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FlywheelGASOLINEVEHICLE-ENGINE

10.Ifnecessary,installpowertrain.SeeTransaxleInstallation,Section24,Page24-12.

11.Connectairintakehose,fuelline,wireharnessconnectors,groundcableandgovernorcable.SeeGasoline

Vehicle-FuelSystem,Section21,Page21-1.

12.Ifequipped,installairdeectorontopofengine.

13.SecureacceleratorcableandgovernorcableP-clampstoengine.TightenP-clampboltsto36in·lb(4.0N·m).

14.Checkallhardwareforpropertorque/tightness.

15.Fillenginetoproperlevelwithcorrecttypeofoil.SeeEngineOil–GasolineVehicle,Section20,Page20-2.

CAUTION

•Donotoverllwithoil.

16.Connectbatteryandsparkplugwire(s).

SeeConnectingtheBattery-GasolineVehiclesonpage1-3.

17.AdjusttheengineRPMsetting.SeeEngineRPMAdjustmentonpage21-13.

18.Test-drivevehicletoensureallsystemsarefunctionalandcorrectlyadjusted.

FLYWHEEL

SeeGeneralWarningsonpage1-2.

Page20-102019PrecedentVillager2MaintenanceandServiceManual

Table of Contents5
SECTION 1 - Safety15
- Safety Details15
- General Warnings16
SECTION 2 - Vehicle Specifications21
- Vehicle Specifications - Electric and Subaru EX4021
- E.r.I.C. Battery Charger Specifications23
SECTION 3 - General Information25
- Model Identification25
- Safety Committee26
- Storage - Electric Vehicle27
  - Preparing the Electric Vehicle for Extended Storage27
  - Returning the Stored Electric Vehicle to Service28
- Storage - Gasoline Vehicle29
  - Preparing the Gasoline Vehicle for Extended Storage29
  - Returning the Stored Gasoline Vehicle to Service30
SECTION 4 - Body and Trim31
- Cleaning the Vehicle31
  - Seat31
- Front and Rear Body Repair32
- Front Body33
  - Front Body Removal33
  - Front Body Installation33
- Front Bumper35
- Headlight Adjustment36
  - Aiming the Headlight Beam36
- Instrument Panel37
  - Instrument Panel Removal37
  - Instrument Panel Installation37
- Floor Mat and Retainers38
  - Floor Mat Retainer Removal38
  - Floor Mat Retainer Installation38
- Kick Plate and Charger Receptacle Bezel - Electric Vehicles39
  - Kick Plate and Charger Receptacle Bezel Removal39
  - Kick Plate and Charger Receptacle Bezel Installation39
- Kick Plate - EFI Gasoline Vehicles40
  - Kick Plate Removal40
  - Kick Plate Installation40
- Seat Bottom41
- Rear Body41
SECTION 5 - Accelerator and Brake Pedal Group47
- Pedal Group - Electric Vehicle47
- Pedal Group - Gasoline Vehicle50
- Debris Shields52
- Accelerator Pedal Removal52
- Accelerator Pedal Installation52
- Brake Pedal Removal53
- Brake Pedal Installation53
SECTION 6 - Wheel Brake Assemblies55
- General Information55
- Brake Shoe Removal57
- Brake Assembly Cleaning58
- Brake Shoe Installation60
- Brake Cable Equalizer Adjustment62
- Brake Cluster Removal and Installation63
  - Brake Cluster Removal63
  - Brake Cluster Installation64
- Brake Cable Removal and Installation66
  - Brake Cable Removal66
  - Brake Cable Installation67
SECTION 7 - Steering and Front Suspension69
- General Information69
- Steering Wheel69
  - Steering Wheel Removal69
  - Steering Wheel Installation70
- Steering Column70
  - Steering Column Removal70
  - Steering Column Installation71
- Rack and Pinion72
- Front Suspension74
  - Lubrication74
  - Wheel Alignment74
- Front Suspension Components76
- Front Wheel Bearings and Hubs82
SECTION 8 - Wheels and Tires85
- General Information85
- Wheels85
  - Wheel Removal85
  - Wheel Installation85
- Tires86
SECTION 9 - Rear Suspension89
- General Information89
- Shock Absorbers89
  - Shock Absorber Removal and Inspection89
