the access panel (2) onto the rear underbody (Figure 4-12). Install the two push rivets (1).

  • Page 54: Visage Display Unit Overhead Baskets

    Visage Display Unit Overhead Baskets BODY AND TRIM VISAGE DISPLAY UNIT OVERHEAD BASKETS OVERHEAD BASKET REMOVAL Remove the screw (1) (Figure 4-13, Page 4-18). Figure 4-13 Overhead Basket Release the tab (2) and remove the overhead basket (3). OVERHEAD BASKET INSTALLATION Align the overhead basket (3) with the display unit support (Figure 4-13, Page 4-18).

  • Page 55: Overhead Speaker Basket Removal

    BODY AND TRIM Visage Display Unit Overhead Baskets OVERHEAD SPEAKER BASKET REMOVAL Remove the screw (1) (Figure 4-14, Page 4-19). Figure 4-14 Overhead Speaker Basket Release the tab (2) and remove the overhead speaker basket (3). Disconnect the electrical connector (4). OVERHEAD SPEAKER BASKET INSTALLATION Connect the electrical connector (4) (Figure 4-14, Page 4-19).

  • Page 56: Two-Passenger - Canopy

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER - CANOPY TWO-PASSENGER CANOPY REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. Figure 4-15 Two-Passenger Canopy Removal Remove the nuts (1), washer (2), and bolts (3) from the canopy (4) and each front canopy strut (Figure 4-15). Remove the nuts (6), washer (7), and bolts (8) from the canopy and each rear canopy support.

  • Page 57: Two-Passenger Canopy Installation

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER CANOPY INSTALLATION Figure 4-16 Two-Passenger Canopy Installation Put the canopy (4) on top of the front and rear canopy supports (Figure 4-16). Make sure that the front supports are correctly positioned between the molded tabs on the underside of the canopy. Make sure that the molded protrusions at the rear of the canopy extend into the top of the rear supports.
  • Page 58 Two-Passenger - Canopy BODY AND TRIM Figure 4-17 Two-Passenger Canopy With Visage Display Unit Removal Remove the nuts (4), washer (5), and bolts (6) from each rear canopy support. Remove the canopy (7). Disconnect the canopy harness (8). Remove the screws (9) (Figure 4-18, Page 4-22). Figure 4-18 Visage Display Unit Removal Remove the Visage display unit (VDU) (10) from the display unit support.

  • Page 59: Two-Passenger Canopy With Visage Display Unit Installation

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER CANOPY WITH VISAGE DISPLAY UNIT INSTALLATION Put the tabs of the display unit support (12) into the front canopy struts (Figure 4-19, Page 4-23). Figure 4-19 Visage Display Unit Installation Install the display unit support onto the front canopy struts. Connect the display unit harness (11).
  • Page 60 Two-Passenger - Canopy BODY AND TRIM Connect the strut harness to the canopy harness (8) (Figure 4-20, Page 4-24). Figure 4-20 Two-Passenger Canopy With Display Unit Installation Install the canopy (7) on top of the front and rear canopy supports. Install the bolts (3), washers (2), and nuts (1).

  • Page 61: Two-Passenger Front Canopy Strut Removal

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER FRONT CANOPY STRUT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 62: Two-Passenger Front Canopy Strut Installation

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER FRONT CANOPY STRUT INSTALLATION Figure 4-22 Front Canopy Strut Installation Install the front canopy strut (3) onto the vehicle (Figure 4-22). Install the front canopy strut cover (2) onto the front canopy strut. Install the screws (4).

  • Page 63: Two-Passenger Rear Canopy Support Removal

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER REAR CANOPY SUPPORT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 64: Two-Passenger Rear Canopy Support Installation

    Two-Passenger - Rear Body BODY AND TRIM TWO-PASSENGER REAR CANOPY SUPPORT INSTALLATION Figure 4-24 Rear Canopy Support Installation Install the rear canopy support (2) into the structural accessory module (SAM) (Figure 4-24). Install the screw (1). Tighten the screw to 88 lb·in (10 N·m). Install the canopy.

  • Page 65: Structural Accessory Module (Sam)

    BODY AND TRIM Two-Passenger - Rear Body STRUCTURAL ACCESSORY MODULE (SAM) Figure 4-25 SAM SAM Removal If the vehicle has a canopy, remove the rear canopy supports from the SAM (2) (Figure 4-25). Remove the four bolts (1). SAM Installation Position the SAM (2) over its mounting holes (Figure 4-25).

  • Page 66: Seat Back

    Two-Passenger - Rear Body BODY AND TRIM SEAT BACK Figure 4-26 Seat Back Seat Back Removal Remove the two screws (1) (Figure 4-26). Remove the seat back (2) from the SAM (3). Seat Back Installation Put the seat back (2) on the SAM (3) (Figure 4-26). Install the two screws (1).

  • Page 67: Bag Rack Assembly

    BODY AND TRIM Two-Passenger - Rear Body BAG RACK ASSEMBLY Figure 4-27 Bag Rack Bag Rack Removal Remove the two screws (1) (Figure 4-27). Remove the bag rack (2) from the SAM (3). Bag Rack Installation Install the bag rack (2) onto the SAM (3) (Figure 4-27). Install the two screws (1).

  • Page 68: Bag Strap

    Two-Passenger - Rear Body BODY AND TRIM BAG STRAP Figure 4-28 Bag Strap Bag Strap Removal Remove the push rivets (1) and screw (2) (Figure 4-28). Remove the bag strap (3) from the bag rack (4). Bag Strap Installation Install the bag strap (3) onto the bag rack (4) (Figure 4-28). Install the push rivets (1) and screw (2).

  • Page 69: Sweater Basket

    BODY AND TRIM Two-Passenger - Rear Body SWEATER BASKET Figure 4-29 Sweater Basket Sweater Basket Removal Remove the three screws (1) (Figure 4-29). Remove the sweater basket (2) from the bag rack (3). Sweater Basket Installation Install the sweater basket (2) onto the bag rack (3) (Figure 4-29). Install the three screws (1).

  • Page 70: Rear Beauty Panel

    Two-Passenger - Rear Body BODY AND TRIM REAR BEAUTY PANEL Two-passenger rear beauty panel procedures. Figure 4-30 Rear Beauty Panel Rear Beauty Panel Removal Remove the structural accessory module (SAM). Remove the screws (1) (Figure 4-30). Remove the canopy support brackets (2). Remove the four screws (3).

  • Page 71: Rear Underbody

    BODY AND TRIM Two-Passenger - Rear Body REAR UNDERBODY Two-passenger rear underbody procedures. Figure 4-31 Rear Underbody Rear Underbody Removal Remove the structural accessory module (SAM). Remove the rear beauty panel. Remove remove the four screws (1) (Figure 4-31). Lift the rear edge of the rear underbody (2) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.

  • Page 72: Rear Crossmember

    Two-Passenger - Rear Body BODY AND TRIM REAR CROSSMEMBER Two-passenger rear crossmember procedures. 2656F Figure 4-32 Rear Crossmember Rear Crossmember Removal Remove the four bolts (1) (Figure 4-32) . Remove the rear crossmember (2). Rear Crossmember Installation Install the rear crossmember (2) onto the vehicle (Figure 4-32). Make sure that the J-clips (3) are installed on the inside of the frame rail.

  • Page 73: Villager 4 - Monsoon Canopy

    BODY AND TRIM Villager 4 - Monsoon Canopy VILLAGER 4 - MONSOON CANOPY MONSOON CANOPY REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. Remove the nuts (1), washers (2), and bolts (3) from the front canopy strut (4) (Figure 4-33). Figure 4-33 Canopy Removal - Front Canopy Strut Remove the screws (5) (Figure 4-34).

  • Page 74: Monsoon Canopy Installation

    Villager 4 - Monsoon Canopy BODY AND TRIM MONSOON CANOPY INSTALLATION Put the canopy (6) on top of the front and rear canopy supports (Figure 4-35). Install the screws (5). Tighten the screws to 80 lb·in (9 N·m). Figure 4-35 Canopy Installation - Rear Canopy Support Install the bolts (3), washers (2), and nuts (1) to secure the front canopy strut (4) (Figure 4-36).

  • Page 75: 2+2 Front Canopy Strut Removal

    BODY AND TRIM Villager 4 - Monsoon Canopy 2+2 FRONT CANOPY STRUT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 76: 2+2 Front Canopy Strut Installation

    Villager 4 - Monsoon Canopy BODY AND TRIM 2+2 FRONT CANOPY STRUT INSTALLATION Figure 4-38 Front Canopy Strut Installation Install the front canopy strut (3) onto the vehicle (Figure 4-38). Install the front canopy strut cover (2) onto the front canopy strut. Install the screws (4).

  • Page 77: 2+2 Rear Canopy Support Removal

    BODY AND TRIM Villager 4 - Monsoon Canopy 2+2 REAR CANOPY SUPPORT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 78: 2+2 Rear Canopy Support Installation

    Villager 4 - Monsoon Canopy BODY AND TRIM 2+2 REAR CANOPY SUPPORT INSTALLATION Figure 4-40 Rear Canopy Support Installation Install the rear canopy support (3) into the rear underbody (Figure 4-40). Install the brackets (2) onto the rear canopy support. Install the screws (1).

  • Page 79: Villager 4 - Rear Body

    BODY AND TRIM Villager 4 - Rear Body VILLAGER 4 - REAR BODY SEAT BACKS Seat Back Removal Figure 4-41 Seat Back Removal Remove the screws (1) from the front seat back (2) (Figure 4-41). Remove the front seat back. Remove the screws (3) from the rear seat back (4).
  • Page 80 Villager 4 - Rear Body BODY AND TRIM Seat Back Installation Figure 4-42 Seat Back Installation Install the front seat back (1) onto the seat support (2). Make sure the seat support tab (3) is installed in the front seat back (Figure 4-42). Install the screws (4).

  • Page 81: Fixed Rear Seat

    BODY AND TRIM Villager 4 - Rear Body FIXED REAR SEAT 2+2 fixed rear seat procedures. Fixed Rear Seat Bottom Removal Figure 4-43 Fixed Rear Seat Bottom Remove the screws (1) (Figure 4-43). Lift and remove the rear seat bottom (2). Fixed Rear Seat Bottom Installation Install the rear seat bottom tabs into the seat supports.
  • Page 82 Villager 4 - Rear Body BODY AND TRIM Fixed Rear Seat Hinge Removal Figure 4-44 Fixed Rear Seat Hinge Remove the rear seat bottom. Remove the screws (1) (Figure 4-44). Remove the hinge (2). Fixed Rear Seat Hinge Installation Install the hinge (2) onto the rear seat bottom (Figure 4-44). Install the screws (1).
  • Page 83 BODY AND TRIM Villager 4 - Rear Body Fixed Rear Seat Hip Restraint Removal Figure 4-45 Fixed Rear Seat Hip Restraint Remove the screws (1) (Figure 4-45). Remove the strut angle (2). Remove the screws (3). Lift and remove the hip restraint (4). Fixed Rear Seat Hip Restraint Installation Install the rear hip restraint (4) onto the foot deck.

  • Page 84: Fold-Down Rear Seat

    Villager 4 - Rear Body BODY AND TRIM FOLD-DOWN REAR SEAT 2+2 fold-down rear seat procedures. Fold-Down Rear Seat Bottom Removal Figure 4-46 Fold-Down Rear Seat Bottom Remove the screws (1) (Figure 4-46). Remove the rear seat bottom (2) from the fold-down hinge (3). Fold-Down Rear Seat Bottom Installation Put the rear seat bottom (2) onto the fold-down hinge (3) (Figure 4-46).
  • Page 85 BODY AND TRIM Villager 4 - Rear Body Fold-Down Rear Seat Assembly Removal Figure 4-47 Fold-Down Rear Seat Assembly Remove the screws (1) (Figure 4-47). Remove the bolts (2) and nuts (3). Remove the bolts (4) washers (5), and nuts (6). Remove the rear seat assembly (7).
  • Page 86 Villager 4 - Rear Body BODY AND TRIM Fold-Down Rear Seat Hip Restraint Removal Figure 4-48 Fold-Down Rear Seat Hip Restraint Remove the screws (1) (Figure 4-48). Remove the strut angle (2). Remove the screws (3). Lift and remove the hip restraint (4). Fold-Down Rear Seat Hip Restraint Installation Install the rear hip restraint (4) onto the foot deck (Figure 4-48).
  • Page 87 BODY AND TRIM Villager 4 - Rear Body Side Frame Removal Figure 4-49 Side Frame Remove the bolt (1), washers (2), and nut (3) (Figure 4-49). Remove the nut (4) and bolt (5). Remove the side frame (6). Side Frame Installation Install the side frame (6) onto the foot deck (Figure 4-49).

  • Page 88: Seat Support

    Villager 4 - Rear Body BODY AND TRIM SEAT SUPPORT 2+2 seat support procedures. Figure 4-50 2+2 Seat Support Seat Support Removal Remove the seat backs. Remove the hip restraints. Remove the rear seat bottom assembly. Remove the screws (1) (Figure 4-50). Remove the screw (2).

  • Page 89: Foot Deck - 2+2

    BODY AND TRIM Villager 4 - Rear Body FOOT DECK - 2+2 2+2 foot deck procedures. Foot Deck Removal Figure 4-51 Foot Deck (2+2) Removal Support the foot deck. Remove the screws (1) (Figure 4-51). Remove the screws (2). Remove the bolts (3) and the foot deck. 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 4-53...
  • Page 90 Villager 4 - Rear Body BODY AND TRIM Foot Deck Disassembly Figure 4-52 Foot Deck (2+2) Disassembly Remove the push rivets (1) (Figure 4-52). Remove the floormat (2). Remove the screws (3). Remove the foot deck (4). Remove the screws (5). Remove the handrail (6) from the foot deck support (7).
  • Page 91 BODY AND TRIM Villager 4 - Rear Body Foot Deck Assembly Figure 4-53 Foot Deck (2+2) Assembly Make sure the J-clips (1) are installed on the foot deck support (2) (Figure 4-53). Install the handrail (3) into the foot deck support. Install the screws (4).
  • Page 92 Villager 4 - Rear Body BODY AND TRIM Foot Deck Installation Figure 4-54 Foot Deck (2+2) Installation Support the foot deck. Install the bolts (3) (Figure 4-54). Tighten the bolts to 22 lb·ft (30 N·m). Install the screws (2). Tighten the screws to 13 lb·ft (18 N·m). Install the screws (1).

  • Page 93: Rear Beauty Panel (2+2 Vehicles)

    BODY AND TRIM Villager 4 - Rear Body REAR BEAUTY PANEL (2+2 VEHICLES) 2+2 rear body component procedures. 2656G Figure 4-55 2+2 Rear Beauty Panel Rear Beauty Panel Removal Remove the front seat bottom. Remove the rear seat assembly. Remove the forward / neutral / reverse (FNR) control. Remove the screws (1) (Figure 4-55).

  • Page 94: Rear Underbody

    Villager 4 - Rear Body BODY AND TRIM REAR UNDERBODY Figure 4-56 2+2 Rear Underbody Rear Underbody Removal Remove the rear beauty panel. Remove the access panel. Remove the screws (1) (Figure 4-56). Lift the rear edge of the rear underbody (2) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.

  • Page 95: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. PEDAL GROUP – ELECTRIC VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect the batteries and discharge the controller.
  • Page 96 Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP 2518 Figure 5-2 Pedal Group – Electric Vehicle Page 5-2 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 97: Mcor

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Electric Vehicle MCOR The pedal group for the electric vehicle includes a Motor Controller Output Regulator (MCOR) mounted on the side of the pedal group. The MCOR detects the position of the GO pedal and sends a corresponding voltage to the motor controller.

  • Page 98: Pedal Group - Gasoline Vehicle

    Pedal Group – Gasoline Vehicle ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP – GASOLINE VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect battery and spark plug wire(s). See Disconnect the Battery - Gasoline Vehicles on page 1-3. Remove screws (1).

  • Page 99: Throttle Position Sensor

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Gasoline Vehicle 2518a Figure 5-4 Pedal Group – Gasoline Vehicle THROTTLE POSITION SENSOR The pedal group for the vehicle includes a throttle position sensor mounted on the side of the accelerator pedal assembly.

  • Page 100: Pedal Group Installation

    Debris Shields ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP INSTALLATION Connect the end of the accelerator cable to the pedal group (Figure 5-4, Page 5-5). See following CAUTION. CAUTION • Make sure the accelerator cable is properly seated to the pedal group. Connect the wire harness (12) to the throttle position sensor (Figure 5-4, Page 5-5).

  • Page 101: Brake Pedal Removal

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Removal Electric Vehicle: Install the MCOR. See MCOR Installation on page 13-8. Install pedal group in vehicle. See Pedal Group Installation on page 5-3. See Pedal Group Installation on page 5-6. BRAKE PEDAL REMOVAL Remove pedal group from vehicle.
  • Page 102 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 and 4 Maintenance and Service Manual...

  • Page 103: Section 6 - Wheel Brake Assemblies

    SECTION 6 — WHEEL BRAKE ASSEMBLIES WARNING Wheel Brake Assemblies Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled. Wear approved eye and respiratory protection when disassembling and cleaning brake mechanisms.
  • Page 104 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES Loosen the left-hand thread jam nut (1) and right-hand thread jam nut (3) 1/2 inch (12.7 mm) away from the turnbuckle (2) (Figure 6-1). Figure 6-1 Loosen Turnbuckle Loosen the turnbuckle to release tension on the equalizer bracket (4) that pulls on the heads of the brake cables (5).

