Front Body; Front Body Removal; Front Body Installation - Club Car Turf 1 Service Manual

4
BODY AND TRIM

FRONT BODY

See General Warning, Section 1, Page 1-1.

FRONT BODY REMOVAL

1. Remove screws (8) and lock nuts (9) and lift front bumper (6) from vehicle frame (Figure 4-1, Page 4-5).
1.1. Turf 1 and Carryall 1 vehicles: Remove blind rivets (10).
2. Vehicles equipped with a heavy-duty front bumper (1):
2.1. Remove the two carriage bolts (5), lock nuts (3), and spacers (4) from the heavy-duty bumper
mounting positions located on both sides of the front body.
2.2. Remove carriage bolts (2) and lock nuts (3) from the heavy-duty bumper support braces and
remove bumper.
3. Remove carriage bolts (15), lock nuts (17), and washers (16) from front body trim. Remove screws (14)
from top of front body.
4. Loosen, but do not remove, screws (18) holding front body trim against front body.
5. Vehicles equipped with headlights: Disconnect the light wiring harness from the headlight assemblies.
6. Pull front body (12) from under trim (13) and remove from vehicle.

FRONT BODY INSTALLATION

1. Install front body (12) under trim (13), align holes and finger-tighten screws (14) holding front body
against frame (Figure 4-1, Page 4-5).
2. Install carriage bolts (15), washers (16), and lock nuts (17) onto front body trim. Tighten bolts to 11 ft-lb
(14.9 N·m). Tighten screws (14) to 20 in-lb (2.3 N·m). See following NOTE.
NOTE: If installing a new front body, two 5/16-inch holes must be drilled after the body has
been placed on the vehicle. Use the body trim (13) as a guide for drilling the holes.
3. Tighten screws (18) holding front body trim against front body to 17 in-lb (1.9 N·m).
4. Vehicles equipped with headlights: Reconnect the light wiring harness to the headlight assemblies.
5. Vehicles equipped with a heavy-duty front bumper:
5.1. Install two carriage bolts (2) and lock nuts (3) from the heavy-duty front bumper support braces and
install bumper (1). Tighten bolts to 65 in-lb (7.3 N·m) (Figure 4-1, Page 4-5).
5.2. Install two carriage bolts (5), spacers (4), and lock nuts (3) into heavy-duty bumper mounting posi-
tions located on sides of front body (12). Tighten bolts to 65 in-lb (7.3 N·m).
6. Turf 1 and Carryall 1 vehicles: Install two push type blind rivets (10) that secure lower front body to
frame (Figure 4-1, Page 4-5).
7. Install front bumper onto vehicle and install screws (8) and lock nuts (9). Tighten to 65 in-lb (7.3 N·m).
Page 4-4 2012 Turf/Carryall Vehicle Maintenance and Service Manual
Front Body Repair