  - Shock Absorber Installation89
- Leaf Springs90
  - Leaf Spring Removal90
  - Leaf Spring Installation91
SECTION 10 - Periodic Maintenance93
- General Information93
- Pre-Operation and Daily Safety Checklist93
  - Performance Inspection94
- Maintenance95
- Periodic Service Schedules96
- Periodic Lubrication Schedules100
SECTION 11 - Controller Diagnostic Tool (CDT)103
- General Information104
  - Features104
- Plugging the CDT into the Vehicle105
  - Introductory Display105
- Quick Reference Guide - Excel with ERIC Charging System106
- System Info107
  - Model Number107
  - Serial Number107
  - Hardware Version107
  - Protocol Version107
  - Param Block Version107
  - MFG Date Code107
  - OS Version107
  - SM Version107
  - VCL App Version107
- Parameters108
  - Settings108
  - Amp Hours110
  - Access Codes110
  - Vehicle ID111
- Monitor Menu111
  - Batt Voltage112
  - Min I112
  - Signed Battery Current112
  - BDI Percent112
  - Speed112
  - Throttle112
  - Temperature112
  - Arm Current112
  - Field Current112
  - Armature PWM113
- Field PWM113
- Speed Pulses113
- Foot Input113
- Key Input113
- Forward Input113
- Reverse Input113
- Mode Switch Input113
- Charger Inhibit113
- Main Cont Driver113
- Password Tries (OEM Access Level Only)114
- Odometer114
- BDI Info114
- Battery Monitor114
- Charging Totals114
- Amp Hours Display115
- Lin115
- Vehicle Speeds115
- Pedal Counters115
- Fault Counters115
- Fault Count Odometers115
Diagnostics Menu116
- Present Errors Folder116
- Fault History Folder116
- Causes of Faults117
- Fault Recovery119
Fault Descriptions120
- Incorrect Password (OEM Access Level Only)120
- Max Password Tries (OEM Access Level Only)120
- Throttle Fault120
- Low Battery Voltage (Undervoltage)120
- Overvoltage120
- Thermal Cutback121
- Anti-Tamper Fault121
- Hpd121
- Main Drvr Overcurrent121
- Lockout Fault121
- Low SOC121
- Main Welded122
- High Speed Walkaway122
- Speed Sensor122
- Main Driver on122
- Main Coil Open122
- Main Dropout (1 or 2)123
- Motor Stall123
- Main Driver off123
- Current Sense Fault123
- M- Shorted123
- FLD (Field) Missing124
- HW Failsafe124
- Fault History124
- Clear Fault History124
Programming124
- Cloning125
Favorites125
HHP Settings125
Plot & Log127
- Plot127
- Log127
CDT Troubleshooting128
Connection Tests129
SECTION 12 - Electric Vehicle - Excel System Troubleshooting133
- General Information133
- Battery Wiring Diagram135
- Sonic Weld, Fuse, and 10K Ohm Resistor Locations136
- Troubleshooting137
- Test Procedures143
  - Testing Basics143
SECTION 13 - Electric Vehicle - Electrical Components165
- Key Switch165
- Charge Indicator Light166
- Forward/Reverse Rocker Switch167
- Electronics Module Cover169
  - Electronics Module Cover Removal169
  - Electronics Module Cover Installation169
- Tow/Run Switch170
- Motor Controller Output Regulator (MCOR)171
- Reverse Buzzer172
- Electronics Module173
  - Electronics Module Removal173
  - Electronics Module Installation174
- Speed Controller175
- Solenoid176
- Charger Receptacle177
SECTION 14 - Electric Vehicle - Batteries179
- General Information179
- Battery Testing Basics - 8 Volt180
- Battery Testing - 8 Volt181
- Battery Regrouping181
- Battery Replacement183
- Battery Care184
- Single Point Watering System (SPWS)188
  - Initial Maintenance of the SPWS188
  - Watering Batteries with the SPWS188
- Battery Storage189
- Deep-Discharge189
- Early Excessive Discharging189
SECTION 15 - Electric Vehicle - Battery Charger191
- General Information192
- External Charger Mounting196