  • Page 105: Brake Shoe Removal

    WHEEL BRAKE ASSEMBLIES Brake Shoe Removal NOTE: When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods, use the following steps to minimize damage to the brake cluster and brake components. 12.1. Insert a 1/2 inch x 5/8 inch cold chisel (8) under the head (9) of each pin and shear them off as illustrated (Figure 6-3).
  • Page 106 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES Remove adjuster wheel (11) with two washers (12 and 13) from the backing plate (Figure 6-5). 2732B Figure 6-5 Remove Adjuster Wheel Page 6-4 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 107: Brake Assembly Cleaning

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING Carefully clean the brake backing plate (1) and all of its mechanical components (Figure 6-6). Remove the dust cover (2) from backing plate and wipe with a clean damp cloth. 1400-18100-10220B Figure 6-6 Backing Plate and Dust Cover Lubricate the slide (3) with dry moly lubricant (Figure 6-7).
  • Page 108 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get onto the friction surfaces of the brake shoe pads or the brake drum. Failure to heed this warning could cause diminished brake performance, possibly resulting in property damage or severe personal injury.
  • Page 109 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning ® BR2-Plus or equivalent) to the brake adjuster assembly, adjuster wheel shoe slots, and the shaft of the adjuster wheel as shown (Figure 6-10).

  • Page 110: Brake Shoe Installation

    Brake Shoe Installation WHEEL BRAKE ASSEMBLIES BRAKE SHOE INSTALLATION Turn the adjusting wheel screw so that the shoe slot is vertical (A) (Figure 6-12). Install the trailing shoe (1) in the slots in the shoe mounting block (2) and the adjuster assembly (3). Make sure that the stamped end (4) of the shoe is on the top of the brake assembly.
  • Page 111 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Attach the springs (7) onto the trailing shoe (8). Then hold the leading shoe next to the trailing shoe, correctly oriented, and attach the springs to it (Figure 6-14). 2738C Figure 6-14 Attach Springs Attach the springs to the leading shoe.
  • Page 112 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Make sure that the shoes can move together up and down and side to side approximately 1/4 to 3/8 inch (6.3 to 9.5 mm) without binding (Figure 6-16). Figure 6-16 Check Shoe Positions Use a flatblade screwdriver to lift the adjusting arm (10) off of the adjusting wheel (11) (Figure 6-17). 648B Figure 6-17 Set Adjusting Wheel Turn the adjusting wheel upward until it stops.
  • Page 113 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Remove the turnbuckle (12) (Figure 6-18). Apply Loctite ® 242 to the threaded ends of the pedal group rod (13) and the brake actuator rod (14). Install the turnbuckle. Make sure that the brake cables (15) are installed in the brake equalizer (16). 636E Figure 6-18 Turnbuckle Installation Adjust the brake cable equalizer.

  • Page 114: Brake Cable Equalizer Adjustment

    Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES BRAKE CABLE EQUALIZER ADJUSTMENT Make sure that the brake pedal is in the fully up position. Adjust the turnbuckle (1) until the distance between the top of the brake cable equalizer (2) and the upper flange surface (3) is 2 inches (±1/16) (51 mm (±1.6) (Figure 6-19).

  • Page 115: Brake Cluster

    WHEEL BRAKE ASSEMBLIES Brake Cluster BRAKE CLUSTER BRAKE CLUSTER REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Loosen the lug nuts on the rear wheels. Lift the rear of the vehicle. WARNING •...
  • Page 116 Brake Cluster WHEEL BRAKE ASSEMBLIES If the brake drum cannot be easily removed: 12.1. Insert a 1/2 inch x 5/8 inch cold chisel (6) under the head (7) of each pin and shear them off as illustrated (Figure 6-21). This will release the shoes from the backing plate, allowing them to pivot away from the inside of the brake drum (8), which should then allow the brake drum to be pulled free.

  • Page 117: Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Remove the clevis pin (10) from brake cable. Remove and discard the bolts (11) and lock nuts (12). Remove the brake back plate (13). BRAKE CLUSTER INSTALLATION CAUTION • Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from the oil seal area.
  • Page 118 Brake Cluster WHEEL BRAKE ASSEMBLIES If the retainer pins were sheared during removal: 5.1. Replace the retainer pins (6) (Figure 6-24). 5.2. Use pliers to compress and install the shoe retainer clip (7), while turning the retainer pin into position. 2737C Figure 6-24 Install Shoe Retainer Clip Electric Vehicle: Install the axle shaft.

  • Page 119: Brake Cable

    WHEEL BRAKE ASSEMBLIES Brake Cable BRAKE CABLE BRAKE CABLE REMOVAL Special Tools Needed Brake Cable Release Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire.
  • Page 120 Brake Cable WHEEL BRAKE ASSEMBLIES 652C Figure 6-26 Brake Cable Mounting Tab Use a brake cable release tool to compress the retaining clips (10) on the end of the cable housing enough to slide the cable end out of the hole in the frame (Figure 6-27). 650D Figure 6-27 Retaining clips Remove and discard the bow tie locking pin (11) (Figure 6-28).
  • Page 121 WHEEL BRAKE ASSEMBLIES Brake Cable 651E Figure 6-28 Disconnect Cables at Rear Brakes Remove the clevis pin (12) from the brake lever on each wheel and pull the clevis (13) away from the lever. Discard the clevis pin. Use a brake cable release tool to compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket (14) and remove the brake cable from the vehicle.

  • Page 122: Brake Cable Installation

    Brake Cable WHEEL BRAKE ASSEMBLIES BRAKE CABLE INSTALLATION NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable. Make sure the correct cable is used on the correct side. Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket. Insert the end of the new brake cable through the hole in the frame (Figure 6-29).
  • Page 123 WHEEL BRAKE ASSEMBLIES Brake Cable Insert the rear cable housing into the shock mount bracket (3) (Figure 6-31). Push the cable housing end into the bracket to ensure the clips on the housing end secure the cable in position. At the rear wheel brake, connect the cable to the brake actuator arm using new clevis pin (4) and new bow tie locking pin (5).
  • Page 124 Brake Cable WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-22 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 125: Section 7 - Steering And Front Suspension

    SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 126: Steering Wheel Installation

    Steering Wheel STEERING AND FRONT SUSPENSION 2519B Figure 7-1 Steering Wheel Removal Remove the cover (2). Remove the steering wheel retaining bolt (3). Put the puller anvil (4) through the top opening of the steering wheel (5). Insert the anvil feet through the two slots in the base plate (marked “B”) (6). Turn the anvil screw (7) clockwise until the base plate contacts the bottom of the steering wheel at the steering column (8) (Figure 7-2).
  • Page 127 STEERING AND FRONT SUSPENSION Steering Wheel 2519C Figure 7-3 Steering Wheel Installation Install steering wheel retaining bolt (3). Tighten the bolt to 37 lb·ft (50 N·m). Put the cover (4) on the steering wheel. Install the screws (5). Tighten the screws to 15 lb·in (1.7 N·m). 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 7-3...

  • Page 128: Steering Column

    Steering Column STEERING AND FRONT SUSPENSION STEERING COLUMN STEERING COLUMN REMOVAL 2622B Figure 7-4 Steering Column Removal Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Remove the steering wheel. Remove the dash insert, instrument panel, dash assembly, and front bumper.

  • Page 129: Steering Column Installation

    STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN INSTALLATION 2622C Figure 7-5 Steering Column Installation Apply a light coat of anti-seize or lubricating compound to the pinion shaft (1) (Figure 7-5). Install the universal joint (2) onto pinion shaft. Install the bolt (3) and tighten by hand. Do not fully tighten the bolt. Install the steering column mounting bracket (4) on the vehicle frame.

  • Page 130: Rack And Pinion

    Rack and Pinion STEERING AND FRONT SUSPENSION RACK AND PINION CAUTION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. The manufacturer recommends inspecting the rack and pinion and replacing if damaged. RACK AND PINION INSPECTION Look for obvious damage to the chassis, where the rack and pinion is mounted, and the rack and pinion housing.

  • Page 131: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion Remove the front bumper. Remove the tie rod end retaining nuts (1) (Figure 7-6, Page 7-6). Remove the tie rod ends (2) from the spindle tabs (3). Remove the bolts (4). Remove the bolt (5) from the universal joint (6). Remove the universal joint from the pinion shaft (7).
  • Page 132 Rack and Pinion STEERING AND FRONT SUSPENSION Test drive the vehicle before returning it to service. Page 7-8 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 133: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-2. LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules on page 10-8. CAUTION •...
  • Page 134 Front Suspension STEERING AND FRONT SUSPENSION Loosen the four bolts (1). Do not remove the bolts (Figure 7-9). 673B Figure 7-9 Adjust Camber Loosen the nut (2) on the adjustment eccentric (3) in the center of the spring. Do not remove the nut. Use a 7 mm deep well socket to rotate the adjustment eccentric and adjust the camber.
  • Page 135 STEERING AND FRONT SUSPENSION Front Suspension Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-10). NOTE: The front measurement must be less than the rear measurement. Figure 7-10 Check Toe-In Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in.

  • Page 136: Front Suspension Components

    Front Suspension Components STEERING AND FRONT SUSPENSION 9.8. After the toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should be at the center of its travel. There should be equal travel to the left and right. FRONT SUSPENSION COMPONENTS See General Warnings on page 1-2.

  • Page 137: Leaf Spring Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components 1311B Figure 7-14 Tie Rod End Installation Install the tie rod ends into the spindle tabs. Install the retaining nuts (2). Adjust the wheel toe-in. Electric Vehicle: Connect the batteries. Gasoline Vehicle: Connect the battery and spark plug wire. LEAF SPRING REMOVAL Disable the vehicle.

  • Page 138: Leaf Spring Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION Remove the bolts (1) from the bottom of each kingpin (2) (Figure 7-15). 1312B Figure 7-15 Leaf Spring Removal Remove the four bolts (3) and bottom spring plate (4). Remove leaf spring (5). Check the condition of the urethane bushings (6) and steel sleeves (7).

  • Page 139: Kingpin And Steering Spindle Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components KINGPIN AND STEERING SPINDLE REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Remove the front wheels. Remove the front hub (1) (Figure 7-17). 1312C Figure 7-17 Kingpin and Steering Spindle Removal Remove the retaining nuts (2).

  • Page 140: Kingpin And Steering Spindle Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION NOTE: New bushings may not fit the kingpin after installing them into the spindle). Ream new bushings as required. 14.1. After installing new bushings, ream bushings to 0.753 inch (±0.0005) (19.13 mm (±0.013)). KINGPIN AND STEERING SPINDLE INSTALLATION Inspect all parts and replace them as necessary.

  • Page 141: Control Arm Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components CONTROL ARM REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Remove the front wheels. Remove the bolts (1). Move the rack and pinion (2) to allow clearance for the control arm bolts (Figure 7-19). 1383C Figure 7-19 Move Rack and Pinion Remove the bolts (3 and 4) (Figure 7-20).

  • Page 142: Control Arm Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION Remove the control arm (5) (Figure 7-21). 1311C Figure 7-21 Control Arm Removal Inspect the bushings (6) and sleeves (7 and 8) in the control arm. Replace as necessary. CONTROL ARM INSTALLATION Put the control arm into position on the vehicle. Install the bolts (1 and 2) (Figure 7-22).

  • Page 143: Front Shock Absorber Inspection

    STEERING AND FRONT SUSPENSION Front Suspension Components Move the rack and pinion (3) into position. Tighten the bolts (4) to 22 lb·ft (30 N·m) (Figure 7-23). 1383D Figure 7-23 Install Rack and Pinion Install the front wheels. Adjust the camber and toe-in. Electric Vehicle: Connect the batteries.

  • Page 144: Front Shock Absorber Removal

    Front Suspension Components STEERING AND FRONT SUSPENSION FRONT SHOCK ABSORBER REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Remove the upper bolt (1) (Figure 7-25). 1312G Figure 7-25 Shock Absorber Removal Remove the lower bolt (2).
  • Page 145 STEERING AND FRONT SUSPENSION Front Suspension Components 1312G Figure 7-26 Shock Absorber Installation Install the shock absorber. Install the bolts (1 and 2). Tighten the bolts to 16 lb·ft (21 N·m). Electric Vehicle: Connect the batteries. Gasoline Vehicle: Connect the battery and spark plug wire. 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 7-21...

  • Page 146: Front Wheel Hubs

    Front Wheel Hubs STEERING AND FRONT SUSPENSION FRONT WHEEL HUBS FRONT WHEEL FREE PLAY INSPECTION NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. Disable the vehicle.

  • Page 147: Front Wheel Hub Installation

    STEERING AND FRONT SUSPENSION Front Wheel Hubs FRONT WHEEL HUB INSTALLATION Lightly sand spindle shaft (4) to clean away any light rust (Figure 7-28). 678B Figure 7-28 Front Wheel Hub Installation Apply a light coat of anti-seize lubricant to the spindle shaft. Install the hub assembly (3) onto the spindle shaft.
  • Page 148 Front Wheel Hubs STEERING AND FRONT SUSPENSION Pagination Page Page 7-24 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 149: Section 8 - Wheels And Tires

    SECTION 8 — WHEELS AND TIRES DANGER Wheels and Tires • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...

  • Page 150: Tires

    Tires WHEELS AND TIRES TIRES See General Warnings on page 1-2. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. Remove the valve cap and valve core and allow air to escape from the tire.

  • Page 151: Tire Installation

    Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at your local Club Car dealer. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-2.
  • Page 152 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 153: Section 9 - Rear Suspension

    SECTION 9 — REAR SUSPENSION See General Warnings Section. Rear Suspension GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame. SHOCK ABSORBERS The following procedures are the same for all vehicles.

  • Page 154: Rear Shock Absorber Removal

    Shock Absorbers REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL Figure 9-2 Rear Shock Absorber Removal Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Remove the nut (1), cup washer (2), and rubber bushing (3) from the top of the shock absorber (Figure 9-2, Page 9-2).

  • Page 155: Rear Shock Absorber Installation

    REAR SUSPENSION Shock Absorbers REAR SHOCK ABSORBER INSTALLATION Figure 9-3 Rear Shock Absorber Installation Install the cup washers (1) and rubber bushings (2) onto the shock absorber (3) (Figure 9-3, Page 9-3). Install the bottom stem of the shock absorber into the shock mount bracket (4). Install the top stem of the shock absorber into the frame shock mount (5).

  • Page 156: Panhard And Bracket

    Panhard and Bracket REAR SUSPENSION PANHARD AND BRACKET Figure 9-4 Panhard and Bracket PANHARD AND BRACKET REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Remove the bolts (1) (Figure 9-4, Page 9-4). Remove the panhard (2).

  • Page 157: Leaf Springs (Two-Passenger)

    REAR SUSPENSION Leaf Springs (Two-Passenger) LEAF SPRINGS (TWO-PASSENGER) LEAF SPRING REMOVAL (TWO-PASSENGER) WARNING • 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 position.
  • Page 158 Leaf Springs (Two-Passenger) REAR SUSPENSION Remove the nut (5), cup washer (6), and rubber bushing (7) from the bottom stem of the shock absorber (Figure 9-6). Figure 9-6 Leaf Spring Removal - Two-Passenger Remove the nuts (8) and the U-bolt (9) securing the spring to the transaxle. Remove the shock mount bracket (10) and the U-bolt.

  • Page 159: Leaf Spring Installation (Two-Passenger)

    REAR SUSPENSION Leaf Springs (Two-Passenger) LEAF SPRING INSTALLATION (TWO-PASSENGER) CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle. Install the front of the leaf spring (1) onto the vehicle frame (Figure 9-7). Figure 9-7 Leaf Spring Installation - Two-Passenger Install the bolt (2) and nut (3).

  • Page 160: Leaf Springs (Four-Passenger)

    Leaf Springs (Four-Passenger) REAR SUSPENSION Install the brake cable onto the shock mount bracket (12) (Figure 9-8). Figure 9-8 Connect Brake Cable Install the cable end (13) onto the brake lever. Install the clevis pin (14) and the bow tie locking pin (15). Lower and remove the floor jack under the transaxle.
  • Page 161 REAR SUSPENSION Leaf Springs (Four-Passenger) 651G Figure 9-9 Connect Brake Cable Remove the cable end (3) from the brake lever. Remove the brake cable from the shock mount bracket (4). Remove the nut (5), cup washer (6), and rubber bushing (7) from the bottom stem of the shock absorber (Figure 9-10, Page 9-9).

  • Page 162: Leaf Spring Installation (Four-Passenger)

    Leaf Springs (Four-Passenger) REAR SUSPENSION Remove the nut (15) and bolt (16) from the front of the leaf spring and remove the leaf spring. Examine the bushings (17) and sleeves (18) in the spring eyes. 14.1. If the bushings or sleeves are worn or have damage, replace them. LEAF SPRING INSTALLATION (FOUR-PASSENGER) CAUTION •...

  • Page 163: Leaf Springs (Four-Passenger - Heavy Duty With Panhard)

    Leaf Springs (Four-Passenger - Heavy Duty REAR SUSPENSION With Panhard) Figure 9-12 Connect Brake Cable Install the cable end (14) onto the brake lever. Install the clevis pin (15) and the bow tie locking pin (16). Lower and remove the floor jack under the transaxle. Install the tire and wheel assembly.
  • Page 164 Leaf Springs (Four-Passenger - Heavy Duty With Panhard) REAR SUSPENSION 651G Figure 9-13 Connect Brake Cable Remove the cable end (3) from the brake lever. Remove the brake cable from the shock mount bracket (4). Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorber (Figure 9-14).

  • Page 165: Leaf Spring Installation (Four-Passenger - Heavy Duty With Panhard)

    Leaf Springs (Four-Passenger - Heavy Duty REAR SUSPENSION With Panhard) Inspect the bushings (16) and sleeves (17) in the spring eyes and replace them if they are worn or damaged. LEAF SPRING INSTALLATION (FOUR-PASSENGER - HEAVY DUTY WITH PANHARD) CAUTION •...
  • Page 166 Leaf Springs (Four-Passenger - Heavy Duty With Panhard) REAR SUSPENSION Install the brake cable onto the shock mount bracket (12) (Figure 9-16). Figure 9-16 Connect Brake Cable Install the cable end (13) onto the brake lever. Install the clevis pin (14) and the bow tie locking pin (15). Lower and remove the floor jack under the transaxle.

  • Page 167: 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 168: Performance Inspection

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

  • Page 169: Maintenance

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

  • Page 170: Periodic Service Schedules

    Periodic Service Schedules PERIODIC MAINTENANCE WARNING • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring. Never allow a positive wire to touch the vehicle frame, engine, or other metal component. PERIODIC SERVICE SCHEDULES WARNING •...
  • Page 171 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE For vehicles newly equipped with the SPWS, Initial (one-time) inspection by owner or Batteries (For vehicles newly equipped with manually check battery electrolyte levels of trained technician after six weeks of use the Single Point Watering System) all cells to verify correct valve operation.
  • Page 172 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-2. Check engine oil level;...
  • Page 173 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Check for leaks around gaskets, fill plugs, etc. Engine Inspect, clean and regap spark plug; replace if necessary. Check air filter element; replace if necessary. Engine air intake system Check clamps for tightness;...

  • Page 174: Periodic Lubrication Schedules

    Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Charger receptacle WD-40 ® Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube, white lithium grease NLGI #2 hours of operation or 100 service manual.
  • Page 175 PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Shifter cable pivots Dry Moly Lube Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube, white lithium grease NLGI #2 hours of operation or every service manual.

  • Page 176: Air Filter

    Air Filter PERIODIC MAINTENANCE AIR FILTER Figure 10-3 Air Filter AIR FILTER REMOVAL Before the air filter is removed: • Disable the vehicle. To remove the air filter: Release the latch (1) (Figure 10-3, Page 10-10). Remove the air cleaner cover (2). Remove the air filter (3).

  • Page 177: Engine Oil Level Inspection

    PERIODIC MAINTENANCE Engine Oil Figure 10-4 Engine Oil Viscosity ENGINE OIL LEVEL INSPECTION Before the engine oil is examined: • Disable the vehicle. To examine the engine oil: Remove the dipstick (1) (Figure 10-5, Page 10-11). Figure 10-5 Dipstick Make sure that there is oil on the dipstick. Install the dipstick.

  • Page 178: Engine Oil Replacement

    Engine Oil PERIODIC MAINTENANCE Remove the dipstick. Make sure that the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-6, Page 10-12). Figure 10-6 Dipstick Indicators If the oil level is below the minimum indicator, add engine oil. Install the dipstick.
  • Page 179 PERIODIC MAINTENANCE Engine Oil Figure 10-7 Dipstick Clean the area around the oil drain plug (2) (Figure 10-8, Page 10-13). Figure 10-8 Oil Drain Plug Put a drain pan below the oil drain plug. Remove the oil drain plug. Drain the oil fully. Clean the oil drain plug.

  • Page 180: Add Engine Oil

    Engine Oil PERIODIC MAINTENANCE Add 39 fl-oz (1.1 l) of recommended engine oil (Figure 10-9, Page 10-14). Figure 10-9 Engine Oil Fill Location Install the dipstick. Connect the battery. ADD ENGINE OIL CAUTION • Do not remove the dipstick while the engine is on. CAUTION •...
  • Page 181 PERIODIC MAINTENANCE Engine Oil Figure 10-10 Dipstick Add engine oil until the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-11, Page 10-15). Figure 10-11 Dipstick Indicators Install the dipstick. 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 10-15...
  • Page 182 Engine Oil PERIODIC MAINTENANCE Pagination Page Page 10-16 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 183: Section 11 - Controller Diagnostic Tool (Cdt)

    SECTION 11 — CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER Controller Diagnostic Tool (CDT) • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: The information presented in this section addresses the following: • The Controller Diagnostic Tool (CDT) handheld programmer which replaced the IQDM series 2 handset. •...

  • Page 184: General Information

    General Information CONTROLLER DIAGNOSTIC TOOL (CDT) GENERAL INFORMATION The CDT is used to adjust and save parameter settings of the controller, monitor real-time data, and perform diagnostics and troubleshooting of the electric vehicle. FEATURES • Batteries: Two AA batteries provide power for the CDT’s real-time clock and they allow for use of the CDT when not connected to a vehicle.

  • Page 185: Plugging The Cdt Into The Vehicle

    CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle PLUGGING THE CDT INTO THE VEHICLE Figure 11-2 Communication Port Under Instrument Panel Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-3).

  • Page 186: Quick Reference Guide - Excel With Eric Charging System

    Quick Reference Guide – Excel with ERIC Charging System CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – EXCEL WITH ERIC CHARGING SYSTEM OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car is not equipped with Visage, make sure Control Main Driver Off: Replace controller.

  • Page 187: System Info

    CONTROLLER DIAGNOSTIC TOOL (CDT) System Info SYSTEM INFO The System Info menu is accessed by using the arrow keys to highlight System Info and pressing the Select softkey to activate the menu. The System Info selection displays information pertaining to the controller. The information provided from this menu selection includes: MODEL NUMBER Displays the model number of the controller.

  • Page 188: Parameters

    Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) PARAMETERS The Parameters menu is accessed by using the arrow keys to highlight Parameters and pressing the Select softkey to activate the menu. The Parameters menu is where you can view and modify the settings of the controller's adjustable parameters. Navigate through this complex menu using the arrow keys, +/- keys, and softkeys.
  • Page 189 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters When going down an incline with the accelerator pedal partially pressed, the motor braking function will activate to assist the operator in maintaining a speed less than the top speed setting. For example, if the vehicle is going down an incline with the accelerator pedal pressed half way, the motor braking function will activate to assist the operator in maintaining a speed approximately half of the speed setting defined in the Program Menu.

  • Page 190: Amp Hours

    Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) Anti-Tamper The anti-tamper setting defines maximum speed if the Anti-Tamper fault is triggered (e.g. controller is disconnected from the Guardian or Visage system). These speeds can only be activated if the Control Mode option is set to 1 (Guardian/Visage) and are intended to be a deterrent.

  • Page 191: Vehicle Id

    15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. NOTE: If controller is replaced, the information below must be entered into the new controller. See Speed Controller Installation, Section 13, Page 13-12.

  • Page 192: Batt Voltage

    Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Since the Monitor menu is updated while the vehicle is in operation, the trained technician has the ability to monitor the status of several components in conditions or locations where a problem with vehicle performance has been reported.

  • Page 193: Armature Pwm

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu ARMATURE PWM Displays motor armature PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is operating at full speed, the pulse width modulation should be at 100%. FIELD PWM Displays motor field PWM (pulse width modulation).

  • Page 194: 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 195: Amp Hours Display

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking. It has a range from negative (–) 300 amps to positive (+) 300 amps. Amp Hours Displays total accumulated amp hours removed from batteries since initial vehicle start-up.

  • Page 196: Diagnostics Menu

    Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.

  • Page 197: Causes Of Faults

    CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu CAUSES OF FAULTS Some common causes of faults are: • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
  • Page 198 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) CONTROLLER FAULT CONTROLLER RESPONSE VEHICLE RESPONSE HW FAILSAFE A, B, C Vehicle comes to a stop THROTTLE FAULT A, C Vehicle comes to a stop SPEED SENSOR Vehicle runs at slow speed MAIN WELDED Vehicle runs at slow speed MAIN DRIVER ON A, B...

  • Page 199: Fault Recovery

    CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu FAULT RECOVERY When a fault is detected by the controller, the controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem, such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.

  • Page 200: 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 201: Thermal Cutback

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 185 °F (±9) (85 °C (±5)) or below –13 °F (±9) (–25 °C (±5)), the thermal cutback fault is detected. What it means: Heatsink temperature rises above 185 °F (85 °C).

  • Page 202: Main Welded

    Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Electric Vehicle - Batteries MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.

  • Page 203: Main Dropout (1 Or 2)

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions large solenoids should read 180 to 190 ohms; small solenoids 200 to 250 ohms), a broken blue/white wire at the 16-pin controller plug or its terminal is loose in the 16-pin plug. MAIN DROPOUT (1 OR 2) If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected.

  • Page 204: Fld (Field) Missing

    Programming CONTROLLER DIAGNOSTIC TOOL (CDT) FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. CAUTION •...

  • Page 205: Cloning

    CONTROLLER DIAGNOSTIC TOOL (CDT) Favorites CLONING Use the “Restore .cpf File” function to clone a controller with a saved .cpf file stored in the CDT. If using an OEM-level CDT, after you highlight a stored .cpf file and choose “Restore,” a pop-up window will ask whether you want to enable Advanced Cloning (“Yes”/“No”) using the softkeys.
  • Page 206 HHP Settings CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Keytone You can choose between several tones to sound each time you press a key, or you can turn the keytone Off for silent programmer operation. Auto Poweroff (battery) You can set the idle time before the programmer will automatically power off when it is powered by its own batteries (i.e., when the control system is not running, or when the programmer is not connected to the control system).

  • Page 207: Plot & Log

    CONTROLLER DIAGNOSTIC TOOL (CDT) Plot & Log PLOT & LOG The Plot & Log menu selection allows the user, with the Plot program, to plot real-time variables on the CDT display screen; or, with the Log program, to create a log file of variable values to view later in a spreadsheet program on a PC. The first step is to add the desired items to the Plot Variable List or the Log Variable List.

  • Page 208: Cdt Troubleshooting

    CDT Troubleshooting CONTROLLER DIAGNOSTIC TOOL (CDT) CDT TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 209: Connection Tests

    CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 14 —...
  • Page 210 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced.
  • Page 211 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests 4.3.1. Disconnect the square four-pin connector (3) from the controller. 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the controller (2) (Figure 11-4, Page 11-29).
  • Page 212 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Pagination Page Page 11-30 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 213: Section 12 - Electric Vehicle - Troubleshooting And Electrical System

    SECTION 12 — ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER Electric Vehicle - Troubleshooting and Electrical System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Shorting of battery terminals can cause personal injury or death. –...

  • Page 214: Key Differences: Excel With Eric Charging System Vs. Powerdrive Chargers

    ELECTRIC VEHICLE - TROUBLESHOOTING General Information AND ELECTRICAL SYSTEM • The Excel minimum motor braking speed has been lowered to almost zero. • Excel has higher energy output during regenerative braking due to the lowered minimum motor braking speed. • The Excel accelerator pedal has more control of downhill speed. •...
  • Page 215 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM General Information • Walk Away Braking: This feature prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without locking the park brake. The vehicle will roll at about 1 to 3 mph (1.5 to 4.8 km/h).

  • Page 216: Battery Wiring Diagram

    ELECTRIC VEHICLE - TROUBLESHOOTING Battery Wiring Diagram AND ELECTRICAL SYSTEM BATTERY WIRING DIAGRAM WD_6x8V_Batteries_ERIC_Charging Figure 12-1 Battery Wiring Diagram Page 12-4 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 217: Sonic Weld, Fuse, And 10K Ohm Resistor Locations

    ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Sonic Weld, Fuse, and 10k Ohm Resistor Locations SONIC WELD, FUSE, AND 10K OHM RESISTOR LOCATIONS 2783 Figure 12-2 Sonic Weld and 10k Ohm Resistor Locations (Approximate) 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 12-5...

  • Page 218: 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 219 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Monitor Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
  • Page 220 ELECTRIC VEHICLE - TROUBLESHOOTING Troubleshooting AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...

  • Page 221: Troubleshooting Guide 2

    ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting 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. 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 12-9...
  • Page 222 ELECTRIC VEHICLE - TROUBLESHOOTING Troubleshooting AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – batteries discharged Charge batteries Batteries – battery connections Check vehicle wiring. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 223 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-25 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Wiring –...

  • Page 224: Test Procedures

    ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 225 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures CAUTION • Be careful not to damage the wire or terminal when back-probing. • When testing voltage, the batteries must remain connected. • When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of the multimeter to the negative post of battery no.
  • Page 226 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Access the Monitor menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons. The CDT should indicate at least 48 volts. See following NOTE. If not, check for loose battery connections or a battery installed in reverse polarity.
  • Page 227 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 2500-30100-10411 Figure 12-4 Battery Discharge Test Turn the discharge machine on and record the voltage reading of battery pack while under load. A fully charged set of batteries in good condition should read between 46 and 49 volts while under load.
  • Page 228 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM If the CDT display screen begins to work, proceed to step 5; otherwise, perform the following procedure, Tow/Run Switch Test without the CDT Handset. With the CDT still connected to vehicle, place Tow/Run Switch in TOW position. If the CDT display screen goes blank, the Tow/Run switch and connecting wires are operating correctly.
  • Page 229 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3.3. If the red wire side does not show BPV, replace fuse. 3.4. If the pink wire side does not show BPV, make sure Tow/Run switch in the RUN position. If it is in RUN, inspect Tow/Run switch, red-to-pink wire spade connector near the solenoid, and sonic welds 5 and 8.
  • Page 230 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Pin 6 Green Wire: Access the controller by removing the access panel in the rear body. See following NOTE. NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 6 green wire in the 16-pin connector.
  • Page 231 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3.2. Place the Forward/Reverse switch in the FORWARD position. The CDT should indicate that FORWARD INPUT is ON. If the CDT indicates any other reading, check vehicle wiring. Also check the 16-pin connector at the speed controller.
  • Page 232 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 7 – Solenoid Activating Coil See General Warnings on page 1-2. NOTE: This is a resistance test. Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is smaller than the service replacement.
  • Page 233 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Place the Tow/Run switch in the TOW position and connect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. TEST PROCEDURE 9 – Solenoid Continuity See General Warnings on page 1-2. Solenoid Continuity Test with the CDT Handset If necessary, see Testing Basics on page 12-12.
  • Page 234 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM the multimeter should show a change in resistance. If not, replace the solenoid. See Solenoid Removal on page 13-13. TEST PROCEDURE 10 – Charger Interlock See General Warnings on page 1-2. Controller Interlock Function Test with the CDT Handset If necessary, see Testing Basics on page 12-12.
  • Page 235 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 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. When finished, install 15-amp fuse and fuse cover. TEST PROCEDURE 11 –...
  • Page 236 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place red (+) probe on battery no.
  • Page 237 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 12 – Motor Speed Sensor See General Warnings on page 1-2. Motor Speed Sensor Test without any Tool CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 238 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 4.1. With Tow/Run switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place red (+) probe on red wire terminal socket in three-pin connector.
  • Page 239 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. See following NOTE.
  • Page 240 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 15 – 16-Pin Connector See General Warnings on page 1-2. Pin 1 – White Pin 5 – Light Blue Pin 9 – Gray Pin 13 – White/Black Pin 2 – Yellow Pin 6 –...
  • Page 241 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures If 16-pin must be disconnected: Keep the 16-pin connector disconnected from the controller. With Tow/Run switch in the TOW position, reconnect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. Place the Tow/Run switch in the RUN position and then check the appropriate wires.
  • Page 242 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM PERFORM TEST WITH 16-PIN CONTROLLER INPUTS CONNECTED TO CONTROLLER? (IF TEST PROCEDURE YES, BACK-PROBE TO TEST) FORWARD INPUT BPV from Forward/Reverse switch in FWD Pin 8 – Brown (Key switch either ON or OFF) B+ INPUT Pin 9 –...
  • Page 243 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures If necessary, see Testing Basics on page 12-12. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4. Remove the instrument panel. See Key Switch Removal, Section 13, Page 13-1. Disconnect the orange/white and pink wires from the reverse buzzer.
  • Page 244 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM – Condition of the 9-pin connector behind instrument panel. – Condition of the yellow/green wire terminal in the instrument panel wire harness. – Continuity of the wires in the wire harnesses. If no problems exist in the above items, replace the charge indicator light.

  • Page 245: Section 13 - Electric Vehicle - Electrical Components

    SECTION 13 — ELECTRIC VEHICLE - ELECTRICAL COMPONENTS DANGER Electric Vehicle - Electrical Components • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See the appropriate troubleshooting section for the type of electrical system used in the vehicle.

  • Page 246: Charge Indicator Light

    ELECTRIC VEHICLE - ELECTRICAL Charge Indicator Light COMPONENTS Figure 13-1 Instrument Panel Removal Figure 13-2 Key Switch CHARGE INDICATOR LIGHT See General Warnings on page 1-2. TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 17 – Charge Indicator Light on page 12-31. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller.

  • Page 247: Usb Port

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS USB Port 2787 Figure 13-3 Charge Indicator Light USB PORT The 5–volt 3 amp USB port (Figure 13-4) provides electricity to power and recharge portable devices. The USB port is not designed for the transfer of data. Figure 13-4 USB Port USB PORT REMOVAL Remove the instrument panel to access the USB port wires and lock tabs (Figure 13-5, Page 13-4).

  • Page 248: Usb Port Installation

    ELECTRIC VEHICLE - ELECTRICAL Forward/Reverse Rocker Switch COMPONENTS Figure 13-5 USB Port Removal Figure 13-6 USB Port Installation USB PORT INSTALLATION Put the USB port wires into the dash. Push the USB port into the dash. Connect the red instrument panel wire to the red USB port wire (1) (Figure 13-6, Page 13-4). Connect the black instrument panel wire to the black USB port wire (2).

  • Page 249: Forward/Reverse Rocker Switch Installation

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Forward/Reverse Rocker Switch Figure 13-7 Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH INSTALLATION Route the three wires through bezel. Connect the blue (4), orange (5) and brown (6) wires to the rocker switch (3), exactly as shown in (Figure 13-7, Page 13-5). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).

  • Page 250: Electronics Module Cover

    ELECTRIC VEHICLE - ELECTRICAL Electronics Module Cover COMPONENTS ELECTRONICS MODULE COVER See General Warnings on page 1-2. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and solenoid. ELECTRONICS MODULE COVER REMOVAL Disconnect the batteries and discharge the controller.

  • Page 251: Tow/Run Switch

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Tow/Run Switch Figure 13-8 Access and Remove Electronics Module Cover TOW/RUN SWITCH See General Warnings on page 1-2. TESTING THE TOW/RUN SWITCH See Test Procedure 3 – Tow/Run Switch on page 12-15. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller.

  • Page 252: Motor Controller Output Regulator (Mcor)

    ELECTRIC VEHICLE - ELECTRICAL Motor Controller Output Regulator (MCOR) COMPONENTS Figure 13-9 Tow/Run Switch MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-2. TESTING THE MCOR See Test Procedure 11 – MCOR Voltage on page 12-23 and Test Procedure 5 – Key Switch and MCOR Limit Switch Circuit on page 12-17.

  • Page 253: Reverse Buzzer

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Reverse Buzzer REVERSE BUZZER See General Warnings on page 1-2. TESTING THE REVERSE BUZZER See 12-30. REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4. Remove instrument panel.

  • Page 254: Electronics Module

    ELECTRIC VEHICLE - ELECTRICAL Electronics Module COMPONENTS ELECTRONICS MODULE See General Warnings on page 1-2. While it is not necessary to remove the electronics module from the vehicle, access to individual components may be easier with the module removed. ELECTRONICS MODULE REMOVAL Disconnect the batteries and discharge the controller (1).

  • Page 255: Electronics Module Installation

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Electronics Module 2771 Figure 13-11 Controller and Solenoid Removal ELECTRONICS MODULE INSTALLATION Return electronics module (3) to its location in vehicle but leave it tilted forward. Complete connections to the controller (1), the Tow/Run switch (5) and the solenoid (4) per the electrical schematics.

  • Page 256: Speed Controller

    ELECTRIC VEHICLE - ELECTRICAL Speed Controller COMPONENTS Set electronics module in place and secure with bolt (2) (Figure 13-11, Page 13-11). Tighten bolt to 40 in·lb (4.5 N·m). Install the batteries and battery cables in their original locations. See Battery Replacement on page 14-5. Place the Tow/Run switch (5) in the TOW position and connect the batteries.

  • Page 257: 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 258: Solenoid Installation

    ELECTRIC VEHICLE - ELECTRICAL Charger Receptacle COMPONENTS Disconnect the heavy gauge wires from the solenoid (4) by removing the nuts (7) and washers (10) (Figure 13-11, Page 13-11). Disconnect the spade connectors from the solenoid (4). Slide solenoid (4) up to disengage the mounting tabs and remove from mounting plate. SOLENOID INSTALLATION Slide solenoid (4) into mounting plate (Figure 13-11, Page 13-11).

  • Page 259: Charger Receptacle Installation

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE INSTALLATION Insert the wires through the hole in the bucket. Insert receptacle (2) into bucket. Install the three screws (1) that secure the receptacle to the bucket. Tighten screws to 16 in·lb (1.8 N·m). Connect 10-gauge red wire to solenoid.
  • Page 260 ELECTRIC VEHICLE - ELECTRICAL Charger Receptacle COMPONENTS Pagination Page Page 13-16 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 261: Section 14 - Electric Vehicle - Batteries

    SECTION 14 — ELECTRIC VEHICLE - BATTERIES DANGER Electric Vehicle - Batteries • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.

  • Page 262: Battery Testing Basics - 8 Volt

    Battery Testing Basics – 8 Volt ELECTRIC VEHICLE - BATTERIES BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-2. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts • Rusted, corroded, loose or broken wires •...

  • Page 263: 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 264 Battery Regrouping ELECTRIC VEHICLE - BATTERIES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 265: Battery Replacement

    ELECTRIC VEHICLE - BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-2. WARNING • Wear steel-toe shoes when replacing batteries. • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.

  • Page 266: 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 267: Deionizer

    Replace filter immediately if the red light comes ON indicating service is required. Replacement filters are available from Club Car Service Parts. • Inspect the condition of all tubing, connections, and couplers. Make sure that all parts are in good working condition, secure, leak free, and properly connected.

  • Page 268: Battery Care - Vehicles Equipped With The Single-Point Watering System

    Battery Care ELECTRIC VEHICLE - BATTERIES Single point watering systems will require seasonal maintenance if vehicles are taken out of service or put into storage for a period of 6 weeks or longer. To prepare the SPWS, ensure the feed tube and coupler are on top of battery. Then, use the following steps to bring vehicle back into service: After the batteries have been fully charged/equalized, connect the system to its water supply for 3 to 5 seconds, then disconnect regardless of whether or not the batteries are completely full.

  • Page 269: Battery Care - Vehicles Without The Single-Point Watering System

    • 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 270: Electrolyte Level

    Battery Care ELECTRIC VEHICLE - BATTERIES Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a set of batteries will discharge. In hotter climates, batteries should be checked more often. When storing batteries, keep in a cool place.

  • Page 271: Single Point Watering System (Spws)

    A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
  • Page 272 Single Point Watering System (SPWS) ELECTRIC VEHICLE - BATTERIES 3083 Figure 14-4 Connecting Hose with Filter to Water Source Figure 14-5 Checking the Water Flow Rate Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement of the red flow indicator balls (6).

  • Page 273: Battery Storage

    ELECTRIC VEHICLE - BATTERIES Battery Storage CAUTION • If at any time water overflows from the batteries, immediately stop the refill process, disconnect the pressure regulator from the battery fill coupling, and call for service. When the red flow indicator balls stop moving, immediately press the grey button to disconnect the hose-end assembly from the battery fill coupling (9), and squeeze the dust cover (10) to lightly secure it to the male connector of the battery fill coupling (Figure 14-6).
  • Page 274 Early Excessive Discharging ELECTRIC VEHICLE - BATTERIES Pagination Page Page 14-14 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 275: Section 15 - Electric Vehicle - Battery Charger

    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 276: General Information

    IC0650-048-COMM). Do not attempt to service a battery charger that has not been properly identified. If a charger cannot be properly identified, contact your local Club Car dealer or distributor. How To Identify A Vehicle That Uses This High-Frequency Charger •...

  • Page 277: 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 15-13.

  • Page 278: Charger Power Connection Fuse

    General Information ELECTRIC VEHICLE - BATTERY CHARGER CHARGER POWER CONNECTION FUSE The charger receptacle harness has an in-line, 30-amp fuse located near the solenoid. CHARGER INTERLOCK External Charger: While the charger DC cord is plugged into the vehicle, the vehicle control circuit is locked out, preventing operation of the vehicle, as well as the possibility of consequent damage to the charger and the vehicle.

  • Page 279: Onboard Charger Status Indicators

    ELECTRIC VEHICLE - BATTERY CHARGER General Information LIGHT STATUS STATUS EXPLANATION Solid red Charger fault condition. Reset charger power. Flashing orange Charger cannot complete charge. Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress.

  • Page 280: Long-Term Storage

    General Information ELECTRIC VEHICLE - BATTERY CHARGER Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress. Battery pack has NOT reached a high state of charge. Flashing green AC power to charger is present.

  • Page 281: External Charger Mounting

    ELECTRIC VEHICLE - BATTERY CHARGER External Charger Mounting EXTERNAL CHARGER MOUNTING WARNING • Make sure the charger is securely mounted. Do not hang the charger by its handle. • Place all cords so they will not be stepped on, tripped over, or otherwise subjected to damage or stress. CAUTION •...

  • Page 282: Ac Power Connection

    • Place all cords so they will not be stepped on, tripped over, or otherwise subjected to damage or stress. 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. Page 15-8...

  • Page 283: The Charge Circuit

    ELECTRIC VEHICLE - BATTERY CHARGER The Charge Circuit Two of these high-frequency chargers can be used on a dedicated 15 or 20 ampere, single-phase branch circuit. This high-frequency charger caps current draw at 6 amps and will operate at full power if the voltage is within the 100 to 240 VAC and 50 to 60 Hz ranges.

  • Page 284: Charger Operation

    Charger Operation ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger: The charge circuit consists of the charger receptacle, interlock wire, controller, solenoid and battery pack (Figure 15-7, Page 15-10). 2789 Figure 15-7 Charge Circuit – Onboard High-Frequency Charger CHARGER OPERATION CHARGING BATTERIES See Dangers and Warnings beginning on page 15-1.
  • Page 285 Vehicles should be restricted to 40 to 50 amp hours of discharge (or 36 holes of golf) 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 286 If the charger does not seem to be operating properly, or if the batteries seem weak, see Charger Troubleshooting on page 15-14. If troubleshooting does not solve the issue, contact your local Club Car distributor/dealer. Figure 15-8 Correct Insertion of External Charger DC Plug...

  • Page 287: Charger Maintenance

    ELECTRIC VEHICLE - BATTERY CHARGER Charger Maintenance CHARGER MAINTENANCE See General Warnings on page 1-2. To ensure trouble-free performance, it is very important to follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Any charger not functioning correctly should be removed from use until it is properly repaired.

  • Page 288: Charger Troubleshooting

    Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER CHARGER TROUBLESHOOTING See General Warnings on page 1-2. DANGER • Do not touch any wire or component in the battery charger while AC power is present. Failure to heed this warning will result in an electric shock. WARNING •...

  • Page 289: Terminal Block Cover

    When the blue AC status indicator light comes on, reconnect the DC cord under the rear-facing seat. 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 vehicle as usual.

  • Page 290: External Charger Troubleshooting Indicators

    Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER EXTERNAL CHARGER TROUBLESHOOTING INDICATORS If a fault occurs, count the number of red flashes (on the charger or dash) between pauses and refer to the table below: EXTERNAL CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES STATUS...
  • Page 291 ELECTRIC VEHICLE - BATTERY CHARGER Charger Troubleshooting EXTERNAL CHARGER TROUBLESHOOTING GUIDE 1. Erroneous event (an unknown variable; Reset charger power. See Resetting Power – External something occurred to Charger on page 15-15. Reconnect DC cord to vehicle. the charger or vehicle that If status goes away, continue using charger.

  • Page 292: Onboard Charger Fault Codes

    Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER ONBOARD CHARGER FAULT CODES The “E” and “F” codes will appear in the display panel followed by three numbers and a period to indicate the different conditions. ONBOARD CHARGER FAULT CODES FAULT CODE DESCRIPTION SOLUTIONS F-0-0-1...
  • Page 293 ELECTRIC VEHICLE - BATTERY CHARGER Charger Troubleshooting ONBOARD CHARGER FAULT CODES Possible causes: Poor battery health, discharged battery, battery not connected correctly, and/or high parasitic loads on the battery while it is charging. • Replace the battery pack. E-0-0-7 Battery amp hour limit reached •...

  • Page 294: Test Procedures

    Test Procedures ELECTRIC VEHICLE - BATTERY CHARGER ONBOARD CHARGER FAULT CODES There has been a problem connecting or disconnect- ing the USB flash drive. • Disconnect and reconnect the USB flash drive. E-0-1-7 USB error • If the problem persists, remove AC and battery for E-0-2-7 minimum 30 seconds and retry charger.
  • Page 295 ELECTRIC VEHICLE - BATTERY CHARGER Test Procedures 3.1. Verify that the 10-gauge red wire from the charger receptacle is connected to the large post of solenoid with 6-gauge red wire (Figure 15-6, Page 15-9). 3.2. Verify that the 10-gauge black wire from the charger receptacle is connected to the B- terminal of controller. 3.3.
  • Page 296 Test Procedures ELECTRIC VEHICLE - BATTERY CHARGER With a multimeter set to 500 volts AC, check incoming AC voltage. Insert multimeter test probes into AC wall outlet; voltage should be between 85 and 270 volts. See AC Input Voltage Detection on page 15-4. If proper voltage is not present, have building wiring checked by a licensed electrical contractor.

  • Page 297: External Charger Repairs

    ELECTRIC VEHICLE - BATTERY CHARGER External Charger Repairs EXTERNAL CHARGER REPAIRS See General Warnings on page 1-2. WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 15-6, Page 15-9). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.

  • Page 298: Terminal Block Cover Installation

    External Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER 2791 Figure 15-11 Terminal Block Cover Mounting Tabs TERMINAL BLOCK COVER INSTALLATION WARNING • The terminal block cover (3) on the DC terminal block (4) must be installed properly to comply with UL code.

  • Page 299: Handle Installation

    ELECTRIC VEHICLE - BATTERY CHARGER External Charger Repairs HANDLE INSTALLATION Place handle (9) onto charger and seat it onto mounting bosses of charger. See following NOTE. NOTE: The handle (9) features locating tabs to aid installation. Secure handle (9) to charger with two torx screws (8). Tighten screws (8) to 39.8 in·lb (4.5 N·m). FOOT REMOVAL Disconnect DC cord (1) from vehicle.

  • Page 300: Onboard Charger Repairs

    Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER ONBOARD CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 15-7, Page 15-10). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.

  • Page 301: Onboard Charger Installation

    ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Disconnect AC cord reel lead (3) from onboard charger (4). Retain sleeve (5). Disconnect DC charging harness (6) from onboard charger DC cord (7). Disconnect 14-pin plug (8) from onboard charger (4). Remove two torx screws (9) securing DC cord connector (7) to seat bottom (2).

  • Page 302: Dc Cord And Strain Relief Removal

    Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER 2793 Figure 15-13 Terminal Block Cover, DC Cord and Strain Relief – Onboard Charger DC CORD AND STRAIN RELIEF REMOVAL Disconnect AC cord from AC outlet. Disconnect DC cord (1) at connector mounted under seat (Figure 15-13, Page 15-28). Remove terminal block cover.

  • Page 303: Dc Charging Harness Installation

    ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Lift rear-facing seat bottom and support in the raised position. Disconnect DC charging harness from onboard charger DC cord. Disconnect 14-pin plug from onboard charger. Remove access panel and electronics module cover. See Electronics Module Cover Removal, Section 13, Page 13-6.
  • Page 304 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Pagination Page Page 15-30 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 305: 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 306 External Motor Testing ELECTRIC VEHICLE - MOTOR MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity A1 to F2 A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground No Continuity...
  • Page 307 ELECTRIC VEHICLE - MOTOR External Motor Testing TEST PROCEDURE 3 – Field Circuit Open See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the F1 and F2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the F1 terminal and the black (–) probe on the F2 terminal.

  • Page 308: Motor

    Motor ELECTRIC VEHICLE - MOTOR MOTOR See General Warnings on page 1-2. MOTOR REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.

  • Page 309: Motor Disassembly

    ELECTRIC VEHICLE - MOTOR Motor Figure 16-3 Lower Axle Remove the bolts and lock washers that secure the motor to the transaxle (Figure 16-24, Page 16-17). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
  • Page 310 Motor ELECTRIC VEHICLE - MOTOR 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 16-15, Page 16-12). 2.2. Remove the screw securing the magnet to the armature shaft (Figure 16-4, Page 16-5). 2.3.
  • Page 311 ELECTRIC VEHICLE - MOTOR Motor CAUTION • Removing the armature from the end cap requires two people: one to operate the press, and another to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing.

  • Page 312: Motor Component Testing And Inspection

    Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR Figure 16-10 Brush Rigging Figure 16-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-2. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-5.
  • Page 313 ELECTRIC VEHICLE - MOTOR Motor Component Testing and Inspection CAUTION • Do not use emery cloth to polish the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.

  • Page 314: Motor Frame And Field Windings Inspection

    Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-5. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
  • Page 315 ELECTRIC VEHICLE - MOTOR Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
  • Page 316 Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 317: Reconditioning The Motor

    ELECTRIC VEHICLE - MOTOR Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-2. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
  • Page 318 Motor Assembly ELECTRIC VEHICLE - MOTOR Figure 16-16 Brush Rigging Figure 16-17 Retracted Brushes Figure 16-18 Armature Installation Figure 16-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-18, Page 16-14).

  • Page 319: Motor Installation

    ELECTRIC VEHICLE - MOTOR Motor Installation Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. MOTOR INSTALLATION See General Warnings on page 1-2. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ®...
  • Page 320 Motor Installation ELECTRIC VEHICLE - MOTOR Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 16-15, Page 16-12).
  • Page 321 ELECTRIC VEHICLE - MOTOR Motor Installation nuts. For 5/16 inch (8mm) diameter studs, tighten the nuts to 100 in·lb (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten the nuts to 45 in·lb (5.0 N·m). 4.8. Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation.
  • Page 322 Motor Installation ELECTRIC VEHICLE - MOTOR Pagination Page Page 16-18 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 323: Section 17 - Electric Vehicle - Transaxle

    SECTION 17 — ELECTRIC VEHICLE - TRANSAXLE DANGER Electric Vehicle - Transaxle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. LUBRICATION See General Warnings on page 1-2. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
  • Page 324 Axle Bearing and Shaft ELECTRIC VEHICLE - TRANSAXLE 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft.
  • Page 325 ELECTRIC VEHICLE - TRANSAXLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 17-3...

  • Page 326: Axle Bearing

    Axle Bearing and Shaft ELECTRIC VEHICLE - TRANSAXLE Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 17-3, Page 17-2).

  • Page 327: Transaxle Removal

    ELECTRIC VEHICLE - TRANSAXLE Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one end...”...
  • Page 328 Transaxle Removal ELECTRIC VEHICLE - TRANSAXLE 2700 Figure 17-8 Disconnect Shocks Figure 17-9 Shackles If a floor jack was used, pull floor jack from beneath the transaxle and allow the springs to rest on the floor. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 17-10, Page 17-6). Carefully lift each end of the transaxle off its positioning pin (on the leaf spring) and slide the transaxle to the rear and out of the vehicle.

  • Page 329: Transaxle Disassembly, Inspection, And Assembly

    ELECTRIC VEHICLE - TRANSAXLE Transaxle Disassembly, Inspection, and Assembly TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-2. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
  • Page 330 Transaxle Disassembly, Inspection, and Assembly ELECTRIC VEHICLE - TRANSAXLE Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 17-5, Page 17-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1.) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 17-13, Page 17-8).

  • Page 331: Transaxle Assembly

    ELECTRIC VEHICLE - TRANSAXLE Transaxle Disassembly, Inspection, and Assembly NOTE: Damaged or worn gears should be replaced as sets. TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 17-5, Page 17-3).

  • Page 332: Transaxle Installation

    Transaxle Installation ELECTRIC VEHICLE - TRANSAXLE WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
  • Page 333 ELECTRIC VEHICLE - TRANSAXLE Transaxle Installation WARNING • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. •...
  • Page 334 Transaxle Installation ELECTRIC VEHICLE - TRANSAXLE Pagination Page Page 17-12 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 335: Section 18 - Gasoline Vehicle - Troubleshooting And Electrical System

    SECTION 18 — GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER Gasoline Vehicle - Troubleshooting and Electrical System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.

  • Page 336: Low Oil Warning Light

    GASOLINE VEHICLE - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM LOW OIL WARNING LIGHT CAUTION • Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage. The low oil warning light gives a visual indication of an oil level problem. Figure 18-1 Low Oil Warning Light STATUS CONDITION...

  • Page 337: Gasoline Powertrain

    GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Maintenance/Operate switch is in the Set the Maintenance/Operate switch to MAINTENANCE position OPERATE Fuse is blown See the Fuses Test Procedure Battery is dead See the Battery Test Procedure See the Key Switch (Start Circuit) Test Starter control circuit is not operating...
  • Page 338 GASOLINE VEHICLE - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine mounting nuts or bolts are loose See the Engine (Kohler ECH440) Section Snubber on frame is worn or damaged See the Engine (Kohler ECH440) Section See the Exhaust System: Gasoline Vehicles Loose muffler mounting hardware Section...

  • Page 339: Fuse And Relay Locations

    GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Fuse And Relay Locations FUSE AND RELAY LOCATIONS Figure 18-2 Fuse and Relay Locations 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 18-5...

  • Page 340: Electrical System

    GASOLINE VEHICLE - TROUBLESHOOTING Electrical System AND ELECTRICAL SYSTEM See Fuse and Relay Locations on page 18-5. CALLOUT NUMBER DESCRIPTION Fuse Holder • 10A Fuse • 5A Fuse • 20A Fuse 2A Fuse 15A Fuse Fuel Pump Relay Fuse Holder •...

  • Page 341: Test Procedures

    GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 342 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Index of Test Procedures 1 – Battery 2 – Fuse Inspection 3 – Ground Cables 4 – Key Switch (Start Circuit) 5 – Key Switch (Engine Kill Circuit) 6 – Throttle Position Sensor (TPS) 7 –...
  • Page 343 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 1 – Battery DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
  • Page 344 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
  • Page 345 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 3 – Ground Cables See General Warnings on page 1-2. NOTE: This is a continuity test for the main ground wire of the vehicle. An additional ground wire is located on top of the fuel tank.
  • Page 346 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM –M WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 1337 Figure 18-3 Key Switch Test – Engine Kill Circuit Put the red (+) probe on the (+M) terminal. Put the black (–) probe on the (–M) terminal.
  • Page 347 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures NOTE: It may be necessary to partially pull the green wire from the switch terminal to attach the black lead. Turn the key switch to the ON position. With accelerator pedal in the up position: The meter should indicate an over limit (no continuity) condition. If the reading is incorrect, replace the accelerator pedal assembly.
  • Page 348 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 7 – Solenoid See General Warnings on page 1-2. NOTE: This is a resistance and voltage test. If necessary, see Testing Basics. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Coil Side: Check the resistance across the small posts of the solenoid.
  • Page 349 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures – With accelerator pedal pressed: The solenoid should click and the meter should read battery voltage. If the reading is incorrect, replace the solenoid. TEST PROCEDURE 8 – Maintenance/Operate Switch NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch.
  • Page 350 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 9 – Transaxle Limit Switch See General Warnings on page 1-2. NOTE: This is a continuity test. This switch is located on the transaxle. A black/pink wire, a red wire, and a gray wire are connected to this limit switch with a 3-pin connector.
  • Page 351 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 10 – Starter/Generator (Generator Function) NOTE: This is a voltage test. If necessary, see Testing Basics. Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Disconnect the yellow wire (1) from the DF terminal (2) on starter/generator (Figure 18-8).
  • Page 352 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 11 – Starter/Generator (Starter Function) NOTE: Observe the following before testing the starter/generator: • This is only testing continuity. • 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.
  • Page 353 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 3030B Figure 18-9 Check Starter Terminal Continuity Put the red (+) probe (one at a time) on the A1, A2, F1, F2 and DF terminals. The readings should be no continuity. 6.1.
  • Page 354 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 12 – Voltage Regulator NOTE: This is a voltage test. Keep the battery connected while performing this test procedure. If necessary, see Testing Basics. Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Make sure that the wires are connected correctly and are tight.
  • Page 355 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 13 – Ignition Spark NOTE: Keep the battery connected while performing this test procedure. ® Use an spark gap test tool (Thexton 404 or equivalent) If necessary, see Testing Basics. Disable the vehicle.
  • Page 356 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 14 – Multi-Purpose Buzzer and Multi-Purpose Buzzer Limit Switch NOTE: Multi-purpose Buzzer: This is a voltage test. A multi-purpose buzzer is mounted on the back side of the instrument panel. On some models, another multi-purpose buzzer is also mounted on a bracket at the left rear of the vehicle.
  • Page 357 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 15 – Malfunction Indicator Light (MIL) NOTE: This is a voltage test. If necessary, see Testing Basics. Remove the instrument panel. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Turn the key switch to ON.
  • Page 358 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 17 – Battery Test (Under Load) NOTE: Keep the battery connected while performing this test procedure. The voltage reading listed is for electrolyte at 70 °F (21 °C). At lower electrolyte temperatures the voltage reading will be lower.
  • Page 359 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 18 – Fuel Pump WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure. NOTE: This is a voltage and resistance test.
  • Page 360 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Fuel Pump Resistance Procedure If necessary, see Testing Basics. Disconnect the battery. Disconnect the fuel pump connector from the top of the fuel pump module. Set the multimeter to 200 Ohms. Check for approximately 2 to 5 ohms between pin (1) and pin (2) terminals in fuel pump module.
  • Page 361 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 5.2. If the reading is correct and the fuel pump does not function correctly, go to step 5.2.1. Leave the battery disconnected while checking continuity. 5.2.1. Check the continuity from the black/white wire of the fuel pump relay to pin (G) of the ECU connector. Wire Color Description Switched 12V Power...
  • Page 362 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Check the resistance between pin (3) and pin (4) terminals in module. Description Wire Color 1. Fuel Pump Positive (+) Red/White 2. Fuel Pump Negative (–) Black/White 3. Sending Unit Positive (+) Orange 4.
  • Page 363 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 20 – Fuel Gauge NOTE: This is a voltage test. Pin Description Wire Color 1. Fuel (-) Black 2. Fuel (+) Blue 4. Fuel Input Orange 6. Hour (-) Black/White 7.
  • Page 364 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Put the red (+) probe of the multimeter on the positive post of the battery. Put the black (–) probe on the negative post of the battery. Record the voltage reading. Put the red (+) probe on terminal 2 of the fuel gauge/hour meter with the blue wire (2) connected.
  • Page 365 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 22 – 4-Pin Connector (to Visage) See General Warnings on page 1-2. NOTE: This is a voltage and continuity test. The Connected Car Device 4-pin connector is used for Guardian/Visage and is labeled “V3 circuit” on the main wire harness.
  • Page 366 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Pagination Page Page 18-32 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 367: Section 19 - Gasoline Vehicle - Electrical Components

    SECTION 19 — GASOLINE VEHICLE - ELECTRICAL COMPONENTS DANGER Gasoline Vehicle - Electrical Components • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. BATTERY DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working on or near batteries.

  • Page 368: Preventive Maintenance

    GASOLINE VEHICLE - ELECTRICAL Battery COMPONENTS PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove any corrosion immediately. Post connections should be clean and tight. Any frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 41 lb·in (4.3 N·m), coat terminals with Battery Terminal Protector Spray to prevent future corrosion.

  • Page 369: Battery Removal

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Battery BATTERY REMOVAL Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Neutral/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Remove the battery hold-down clamp from the battery.

  • Page 370: Battery Storage

    GASOLINE VEHICLE - ELECTRICAL Ground Cables COMPONENTS BATTERY STORAGE Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 19-2. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.

  • Page 371: Disassembly Of The Starter/Generator To Service The Brushes

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator Loosen the pivot nuts (7) and bolts (5) (Figure 19-13, Page 19-15). Remove the adjustment nut (4), washer (6) and adjustment bolt (1) (Figure 19-13, Page 19-15). Lower the starter/generator and remove the belt (2) from the pulley. Support the starter/generator so that when the pivot bolts (5) are removed the starter/generator will not fall.

  • Page 372: Brush Spring Inspection And Replacement

    GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS Figure 19-3 Inspect Brushes and Measure Length BRUSH SPRING INSPECTION AND REPLACEMENT Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 19-2, Page 19-5). Using a spring scale, test brush spring tension.

  • Page 373: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator To prevent contact between the brushes and commutator as the commutator is installed, and possible damage to the brushes, lift the brush springs and pull the brushes back from the center of the commutator end cover. The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover (Figure 19-5, Page 19-7).

  • Page 374: Bearing Cleaning And Inspection

    GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 1342 Figure 19-6 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 19-7, Page 19-8).

  • Page 375: Bearing Removal

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator BEARING REMOVAL Place the wedge attachment tool between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller to the wedge attachment tool and pull the bearing off of the end of the armature shaft.

  • Page 376: Commutator Cleaning And Inspection

    GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS Figure 19-9 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.

  • Page 377: Armature Ground Test

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator 1. Measure each position in two places, 90 degrees apart Figure 19-10 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.

  • Page 378: Visual Inspection Of Field Coils

    GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 19-11 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
  • Page 379 GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator Press a new ball bearing (35) onto the output end of the armature (Figure 19-6, Page 19-8). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
  • Page 380 GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 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 Page 19-14 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 381: Starter/Generator Installation

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator STARTER/GENERATOR INSTALLATION 2997 Figure 19-13 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 19-14, Page 19-16). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 lb·in (5.4 N·m). Position the starter/generator over the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.

  • Page 382: Belt Tension Adjustment For Efi Engines

    GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 3033 Figure 19-14 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES NOTE: To prevent belt slipping while starting an EFI engine, follow procedure outlined below which is best performed by two people to expedite the process, but can be performed by a single individual if required. The amount a starter/generator belt is tensioned varies between a used and new belt.
  • Page 383 GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator – Use combination of above methods. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. For Existing Belts Only: Verify current belt tension using Universal Belt Tension Gauge (OTC 6673 ®...

  • Page 384: Solenoid

    GASOLINE VEHICLE - ELECTRICAL Solenoid COMPONENTS 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 19-15, Page 19-16). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.

  • Page 385: Solenoid Installation

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Solenoid Figure 19-18 Solenoid Removal Disconnect all the wires from the solenoid (2). Remove the two screws (3). Remove the solenoid. SOLENOID INSTALLATION Install the solenoid (1) in the vehicle (Figure 19-19, Page 19-19). Figure 19-19 Solenoid Installation Install the two screws (2).

  • Page 386: Voltage Regulator

    GASOLINE VEHICLE - ELECTRICAL Voltage Regulator COMPONENTS Figure 19-20 Solenoid Large Posts Connect the red wire to the large post (4) on the solenoid. Install the nuts (5). Tighten the nuts to 59 lb·in (6.7 N·m). Connect the blue wire to the small post (6) on the solenoid (Figure 19-21, Page 19-20). Figure 19-21 Solenoid Small Posts Connect the orange wire to the small post (7) on the solenoid.

  • Page 387: Voltage Regulator Installation

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Engine Control Unit (ECU) Disconnect the voltage regulator connector (3) from the wire harness (Figure 19-22, Page 19-21). Remove the voltage regulator mounting screw (2) and remove the voltage regulator (1). 2432 Figure 19-22 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (1) and install the mounting screw (2) (Figure 19-22, Page 19-21).

  • Page 388: Engine Control Unit Installation

    GASOLINE VEHICLE - ELECTRICAL Fuel Level Sending Unit COMPONENTS ENGINE CONTROL UNIT INSTALLATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help prevent accidentally installing it in the gray port.

  • Page 389: Maintenance/Operate Switch Installation

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Accelerator Pedal Limit Switch Disconnect the wires and remove Maintenance/Operate switch. MAINTENANCE/OPERATE SWITCH INSTALLATION Connect the wires to the Maintenance/Operate switch. Pedal-Start Terminal Wire Color Black / Pink Black Black / Yellow Make sure that the groove switch is aligned with tang on bracket (3) and install the Maintenance/Operate switch (2) (Figure 19-24, Page 19-23).

  • Page 390: Kill Limit Switch

    GASOLINE VEHICLE - ELECTRICAL Kill Limit Switch COMPONENTS KILL LIMIT SWITCH See General Warnings on page 1-2. The kill limit switch is housed inside the 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.

  • Page 391: Multi-Purpose Buzzer Limit Switch Installation

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Neutral Lockout Limit Switch MULTI-PURPOSE BUZZER LIMIT SWITCH INSTALLATION Install the multi-purpose buzzer limit switch (5) on the two bolts (Figure 19-25, Page 19-24). Install washers (4) and neutral lockout limit switch (3). CAUTION • Do not overtighten the nuts. If the nuts are over tightened, the limit switches could be damaged. Install the washers (2) and nuts (1).

  • Page 392: Neutral Lockout Limit Switch Installation

    GASOLINE VEHICLE - ELECTRICAL Neutral Lockout Limit Switch COMPONENTS Remove the nuts (2) and washers (3). Remove the neutral lockout limit switch. NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION Install the neutral lockout limit switch (1) on the bolts (Figure 19-27, Page 19-26). Figure 19-27 Neutral Lockout Limit Switch Installation CAUTION •...

  • Page 393: Transaxle Limit Switch

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Transaxle Limit Switch Connect the battery and spark plug wire. Set the FNR to R. Make sure that the multi-purpose buzzer operates. TRANSAXLE LIMIT SWITCH See General Warnings on page 1-2. TRANSAXLE LIMIT SWITCH REMOVAL Disable the vehicle.

  • Page 394: Brake Light Relay

    GASOLINE VEHICLE - ELECTRICAL Brake Light Relay COMPONENTS 000999-003 Figure 19-30 Transaxle Limit Switch Move the Forward/Neutral/Reverse control (FNR) to make sure that the switch actuates. Connect the 3-wire connector to the transaxle limit switch lead. Connect the battery and spark plug wire. Test drive the vehicle in both forward and reverse for proper operation.

  • Page 395: Brake Light Relay Installation

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Fuel Gauge/Hour Meter Remove the screws (2). Remove the brake light relay. BRAKE LIGHT RELAY INSTALLATION Install the brake light relay (1) on the instrument panel (Figure 19-31, Page 19-28). Install the screws (2). Connect the wires to the brake light relay terminals (Figure 19-32, Page 19-29). Pin Description Wire Color Blue...

  • Page 396: Fuel Gauge/Hour Meter Removal

    GASOLINE VEHICLE - ELECTRICAL Fuel Gauge/Hour Meter COMPONENTS Figure 19-33 Fuel Gauge / Hour Meter FUEL GAUGE/HOUR METER REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the wires from the fuel gauge/hour meter (1) (Figure 19-33, Page 19-30). Do not allow wires to touch. Alternate pulling the lower and upper tabs away from the gauge housing (2) to remove clip.

  • Page 397: Headlight Switch

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Headlight Switch 2. Fuel (+) Blue 4. Fuel Input Orange 6. Hour (-) Black/White 7. Hour Input Figure 19-34 Fuel Gauge/Hour Meter Install the instrument panel. Connect the battery and spark plug wire. HEADLIGHT SWITCH Figure 19-35 Headlight Switch HEADLIGHT SWITCH REMOVAL Disconnect the battery and spark plug wire.

  • Page 398: Key Switch

    GASOLINE VEHICLE - ELECTRICAL Key Switch COMPONENTS Connect the blue and yellow wires to the headlight switch terminals. Install the instrument panel. Connect the battery and spark plug wire. KEY SWITCH See General Warnings on page 1-2. Figure 19-36 Key Switch KEY SWITCH REMOVAL Disconnect the battery and spark plug wire.

  • Page 399: Low Oil Warning Light

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Low Oil Warning Light Black White / Black Install the instrument panel. Connect the battery and spark plug wire. LOW OIL WARNING LIGHT See General Warnings on page 1-2. Figure 19-37 Low Oil Warning Light LOW OIL WARNING LIGHT REMOVAL Disconnect the battery and spark plug wire.

  • Page 400: Malfunction Indicator Light (Mil)

    GASOLINE VEHICLE - ELECTRICAL Malfunction Indicator Light (MIL) COMPONENTS MALFUNCTION INDICATOR LIGHT (MIL) Figure 19-38 Malfunction Indicator Light (MIL) MALFUNCTION INDICATOR LIGHT REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the wires (1) (Figure 19-38, Page 19-34). Do not allow wires to touch. Push the retaining tabs (2) and remove the malfunction indicator light (3) from the instrument panel.

  • Page 401: Multi-Purpose Buzzer

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Multi–Purpose Buzzer MULTI–PURPOSE BUZZER See General Warnings on page 1-2. Figure 19-39 Multi-Purpose Buzzer MULTI–PURPOSE BUZZER REMOVAL Disconnect battery and spark plug wire. Remove the instrument panel. Disconnect the wires from the multi-purpose buzzer (1) (Figure 19-39, Page 19-35). Remove the two mounting screws (2).

  • Page 402: Usb Receptacle

    GASOLINE VEHICLE - ELECTRICAL USB Receptacle COMPONENTS USB RECEPTACLE The 5-volt, 2.1 amp USB receptacle supplies electricity to power and charge portable devices. The USB receptacle is not for movement of data. The USB receptacle will only operate when a shielded USB cord is connected. When the USB receptacle is not in use, remove the shielded USB cord to prevent battery drain.

  • Page 403: Oxygen Sensor

    GASOLINE VEHICLE - ELECTRICAL COMPONENTS Oxygen Sensor OXYGEN SENSOR OXYGEN SENSOR REMOVAL Disconnect the battery. Disconnect the oxygen sensor connector from the engine wire harness (1) (Figure 19-41, Page 19-37). Figure 19-41 Oxygen Sensor Remove the oxygen sensor (2). OXYGEN SENSOR INSTALLATION Install the oxygen sensor (2) into the muffler tube (Figure 19-41, Page 19-37).
  • Page 404 GASOLINE VEHICLE - ELECTRICAL Oxygen Sensor COMPONENTS Pagination Page Page 19-38 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 405: Section 20 - Gasoline Vehicle - Engine

    SECTION 20 — GASOLINE VEHICLE - ENGINE DANGER Gasoline Vehicle - Engine • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION This vehicle is powered by a Kohler, high-compression, chain driven, overhead valve engine (OHV). See following NOTE.

  • Page 406: Engine Removal

    Engine Removal GASOLINE VEHICLE - ENGINE ENGINE REMOVAL CAUTION • Before removal and disassembly, clean the engine. Disconnect the battery. Disconnect the spark plug wire. For some vehicles, the engine 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.
  • Page 407 GASOLINE VEHICLE - ENGINE Engine Removal Remove the bolts (5 and 6) (Figure 20-2, Page 20-3). Figure 20-2 Clutch Plate Removal Remove the clutch plate (7). Remove the bolts (8) (Figure 20-3, Page 20-3). Figure 20-3 Exhaust Weldment Removal Remove the exhaust weldment (9). 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 20-3...
  • Page 408 Engine Removal GASOLINE VEHICLE - ENGINE Remove the bolts (10), washers (11), and nuts (12) (Figure 20-4, Page 20-4). Figure 20-4 Engine Pan Removal Lift the engine from engine pan (13). See following NOTE. NOTE: The engine weighs approximately 54 lb (24.5 kg). Remove the oil drain plug and drain all oil from crankcase.

  • Page 409: Engine Installation

    GASOLINE VEHICLE - ENGINE Engine Installation ENGINE INSTALLATION If replacing engine, install starter/generator mounting weldment on engine with the screws. Tighten the screws to 17 ft·lb (23 N·m). Install oil drain plug and tighten to 13 ft·lb (18 N·m). Place the engine onto the engine pan (13) and secure with mounting hardware (10, 11, and 12) (Figure 20-5, Page 20-5).
  • Page 410 Engine Installation GASOLINE VEHICLE - ENGINE Install the clutch plate (7) with bolts (5 and 6) (Figure 20-7, Page 20-6). Tighten the bolts (5) to 27 ft·lb (36 N·m). Tighten the bolts (6) to 50 ft·lb (68 N·m). Figure 20-7 Clutch Plate Installation Install the drive clutch.
  • Page 411 GASOLINE VEHICLE - ENGINE Engine Installation Connect the ground cable to the engine (4) (Figure 20-8, Page 20-7). Figure 20-8 Throttle Cover and Ground Cable Installation Route the vent line (3) through the throttle body cover (2). Connect the vent line. Install the throttle body cover with the screw (1).

  • Page 412: Snubber

    Snubber GASOLINE VEHICLE - ENGINE SNUBBER NOTE: The snubber is installed on the gasoline vehicle only. Figure 20-9 Snubber SNUBBER REMOVAL Support the powertrain with a floor jack under the engine pan (1) so that the snubber (2) is raised slightly and does not rest on the vehicle frame (Figure 20-9, Page 20-8).

  • Page 413: Section 21 - Gasoline Vehicle - Fuel System

    SECTION 21 — GASOLINE VEHICLE - FUEL SYSTEM DANGER Gasoline Vehicle - Fuel System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. WARNING • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.

  • Page 414: Engine Control Linkages

    Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM ENGINE CONTROL LINKAGES DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push cable, do the following: – Turn key switch OFF and remove key, place Forward/Neutral/Reverse handle in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.
  • Page 415 GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages 3.2. Remove the governor cable fitting (1) from the linkage retainer (2) (Figure 21-1, Page 21-3). Figure 21-1 Governor Cable Removal - Throttle Body 3.3. Disconnect the governor cable fitting from throttle lever (3). 3.4.
  • Page 416 Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM Figure 21-3 Governor Cable Installation - Throttle Body 1.2. Connect the governor cable fitting (1) to throttle lever (2). 1.3. Install the governor cable fitting into the linkage retainer (3). At transaxle: 2.1.

  • Page 417: Accelerator Cable

    GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages Adjustment: 3.1. Connect the diagnostic tool. 3.2. Loosen the jam nuts (7 and 11) and back off the throttle stop screws (8 and 12) several turns (Figure 21-5, Page 21-5). Figure 21-5 Governor Cable Adjustment 3.3.
  • Page 418 Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM 3130B Figure 21-6 Accelerator Cable At Transaxle 4.2. Remove the dust shield (4) from the end of the cable housing. 4.3. Unsnap the accelerator cable from FNR/accelerator cable bracket (5). At pedal group: 5.1.
  • Page 419 GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages 5.4. Remove the debris shield (8). 5.5. Disconnect the accelerator cable clip (9) from the accelerator pedal (10). 5.6. Loosen the jam nuts (11) and remove accelerator cable from vehicle. Accelerator Cable Installation At transaxle: 1.1.

  • Page 420: Idle Adjustment

    Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM Figure 21-9 Accelerator Cable At Pedal Group 2.3. Install the debris shield (8). 2.4. Separate the jam nuts (11) on cable and put the threaded end into slot in underbody. Tighten the jam nuts finger-tight.

  • Page 421: Engine Rpm Adjustment

    GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages Drive vehicle and bring to maximum speed before reaching the first cone. Using a stopwatch, record the amount of time it takes to travel from the first cone to the second cone at maximum speed.

  • Page 422: Air Intake System

    Air Intake System GASOLINE VEHICLE - FUEL SYSTEM AIR INTAKE SYSTEM Figure 21-10 Air Intake System AIR CLEANER REMOVAL Disable the vehicle. Disconnect battery and spark plug wire. Loosen the clamp (1) and disconnect air intake hose from throttle body (Figure 21-10, Page 21-10). Remove the screws (2).

  • Page 423: Relieving Fuel Pressure

    GASOLINE VEHICLE - FUEL SYSTEM Relieving Fuel Pressure RELIEVING FUEL PRESSURE In the event that servicing the EFI fuel system necessitates removal of the fuel delivery hose, extreme caution must be exercised. The fuel system is under high pressure even with the engine not running. Disconnecting any part of the fuel delivery system, without first depressurizing the system, will result in a sudden release of pressurized gasoline at the connection.

  • Page 424: Carbon Canister

    Carbon Canister GASOLINE VEHICLE - FUEL SYSTEM CARBON CANISTER Figure 21-11 CARBON CANISTER REMOVAL Disable the vehicle. Relieve the fuel pressure. Disconnect the battery. Clean the area around the vent line (1) and purge line (2) on the carbon canister (3). Remove the clamps (4).

  • Page 425: Fuel Line

    CAUTION • This EFI gasoline vehicle is equipped with 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 426 Fuel Line GASOLINE VEHICLE - FUEL SYSTEM At engine: 5.1. Remove the bolt (1), washer (2), and P-clamp (3) from the fuel line support bracket (4) (Figure 21-12, Page 21-14). Figure 21-12 5.2. Pull out the locking clip (4) (Figure 21-13, Page 21-14). Figure 21-13 5.3.

  • Page 427: Fuel Line Installation

    GASOLINE VEHICLE - FUEL SYSTEM Fuel Line FUEL LINE INSTALLATION Clean the nipple on the throttle body. DANGER • Make sure that the fuel line is connected properly to avoid a leak that can cause a fire. Push the fuel line (1) onto the nipple until it locks into place (Figure 21-14). Figure 21-14 Push in the locking clip (2) until it is fully seated.
  • Page 428 Fuel Line GASOLINE VEHICLE - FUEL SYSTEM Install the P-clamp (1), washer (2), and bolt (3) onto the fuel line support bracket (4) (Figure 21-16). Tighten the bolt to 93 to 111 in·lb (10.5 to 12.5 N·m). Figure 21-16 Clean the nipple on top of fuel pump module. Rotate the fuel line connector (1) 180 degrees and connect it to the nipple (Figure 21-17, Page 21-16).

  • Page 429: Fuel Pump Module

    GASOLINE VEHICLE - FUEL SYSTEM Fuel Pump Module Make sure that the fuel line is routed correctly (Figure 21-18). Figure 21-18 Clean spilled and remove any drained gasoline from the area. Connect the battery. Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Turn the key switch to the ON position and check for fuel leaks.
  • Page 430 Fuel Pump Module GASOLINE VEHICLE - FUEL SYSTEM Disconnect the battery. Clean the top of the fuel tank and fuel pump module. With a marker pen, make a mark across the top of the fuel pump module and onto the tank to note orientation before removal.

  • Page 431: Fuel Pump Module Installation

    GASOLINE VEHICLE - FUEL SYSTEM Fuel Pump Module FUEL PUMP MODULE INSTALLATION Clean the groove on top of fuel tank. Install the new fuel module o-ring (9) into groove on top of fuel tank (Figure 21-20, Page 21-19). Figure 21-20 Fuel Pump Module Installation Lower the fuel pump module (8) into fuel tank noting correct orientation marked before removal.

  • Page 432: 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 Disable the vehicle.
  • Page 433 GASOLINE VEHICLE - FUEL SYSTEM Fuel Tank Remove gas cap and siphon all fuel from tank into an approved container. See following DANGER and WARNING. DANGER • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area.

  • Page 434: 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. Install the fuel tank (8) in vehicle (Figure 21-22, Page 21-23).
  • Page 435 GASOLINE VEHICLE - FUEL SYSTEM Fuel Tank Figure 21-22 Fuel Tank Installation Install the fuel tank retaining strap (7). 2.1. Insert the tabs on the rear of the fuel tank retaining strap into the slots on the back of the bucket. 2.2.

  • Page 436: Fuel Filter

    Fuel Filter GASOLINE VEHICLE - FUEL SYSTEM Turn key switch to the ON position and check for fuel leaks. Repeat as necessary to build fuel pressure. Any leaks found must be fixed. DANGER • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, set the Maintenance/Operate switch to OPERATE.

  • Page 437: Fuel Filter Installation

    GASOLINE VEHICLE - FUEL SYSTEM Fuel Filter FUEL FILTER INSTALLATION CAUTION • Fuel filter flex hoses are keyed to aid proper installation into fuel pump module. NOTE: The fuel filter is keyed to the fuel pump module to prevent incorrect assembly. The inlet and outlet flex hoses are keyed to the fuel filter ports to prevent incorrect assembly.
  • Page 438 Fuel Filter GASOLINE VEHICLE - FUEL SYSTEM Pagination Page Page 21-26 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 439: Section 22 - Gasoline Vehicle - Exhaust System

    SECTION 22 — GASOLINE VEHICLE - EXHAUST SYSTEM DANGER Gasoline Vehicle - Exhaust System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. MUFFLER MUFFLER REMOVAL Disconnect the battery and spark plug wire. If necessary, remove the oxygen sensor (1) from the muffler (2) (Figure 22-1, Page 22-1). See Oxygen Sensor Removal.

  • Page 440: Muffler Installation

    Muffler GASOLINE VEHICLE - EXHAUST SYSTEM MUFFLER INSTALLATION Install the new exhaust gasket (7) on the exhaust port studs (Figure 22-2, Page 22-2). Figure 22-2 Muffler Installation Put the muffler (2) into position on the engine. Install the nuts (3), bolt (4), washer (5), and bolts (6). Tighten the hardware by hand. Tighten the hardware in the following order: 4.1.

  • Page 441: Section 23 - Gasoline Vehicle - Clutches

    SECTION 23 — GASOLINE VEHICLE - CLUTCHES DANGER Gasoline Vehicle - Clutches • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
  • Page 442 Troubleshooting GASOLINE VEHICLE - CLUTCHES If the torque converter is not operating properly, perform the following steps: Check the governor and throttle settings. See Engine Control Linkages. 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.

  • Page 443: Drive Belt

    GASOLINE VEHICLE - CLUTCHES Drive Belt DRIVE BELT The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.

  • Page 444: Drive Clutch

    Drive Clutch GASOLINE VEHICLE - CLUTCHES DRIVE CLUTCH 1. Screw, 3/8-24 x 5.75, Patch 10. Retainer 2. Washer, Hard, M10 11. Ring, Spiral Backup 3. Washer, 3/8, Type A, Flat 12. Bushing, Split, Drive Clutch 4. Cap Plug 13. Sheave, Moveable, Drive 5.

  • Page 445: Drive Clutch Removal

    GASOLINE VEHICLE - CLUTCHES Drive Clutch CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.

  • Page 446: Drive Clutch Cleaning And Inspection

    Drive Clutch GASOLINE VEHICLE - CLUTCHES WARNING position. Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Remove the drive clutch retaining bolt (1) and mounting washers (2 and 3) (Figure 23-2, Page 23-4).
  • Page 447 GASOLINE VEHICLE - CLUTCHES Drive Clutch Remove the drive clutch hub (5) (Figure 23-2, Page 23-4): 2.1. Remove the three plugs (4) from the clutch puller attachment holes. 2.2. Thread the center bolt of the Drive Clutch Hub Puller (1) into clutch until the stop nut touches the clutch, then back the bolt out one-half turn (Figure 23-6, Page 23-7).
  • Page 448 Drive Clutch GASOLINE VEHICLE - CLUTCHES 3053 Figure 23-7 Drive Button Mounting Figure 23-8 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 23-8, Page 23-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch.

  • Page 449: Inspection Of Drive Clutch Parts

    GASOLINE VEHICLE - CLUTCHES Drive Clutch Figure 23-9 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 23-2, Page 23-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 23-2, Page 23-4).

  • Page 450: Drive Clutch Assembly

    Drive Clutch GASOLINE VEHICLE - CLUTCHES Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).

  • Page 451: Drive Clutch Installation

    GASOLINE VEHICLE - CLUTCHES Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 23-12, Page 23-11).

  • Page 452: Driven Clutch

    Driven Clutch GASOLINE VEHICLE - CLUTCHES DRIVEN CLUTCH 1. Screw, 5/16-18 X 3/4 Hex-Head with Patch 7. Screw, #8-32 X 3/4, Socket-Head Cap 2. Washer, Driven Clutch 8. Button, Drive 3. Ring, Retaining 9. Sheave, Movable, Driven 4. Key, Driven Clutch 10.

  • Page 453: Driven Clutch Removal

    GASOLINE VEHICLE - CLUTCHES Driven Clutch DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed. See Drive Belt Removal on page 23-3. Remove the bolt (1) and mounting washer (2) from the transaxle input shaft (Figure 23-13, Page 23-12). Discard the bolt. NOTE: The bolt (1) must be replaced with a new bolt containing a locking patch that will prevent the bolt from loosening.
  • Page 454 Driven Clutch GASOLINE VEHICLE - CLUTCHES WARNING • Do not place fingers under the cam when removing the cam. The moveable face may spin when the cam buttons release from the cam ramps, resulting in severe personal injury. Remove the retaining ring (10) (Figure 23-15, Page 23-14). 608B Figure 23-15 Remove Retaining Ring Insert a puller plug (11) into the shaft bore (Figure 23-16, Page 23-14).

  • Page 455: Driven Clutch Inspection

    GASOLINE VEHICLE - CLUTCHES Driven Clutch Remove the spring (14) (Figure 23-17, Page 23-15). 2961B Figure 23-17 Driven Clutch Disassembly Retain the key (15). Slide the moveable sheave (16) off the fixed sheave (17). DRIVEN CLUTCH INSPECTION Inspect the cam for excessive wear. Replace it if necessary. Inspect the drive buttons (2) for excessive wear (Figure 23-18, Page 23-16).

  • Page 456: Driven Clutch Assembly

    Driven Clutch GASOLINE VEHICLE - CLUTCHES 2961C Figure 23-18 Drive Button Inspection Inspect the smooth surface on the fixed and moveable sheaves. Sheaves must be replaced if surfaces are worn more than 0.060 in. (1.5 mm). Inspect the bronze bearing in the moveable sheave. If the bearing bore diameter is more than 1.384 in. (35.15 mm), the entire moveable sheave must be replaced.
  • Page 457 GASOLINE VEHICLE - CLUTCHES Driven Clutch 2961D Figure 23-20 Driven Clutch Assembly Place the end of the spring (6) into the hole in the moveable sheave (9). Install the key (7) into the keyway of the fixed sheave shaft. Holding the cam (8) in position for assembly on the shaft, install the other end of the spring into the center spring hole of the cam.

  • Page 458: Driven Clutch Installation

    Driven Clutch GASOLINE VEHICLE - CLUTCHES Slide the threaded bolt assembly through the clutch body until the threaded bolt and thrust collar are against the fixed sheave. Hold the clutch assembly and cam installation tool together and place the fixed sheave down on spaced blocks. Install the cam press plate (13), thrust washer (14), thrust bearing (15), thrust washer (16), and nut (17) onto the threaded bolt.

  • Page 459: Section 24 - Gasoline Vehicle - Transaxle

    SECTION 24 — GASOLINE VEHICLE - TRANSAXLE DANGER Gasoline Vehicle - Transaxle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty transaxles. The transaxle utilizes internal gearing to change vehicle direction.

  • Page 460: Governor System

    General Information GASOLINE VEHICLE - TRANSAXLE POSITION DESCRIPTION Normal Operation OPERATE The engine will not operate in neutral. The engine will operate in neutral (N). MAINTENANCE The vehicle will not operate in the forward (F) or reverse (R) position. GOVERNOR SYSTEM The governor system regulates vehicle ground speed.

  • Page 461: Tools Required For This Section

    GASOLINE VEHICLE - TRANSAXLE General Information 3055 Figure 24-2 Lubricant Level Plug and Drain Plug TOOLS REQUIRED FOR THIS SECTION Hydraulic floor jack (or chain hoist) Torque wrench, 3/8-in. drive 1/2-in. combination wrench Jack stands (2) (one ton capacity) 3/8-in. socket, 3/8-in. drive 9/16-in.

  • Page 462: Rear Hubs

    Rear Hubs GASOLINE VEHICLE - TRANSAXLE REAR HUBS REAR HUB REMOVAL Turn the key switch to the OFF position and remove the key, and place the Forward/Neutral/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
  • Page 463 GASOLINE VEHICLE - TRANSAXLE Rear Hubs CAUTION • Do not allow anti-seize compound to contact the brake drum or shoes. Slide hub (6) onto axle shaft (Figure 24-3, Page 24-4). Install the large flat washer (5) onto the threaded portion of the axle. Install hub nut (4) and advance the nut to the large flat washer.

  • Page 464: Axle Tubes, Axle Shafts And Wheel Bearings

    Axle Tubes, Axle Shafts and Wheel Bearings GASOLINE VEHICLE - TRANSAXLE AXLE TUBES, AXLE SHAFTS AND WHEEL BEARINGS Removal of the transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals. If the transaxle is to be removed from the vehicle, do not remove the wheels, axle shafts, or axle tubes first. Instructions for removing the transaxle from the vehicle begin on page 24-9.

  • Page 465: Axle Tube And Axle Shaft Installation

    GASOLINE VEHICLE - TRANSAXLE Axle Tubes, Axle Shafts and Wheel Bearings AXLE TUBE AND AXLE SHAFT INSTALLATION Clean mating surfaces of axle tube (2) flange and transaxle gearcase (4). Also clean the threads of the five axle tube mounting holes in the gearcase. See following CAUTION. CAUTION •...

  • Page 466: Axle Shaft Oil Seal Installation

    Axle Tubes, Axle Shafts and Wheel Bearings GASOLINE VEHICLE - TRANSAXLE Remove axle tube (2) from gearcase (4) (Figure 24-5, Page 24-6). See Axle Tube and Axle Shaft Removal on page 24-6. Pull oil seal (7) from gearcase (4). AXLE SHAFT OIL SEAL INSTALLATION Clean bore in gearcase (4) where new oil seal (7) will sit (Figure 24-5, Page 24-6).

  • Page 467: Transaxle Removal

    GASOLINE VEHICLE - TRANSAXLE Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Turn the key switch to the OFF position and remove the key, and place the Forward/Neutral/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
  • Page 468 Transaxle Removal GASOLINE VEHICLE - TRANSAXLE 2700 2401 Figure 24-8 Disconnect Rear Shackles Figure 24-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 24-10, Page 24-10). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-2. Raise vehicle just enough to relieve weight on leaf springs, then remove bolts securing leaf springs to shackles (Figure 24-8, Page 24-10).
  • Page 469 GASOLINE VEHICLE - TRANSAXLE Transaxle Removal Roll powertrain out from under vehicle. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 24-12, Page 24-11). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the powertrain.

  • Page 470: Transaxle Installation

    Transaxle Installation GASOLINE VEHICLE - TRANSAXLE 3063 Figure 24-13 Transaxle Mounting Bolts TRANSAXLE INSTALLATION See General Warnings on page 1-2. Installation is reverse of removal procedure. When attaching transaxle to powertrain, initially install the eight bolts (1) finger-tight (Figure 24-13, Page 24-12). Then, tighten fasteners in the following order: 1.1.

  • Page 471: Forward/Neutral/Reverse Handle

    GASOLINE VEHICLE - TRANSAXLE Forward/Neutral/Reverse Handle FORWARD/NEUTRAL/REVERSE HANDLE FORWARD/NEUTRAL/REVERSE HANDLE REMOVAL Remove the bolt (1) from the Forward/Neutral/Reverse handle (2) (Figure 24-14, Page 24-13). Remove the bolts (3) from the bezel (4). Remove the bezel. FORWARD/NEUTRAL/REVERSE HANDLE INSTALLATION Install the bezel (4) and the bolts (3). Tighten the bolts to 22 lb·in (2.5 N·m) (Figure 24-14, Page 24-13). Install the Forward/Neutral/Reverse handle (2).

  • Page 472: Shifter Cable Installation

    Shifter Cable GASOLINE VEHICLE - TRANSAXLE Push the cable end socket (1) off the stud (3) on the Forward/Neutral/Reverse shifter handle (Figure 24-15, Page 24-14). Press in tangs (4) anchoring shifter cable (2) to chassis and push out of mounting hole. Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 24-16, Page 24-14).
  • Page 473 GASOLINE VEHICLE - TRANSAXLE Shifter Cable 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 lb·ft (29.8 N·m). 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 24-15...
  • Page 474 Shifter Cable GASOLINE VEHICLE - TRANSAXLE Pagination Page Page 24-16 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...

  • Page 475: Section 25 - Kohler Engine Service Manual

    SECTION 25 — KOHLER ENGINE SERVICE MANUAL Kohler Engine Service Manual 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 25-1...
  • Page 476 ECH440 for CLUB CAR Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Specifi...
  • Page 477 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...
  • Page 478 Maintenance MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 479 Maintenance OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
  • Page 480 Specifi cations Engine Dimensions-Flywheel Side 214.1 mm (8.43 in.) 164.3 mm (6.47 in.) 138.6 mm (5.46 in.) 2 X 112.1 mm Throttle Body Throttle Cable Throttle Cable (4.42 in.) Evap Fitting Mount Face Center Line 239.0 mm (9.41 in.) 116.4 mm (4.58 in.) Oil Fill Plug Oil Drain Plug Throttle Body...
  • Page 481 Specifi cations Engine Dimensions-Top Side 164.5 mm (6.48 in.) 288.2 mm (11.35 in.) 472.4 mm (18.60 in.) 155.1 mm (6.11 in.) Oxygen Sensor Fuel Injector Cap Bracket 155.8 mm (6.13 in.) M8 X 1.25-6H Tap Oxygen Sensor 64.1 mm (2.53 in.) 19.0 mm (0.75 78.6 mm (3.09) in.) Harness Clip...
  • Page 482 Specifi cations Engine Dimensions-PTO Side 6 X M8 X 1.25-6H 202.7 mm (7.98 in.) Dipstick and 188.2 mm (7.41 in.) 18.00 mm Exhaust Port Oil Fill Tube (0.71 in.) Deep 300.9 mm (11.85 in.) 218.6 mm (8.61 in.) Oxygen Sensor 35.0 mm (1.38 in.) 32.4 mm (1.28 in.) Exhaust Port...
  • Page 483 Specifi cations Engine Dimensions-Opposite Cylinder Head Side 229.8 mm (9.05 in.) 2 X M8 X 1.25-6H Throttle Cable 105.0 mm (4.13 in.) 56.6 mm (2.23 in.) Tap 22.0 mm Mount Face (0.87 in.) Deep M6 X 1.0-6H 14.5 mm Min. Primary Mounting 29.1 mm (1.14 in.) Full Thread...
  • Page 484 Specifi cations Engine Dimensions-Bottom Side 195.5 mm ± 0.50 mm 2 X Ø 11.25 mm ± 2 X 94.5 mm ± 0.75 (7.70 in. ± 0.02 90.5 mm (3.56 in.) 0.25 mm (0.44 mm (3.72 in. ± in.) Machined in. ± 0.01 in.) 0.03 in.) Holes Distance 195.5 mm ±...
  • Page 485 Year Manufactured Code Factory Code Code Year 2018 2019 2020 GENERAL SPECIFICATIONS ECH440 for Club Car Bore 89 mm (3.5 in.) Stroke 69 mm (2.7 in.) Displacement 429 cc (26.2 cu. in.) Oil Capacity (refi ll) 1.1 L (1.16 U.S. qt.) Maximum Angle of Operation (@ full oil level) 25°...
  • Page 486 Specifi cations TORQUE SPECIFICATIONS ECH440 for Club Car Air Cleaner (OEM Supplied) Air Inlet Elbow Mounting Nuts 8.0 N·m (71 in. lb.) Blower Housing and Sheet Metal M6 Screw 10 N·m (89 in. lb.) Cylinder Shield to Cylinder Head Ground Stud and Screw 8.0 N·m (71 in.
  • Page 487 Specifi cations TORQUE SPECIFICATIONS ECH440 for Club Car Throttle Body Studs 10 N·m (89 in. lb.) Primary Mounting Nuts 8.0 N·m (71 in. lb.) Temperature/Manifold Absolute Pressure (TMAP) Sensor Fastener 7.3 N·m (65 in. lb.) Throttle Position Sensor (TPS) Fastener 1.3 N·m (11.5 in.
  • Page 488 Specifi cations CLEARANCE SPECIFICATIONS ECH440 for Club Car Crankshaft End Play (free) 0.0508/0.254 mm (0.002/0.010 in.) Ball Bearing Internal Clearance 0.006/0.020 mm (0.0002/0.0008 in.) Crankshaft O.D. (new) PTO end 34.975/34.989 mm (1.3770/1.3775 in.) 35.009/35.027 mm (1.3783/1.3790 in.) Flywheel end Connecting Rod Journal O.D.
  • Page 489 Specifi cations CLEARANCE SPECIFICATIONS ECH440 for Club Car Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.002/0.016 mm (0.0001/0.0006 in.) Piston Pin Bore I.D. 20.000/20.008 mm (0.7874/0.7877 in.) Max. Wear Limit 20.05 mm (0.7894 in.) Piston Pin O.D.
  • Page 490 Specifi cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
  • Page 491 Tools and Aids Certain quality tools are designed to help you perform specifi c disassembly, repair, and reassembly procedures. By using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Here is a list of tools and their source.
  • Page 492 Tools and Aids TOOLS Description Source/Part No. Flywheel Puller SE Tools KLR-82408 For properly removing fl ywheel from engine. Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S Used to properly remove fuel hose from engine components. Hydraulic Valve Lifter Tool Kohler 25 761 38-S For removing and installing hydraulic lifters.
  • Page 493 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft fl ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
  • Page 494 Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. NOTE: An EFI engine will not operate without a battery connected to system. Some general common causes of EFI engine troubles are listed below and vary by engine specifi...
  • Page 495 Troubleshooting ● Check air cleaner element (OEM supplied). Look for Engine Loses Power holes, tears, cracked or damaged sealing surfaces, or ● Dirty air cleaner element (OEM supplied). other damage that could allow unfi ltered air into ● Engine overheated. engine.
  • Page 496 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
  • Page 497 Troubleshooting COMPRESSION TEST This engine is equipped with an automatic compression release (ACR) mechanism. It is diffi cult to obtain an accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described below. CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable alternative to a compression test.
  • Page 498 Air Cleaner/Intake BREATHER TUBE AIR CLEANER (OEM Supplied) Ensure both ends of breather tube are properly These systems are CARB/EPA certifi ed and components connected. should not be altered or modifi ed in any way. AIR COOLING Refer to operating instructions of equipment this engine powers for specifi...
  • Page 499 EFI SYSTEM An in-tank fuel pump is used to move fuel from tank WARNING through a fuel fi lter and fuel line. Fuel pump regulates fuel pressure to a system operating pressure of 50 psi. Explosive Fuel can cause fi res and severe Fuel is delivered through high pressure fuel line into burns.
  • Page 500 EFI SYSTEM ECU continually performs a diagnostic check of itself, Crankshaft position sensor is essential to engine each sensor, and system performance. If a fault is operation; constantly monitoring rotation and speed detected, ECU can turn on a Malfunction Indicator Light (RPM) of crankshaft.
  • Page 501 EFI SYSTEM Purpose of sensing air temperature is to help ECU Injector has sequential fueling that opens and closes calculate air density. Higher air temperature less dense once every other crankshaft revolution. Amount of fuel air becomes. As air becomes less dense ECU knows injected is controlled by ECU and determined by length that it needs to lessen fuel fl...
  • Page 502 EFI SYSTEM EFI engines have no carburetor, so throttle function IMPORTANT NOTES! (regulate incoming combustion airfl ow) is achieved with ● Cleanliness is essential and must be maintained at all a throttle valve in a separate throttle body attached to times when servicing or working on EFI system.
  • Page 503 EFI SYSTEM ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Side Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil Ground Not Used Battery Ground Not Used Diagnostic Communication Line Not Used Speed Sensor input...
  • Page 504 EFI SYSTEM Never attempt to disassemble ECU. It is sealed to TPS Learn Procedure for Pedal Start Applications prevent damage to internal components. Warranty is NOTE: Refer to equipment manufacturer's manual for void if case is opened or tampered with in any way. details on throttle body cover and throttle cable removal/reinstallation.
  • Page 505 EFI SYSTEM KohlerEngines.com 17 690 15 Rev. --...
  • Page 506 EFI SYSTEM Since there is no longer any wear elements inside Crankshaft Position Sensor sensor, most likely faults will be in electrical connections A sealed, non-serviceable assembly. If fault code P0337 between sensor and wire harness and wire harness to is present and engine does not start/run, proceed to step ECU.
  • Page 507 EFI SYSTEM 4. With throttle blade in full open position (WOT), press Temperature/Manifold Absolute Pressure (TMAP) magnet assembly fully on to throttle shaft. Full Sensor insertion can be checked by measuring height from A sealed non-serviceable integrated sensor that checks throttle body sensor mounting face to end of magnet both intake air temperature and manifold absolute assembly.
  • Page 508 EFI SYSTEM It is advisable to use an electronic meter such as a Oxygen Sensor (O2) digital voltmeter. Simple mechanical meters may place Detail a heavy electrical load on sensor and cause inaccurate readings. Since resistance of sensor is highest at low temperatures, such meters will cause largest inaccuracies when sensor is in a cool exhaust.
  • Page 509 EFI SYSTEM Sensor Signal Observation Removal Inspection NOTE: Apply anti-seize compound only to threads. Engine Harness O2 Sensor Connector Plug Detail Anti-seize compound will aff ect sensor performance if it gets into lower shield of sensor. 1. If sensor has heavy deposits on lower shield, engine, oil, or fuel may be source.
  • Page 510 EFI SYSTEM Troubleshooting-Oxygen (O2) Sensor Condition Possible Cause Conclusion Continuous low voltage output (less Shorted sensor or sensor circuit. Replace sensor or replace and than 400mV) observed with throttle properly route wiring. Shorted lead wire. openings of 38-50% or more. Wiring shorted to ground.
  • Page 511 EFI SYSTEM Injector clogging is usually caused by a buildup of Fuel Injector deposits on director plate, restricting fl ow of fuel, resulting in a poor spray pattern. Some contributing WARNING factors to injector clogging include higher than normal operating temperatures, short operating intervals, and Explosive Fuel can cause fi...
  • Page 512 EFI SYSTEM 6. Pull retaining clip to separate fuel injector cap/ FUEL COMPONENTS bracket assembly from injector. Remove screw holding fuel injector cap/bracket assembly to throttle WARNING body. Lift injector from throttle body. Explosive Fuel can cause fi res and severe 7.
  • Page 513 EFI SYSTEM 4. Check that hook is in upper 1/3 to 1/2 of window in Throttle Body Assembly throttle lever. If hook is further down in window, wire NOTE: ECU Reset is required if throttle body is is bound and steps 2 and 3 should be repeated. replaced.
  • Page 514 EFI SYSTEM TROUBLESHOOTING Troubleshooting Guide Condition Possible Cause Fuel pump not running. Empty fuel tank. Faulty spark plug. Old/stale fuel. Incorrect fuel pressure. Crankshaft position sensor loose or faulty. Engine Starts Hard TPS set incorrect (ECU Reset and TPS Learn). or Fails to Start TPS faulty.
  • Page 515 EFI SYSTEM Troubleshooting Guide Condition Possible Cause Faulty/malfunctioning ignition system. Dirty air fi lter. Insuffi cient fuel delivery. Improper governor adjustment. Low Power Plugged/restricted exhaust. Basic engine problem exists. TPS faulty or mounting exists. Throttle plate in throttle body not fully opening to WOT stop (if equipped). Function Test Fault Codes Example of Diagnostic Display...
  • Page 516 EFI SYSTEM Diagnostic Fault Code Summary Fault Code Connection or Failure Description 0031 Oxygen Sensor Heater Circuit Low Voltage 0032 Oxygen Sensor Heater Circuit High Voltage 0107 Manifold Absolute Pressure (TMAP) Circuit Low Voltage or Open 0108 Manifold Absolute Pressure (TMAP) Circuit High Voltage 0112 Intake Air Temperature (TMAP) Circuit Low Voltage 0113...
  • Page 517 EFI SYSTEM Diagnostic Code Summary Code 0107 Code 0031 Component: Manifold Absolute Pressure (TMAP) NOTE: Codes 0031 and 0032 may have been Fault: MAP Circuit Low Voltage or Open mistakenly activated by turning key ON with Condition: Throttle body leak, open connection or oxygen sensor disconnected.
  • Page 518 EFI SYSTEM Code 0112 Code 0117 Component: Intake Air Temperature (TMAP) Component: Engine Temperature Sensor Fault: Intake Air Temperature Sensor Circuit Fault: Engine Temperature Sensor Circuit Low Low Voltage Voltage Condition: Shorted connection, faulty sensor or Condition: Shorted connection, faulty sensor or shorted wire.
  • Page 519 EFI SYSTEM Code 0122 Code 0131 Component: Throttle Position Sensor (TPS) Component: Oxygen Sensor Fault: TPS Circuit Low Voltage or Open Fault: O2S 1 Circuit Low Voltage Condition: Open connection, broken wire or faulty Condition: Open connection, broken wire or faulty sensor.
  • Page 520 EFI SYSTEM Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel inlet screen/fi lter plugged, low Condition: Too high pressure at high pressure fuel pressure at high pressure fuel line, TPS line, TPS malfunction, shorted malfunction, shorted connection, faulty connection, faulty sensor or fuel pump...
  • Page 521 EFI SYSTEM Code 0174 Code 0230 Component: Fuel System Component: Fuel Pump Relay Fault: Lean fuel condition Fault: Circuit Low Voltage or Open Condition: Fuel inlet screen/fi lter plugged, low Condition: Shorted or open connection. pressure at high pressure fuel line, TPS Conclusion: Fuel Pump Relay Related malfunction, shorted connection or faulty ●...
  • Page 522 EFI SYSTEM Code 0336 Code 0337 NOTE: If fault code P0337 is present and engine does Component: Crankshaft Position Sensor not start/run, proceed to step 1 of Crankshaft Fault: Crankshaft Position Sensor Noisy Signal Position Sensor earlier in this section. If P0337 is present and engine operates, clear codes and Condition: Loose sensor, faulty/bad battery, shorted...
  • Page 523 EFI SYSTEM Code 0351 Code 0650 Component: Ignition Coil Component: MIL Circuit Fault: Ignition Coil Malfunction Fault: MIL Circuit Malfunction Condition: Broken wire in harness (may not be Condition: Failure in MIL circuit detected. visible), shorted connection or faulty Conclusion: Bad Connection. sensor.
  • Page 524 EFI SYSTEM EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?
  • Page 525 EFI SYSTEM Flow Chart Diagnostic Aids Diagnostic Aid #5 FUEL PUMP (fuel pump not turning on) Diagnostic Aid #1 SYSTEM POWER Condition (MIL does not illuminate for 3 seconds when key is fi rst ● Inspect fuse(s) turned ON) ● Fuel pump relay circuit problem, pin circuits Black 9 NOTE: MIL is installed by vehicle OEM.
  • Page 526 Governor System GOVERNOR (OEM Supplied) Refer to operating instructions of equipment this engine powers for specifi c governor instructions. 17 690 15 Rev. -- KohlerEngines.com...
  • Page 527 Lubrication System These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components. Lubrication Components Dipstick Tube Oil Drain Plug Oil Fill Plug Filler Neck OIL RECOMMENDATIONS WINTER LUBRICATION Refer to Maintenance. If engine is frequently used for short periods of time in ambient temperatures below 4°C (40°F), reduce oil CHECK OIL LEVEL...
  • Page 528 Lubrication System 4. Fill crankcase with new oil, up to point of overfl owing fi ller neck. 5. Reinstall oil fi ll plug/dipstick and tighten securely. 6. Dispose of used oil in accordance with local ordinances. OIL SENTRY (if equipped) ™...
  • Page 529 Electrical System BATTERY CHARGING SYSTEM (OEM Supplied) 5. Insert fuse into fuse holder until it is seated properly. Install fuse cover. 6. If replacement fuse fails, there is a problem within CAUTION circuit. Diagnostics are required. Identify which Electrical Shock can cause injury. circuit is aff...
  • Page 530 Electrical System Carbon Fouled Inspection Inspect spark plug as it is removed from cylinder head. Deposits on tip are an indication of general condition of piston rings, valves, and fuel mixture. Normal and fouled plugs are shown in following photos: Normal Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich...
  • Page 531 Electrical System Troubleshooting Guide Test Ignition System Isolate and verify trouble is within engine. 1. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is displayed, equipment safety circuit is active (Refer to equipment manufacturer's manual for safety system information).
  • Page 532 Starter System Starter (OEM Supplied) Refer to operating instructions of equipment this engine powers for specifi c starter system instructions. 17 690 15 Rev. -- KohlerEngines.com...
  • Page 533 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 534 Disassembly/Inspection and Service Remove Throttle Body Assembly Remove Fuel Injector NOTE: Unless fuel injector is damaged or malfunctioning, disassembly from throttle body is unnecessary. NOTE: Make note of fuel injector position before removing. NOTE: Unless fuel injector cap is damaged, removing retainer securing cap to injector is unnecessary.
  • Page 535 Disassembly/Inspection and Service Fuses and ECU Components Blower Housing Components Fuses/Fuse Holders Screw Cable Clip Ignition Coil Blower Housing Screw Remove Fuses Screen Remove fuses from holders located on lower shield. Screw Blower Housing Clamp Remove Electronic Control Unit (ECU) 1.
  • Page 536 Disassembly/Inspection and Service Remove Crankshaft Position Sensor Remove Valve Cover NOTE: Do not remove sensor from bracket unless sensor is being replaced. 1. Unplug crankshaft position sensor electrical connector. 2. Remove upper screw securing crankshaft position sensor bracket to crankcase post. 3.
  • Page 537 Disassembly/Inspection and Service Cylinder Head Components Rocker Arm Pivot Hex Jam Nut Rocker Arm Rocker Arm Stud Adjuster Valve Spring Push Rod Guide Push Rod Valve Spring Retainer Valve Stem Seal Cylinder Head Screw Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Gasket...
  • Page 538 Disassembly/Inspection and Service Valve Guides If a valve guide is worn beyond specifi cations, it will not guide valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide.
  • Page 539 Disassembly/Inspection and Service Crankcase/Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Screw Closure Plate Bearing Closure Plate Balance Closure Plate Gasket Wave Spring Balance Shaft Shaft Bearing Crankcase Balance Connector Rod Crankshaft Connector Rod Shaft Bearing End Cap Piston Piston Pin Retainer Piston Pin Piston Ring Set...
  • Page 540 Disassembly/Inspection and Service Automatic Compression Release (ACR) Remove Oil Fill Tube ACR Operation Details Details Oil Fill Tube Oil Fill Tube Bracket Bracket Screw NOTE: Unless oil fi ll tube is damaged, disassembly from closure plate is unnecessary. Camshaft Exhaust Cam Lobe 1.
  • Page 541 Disassembly/Inspection and Service Inspection and Service Dimension C Dimension A Camshaft Journal Specifi cations Cam Lobe Dimension C Limit 32.286 mm 32.032 mm 15.900 mm INTAKE 15.975 mm (0.6289 in.) (1.271 in.) (1.261 in.) (0.6260 in.) 32.506 mm 32.252 mm EXHAUST (1.280 in.) (1.270 in.)
  • Page 542 Disassembly/Inspection and Service Some important points to remember when servicing Piston and Rings Inspection piston rings: Scuffi ng and scoring of piston and cylinder wall occurs 1. Cylinder bore must be deglazed before service ring when internal engine temperatures approach welding sets are used.
  • Page 543 Disassembly/Inspection and Service NOTE: Rings must be installed correctly. Use a piston 3. Remove oil seal from closure plate. ring expander to install rings. Install bottom (oil 4. Using a suitable press, push crankshaft bearing from control) ring fi rst and top compression ring last. closure plate.
  • Page 544 Disassembly/Inspection and Service Honing Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and/ Crosshatch Detail or honing is very critical to a successful overhaul. Machining grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild. Final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water.
  • Page 545 Reassembly Crankcase/Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Screw Closure Plate Bearing Closure Plate Balance Closure Plate Gasket Wave Spring Balance Shaft Shaft Bearing Crankcase Balance Connector Rod Crankshaft Connector Rod Shaft Bearing End Cap Piston Piston Pin Retainer Piston Pin Piston Ring Set Oil Sentry...
  • Page 546 Reassembly Install Crankcase Bearings and Oil Seals Install Crankshaft Carefully slide fl ywheel end of crankshaft through main Details ball bearing and seal. Install Connecting Rod with Piston and Rings Connecting Rod Details Outer Surface Seal Depth NOTE: Oil bearings liberally with engine oil when installing.
  • Page 547 Reassembly Install Balance Shaft Install Valve Tappets and Camshaft Timing Mark Detail Timing Mark Detail Camshaft Drive Balance Shaft Drive Camshaft Gear Balance Shaft Gear on Crankshaft Gear on Crankshaft Timing Mark Timing Mark Timing Mark Timing Mark 1. Lubricate face and stem of each tappet with engine 1.
  • Page 548 Reassembly Install Oil Fill Tube Install Closure Plate Details Torque Sequence Oil Fill Tube Oil Fill Tube Bracket 1. Check to make sure sealing surfaces of crankcase Bracket Screw and closure plate are clean and free of nicks/burrs. 1. If oil fi ll tube was removed from closure plate, apply 2.
  • Page 549 Reassembly Cylinder Head Components Rocker Arm Pivot Hex Jam Nut Rocker Arm Rocker Arm Stud Adjuster Valve Spring Push Rod Guide Push Rod Valve Spring Retainer Valve Stem Seal Cylinder Head Screw Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Torque Sequence Gasket Assemble Cylinder Head...
  • Page 550 Reassembly Install Push Rods and Rocker Arms Flywheel Components NOTE: Push rods should always be installed in original location. 1. Identify proper position of each push rod. Dip ends of push rods in engine oil and install them in their respective locations, seating each into tappet socket.
  • Page 551 Reassembly Install Crankshaft Position Sensor Install Cylinder Shield NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connectors have seal in place. NOTE: When mounting ground wire on bottom screw of bracket, ensure ground wire is routed outside and away from fl...
  • Page 552 Reassembly Install Upper Heat Shield and Engine Temperature Install Fuel Injector and TMAP Sensor Engine Temperature Upper Heat Shield Sensor Dipstick Tube Screw Bracket Oxygen Sensor Fuel Injector Cap Screw Clip Connector Metal Retaining Clip Fuel Injector 1. Position upper heat shield on crankcase and start 2 screws securing to crankcase.
  • Page 553 Reassembly Install Throttle Body Assembly Install Air Inlet Elbow Throttle Body Fuel Injector Throttle Position TMAP Air Inlet Elbow Sensor (TPS) Breather Hose with Insulator to Throttle Clamp Insulator Sleeve Body Gasket Throttle Body Gasket Governor Bracket Insulator to Cylinder Intake Studs Head Gasket Throttle Body...
  • Page 554 Reassembly External Engine Components Oil Fill Plug Dipstick Spark Plug Lead Oil Drain Plug Connect Spark Plug Lead Connect lead to spark plug. Secure lead to dipstick tube with a new wire tie. Prepare Engine for Operation NOTE: If ECU, throttle body, TPS, or fuel pump were replaced, an ECU Reset and TPS Learn is required.
  • Page 555 © 2018 by Kohler Co. All rights reserved. KohlerEngines.com 17 690 15 Rev. --...
  • Page 556 Shifter Cable KOHLER ENGINE SERVICE MANUAL Pagination Page Page 25-2 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...
  • Page 557 SECTION 26 — WIRING DIAGRAMS GENERAL INFORMATION Wiring Diagrams Wire Description EXAMPLE: 18_GRN_RED • 18 = 18 gauge wire • GRN_RED = Green wire with red stripe Wire Colors NOTE: The following colors will represented as a black wire in the wiring diagrams: •...
  • Page 558 Engine Harness Wiring Diagram Table WIRING DIAGRAMS GRN_WHT Green with White Stripe ORG_BLK Orange with Black Stripe 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 ENGINE HARNESS WIRING DIAGRAM TABLE...
  • Page 559 WIRING DIAGRAMS Engine Harness Wiring Diagram Table TMAP Sensor Engine Temperature Sensor Diagnostic Connector 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 26-3...
  • Page 560 Engine Harness Wiring Diagram Table WIRING DIAGRAMS Pagination Page Page 26-4 2019 Precedent,Villager 2 and 4 Maintenance and Service Manual...
  • Page 561 Wiring Diagrams Gasoline: Engine Harness GASOLINE: ENGINE HARNESS...
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  • Page 563 Wiring Diagrams Gasoline: Main Harness GASOLINE: MAIN HARNESS...
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  • Page 565 Wiring Diagrams Gasoline: Instrument Panel Harness GASOLINE: INSTRUMENT PANEL HARNESS...
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  • Page 567 Wiring Diagrams Gasoline: Instrument Panel Light Harness GASOLINE: INSTRUMENT PANEL LIGHT HARNESS...
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  • Page 569 Wiring Diagrams Electric: Main Harness ELECTRIC: MAIN HARNESS...
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  • Page 571 Wiring Diagrams Electric: Instrument Panel Dash Harness ELECTRIC: INSTRUMENT PANEL DASH HARNESS...
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  • Page 573 Wiring Diagrams Electric: DC to DC Converter Harness ELECTRIC: DC TO DC CONVERTER HARNESS...
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  • Page 575 Wiring Diagrams Electric: Instrument Panel Light Harness ELECTRIC: INSTRUMENT PANEL LIGHT HARNESS...
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  • Page 577 Wiring Diagrams Electric: Light Harness ELECTRIC: LIGHT HARNESS...
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  • Page 579 Index Index numbering vehicles and chargers ...... 15-14 Index resetting power – external......... 15-15 AC power and circuit resetting power – onboard ........ 15-15 testing (ERIC charger) ........15-21 terminal block cover.......... 15-15 accelerator USB service port ..........15-14 cable battery wiring diagram..........
  • Page 580 INDEX installation ............4-26 removal ............. 4-14 removal ............4-25 charging system rear canopy support test procedures ..........15-20 installation ............4-28 choke button bezel removal ............4-27 installation ............4-16 removal ............. 4-16 amp hours ............11-8 cleaning anti-tamper speed ..........11-8 brake assembly............
  • Page 581 INDEX inspection ............23-15 installation ............7-23 installation ............23-18 removal ............7-22 removal ............23-13 fuel relieving pressure ..........21-11 fuel filter installation ............21-25 removal ............21-24 fuel gauge/hour meter .......... 19-29 fuel gauge circuit installation ............19-22 testing ............18-29 removal ............
  • Page 582 INDEX adjustment ............4-9 testing ............. 18-13 aiming .............. 4-9 headlight switch........... 19-31 installation ............19-31 removal ............19-31 high pedal detect ........... 12-3 low oil warning light hip restraint ............. 4-5 installation ............19-33 installation ............4-5 removal ............19-33 removal ...............
  • Page 583 INDEX muffler fold-down rear seat..........4-48 installation ............22-2 hip restraint installation........4-50 removal ............. 22-1 hip restraint removal........4-50 see also exhaust system........22-1 seat assembly installation ........ 4-49 multi-purpose buzzer ........... 19-35 seat assembly removal........4-49 installation ............19-35 seat bottom installation........
  • Page 584 INDEX rear wheel bearing inspection............. 19-10 see wheel bearing ..........24-7 disassembly..........19-5, 19-7 receptacle field coil see charger receptacle ........13-14 inspection............. 19-12 regenerative braking ..........12-3 removal ............19-9 repair installation ............19-15 tire............... 8-2 removal ............. 19-4 resistor location ............. 12-5 rework .............
  • Page 585 INDEX 15-amp fuse............. 12-16 tire 16-pin connector ..........12-28 installation ............8-3 4-pin connector ..........12-32 removal ............... 8-2 batteries/voltage check ........12-13 repair..............8-2 battery pack voltage (under load) ...... 12-14 tools charge indicator light ........12-31 see service tools ..........24-3 charger interlock..........
  • Page 586 INDEX see test procedures......12-32, 18-31 voltage regulator installation ............19-20 removal ............19-20 testing ............. 18-20 walk away braking ..........12-3 water level see batteries, electrolyte level ......14-10 wheel installation ............8-1 removal ............... 8-1 see also tire ............8-1 wheel bearing installation ............
  • Page 587 NOTES...
  • Page 588 NOTES...

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Precedent villager 4 2019

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