- AC Power Connection197
- The Charge Circuit198
- Charger Operation199
  - Charging Batteries199
- Charger Maintenance201
  - USB Service Port Cleaning and Care201
- Charger Troubleshooting202
- Test Procedures206
- External Charger Repairs209
SECTION 16 - Electric Vehicle - Motor213
- General Information213
- External Motor Testing213
- Motor216
  - Motor Removal216
  - Motor Disassembly217
- Motor Component Testing and Inspection220
- Reconditioning the Motor225
  - Motor Specifications225
- Motor Assembly225
- Motor Installation227
SECTION 17 - Electric Vehicle - Transaxle231
- Lubrication231
- Axle Bearing and Shaft231
  - Axle Shaft231
  - Axle Bearing234
- Transaxle Removal235
- Transaxle Disassembly, Inspection, and Assembly237
  - Transaxle Disassembly and Inspection237
  - Transaxle Assembly239
- Transaxle Installation240
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System243
- General Information243
- Troubleshooting Guide244
  - ECU Error Codes (Displayed by the Low Oil Warning Light)244
  - Gasoline Powertrain246
- Sonic Weld, Fuse, and Diode Locations250
- Electrical System251
- Test Procedures252
  - Testing Basics252
SECTION 19 - Gasoline Vehicle - Electrical Components279
- Starter/Generator279
- Voltage Regulator293
  - Voltage Regulator Removal293
  - Voltage Regulator Installation294
- Engine Control Unit (ECU)295
  - Engine Control Unit Removal295
  - Engine Control Unit Installation295
- Key Switch296
  - Key Switch Removal296
  - Key Switch Installation297
- Maintenance/Operate Switch297
  - Maintenance/Operate Switch Removal297
  - Maintenance/Operate Switch Installation297
- Neutral Lockout Limit Switch298
  - Neutral Lockout Limit Switch Removal298
  - Neutral Lockout Limit Switch Installation298
- Solenoid299
- Fuse300
  - Fuse Removal300
  - Fuse Installation300
- Accelerator Pedal Limit Switch301
  - Testing the Accelerator Pedal Limit Switch301
- Kill Limit Switch301
  - Testing the Kill Limit Switch301
- Reverse Warning Buzzer301
  - Reverse Warning Buzzer Removal301
  - Reverse Warning Buzzer Installation302
- Reverse Buzzer Limit Switch303
  - Reverse Buzzer Limit Switch Removal303
  - Reverse Buzzer Limit Switch Installation303
- Low Oil Warning Light305
  - Low Oil Warning Light Removal305
  - Low Oil Warning Light Installation305
- Fuel Gauge306
  - Fuel Gauge Removal306
  - Fuel Gauge Installation306
- Fuel Level Sending Unit307
- Hour Meter307
- Oil Level Sensor308
  - Oil Level Sensor Removal308
  - Oil Level Sensor Installation308
- Battery309
- Ground Cables312
SECTION 20 - Gasoline Vehicle - Engine313
- General Information313
- Engine Removal320
- Engine Installation321
- Flywheel322
  - Flywheel Removal323
  - Flywheel Installation324
- Oil Level Sensor324
- Ignition Coil326
- Snubber327
  - Snubber Removal327
  - Snubber Installation327
SECTION 21 - Gasoline Vehicle - Fuel System329
- General Information329
  - EFI System Features/Specifications329
- Refuel331
- Relieving Fuel Pressure332
  - To Relieve Fuel Pressure332
- Throttle Body333
  - Throttle Body Removal333
  - Throttle Body Installation335
- Engine Control Linkages336
- Air Intake System342
- Fuel Line345
  - Fuel Line Removal345
  - Fuel Line Installation346
- Fuel Pump Module347
- Fuel Tank351
- Fuel Filter354
- Carbon Canister355
  - Carbon Canister Removal355
  - Carbon Canister Installation355
SECTION 22 - Gasoline Vehicle - Exhaust System357
- Muffler357
  - Muffler Removal357
  - Muffler Installation357
SECTION 23 - Gasoline Vehicle - Clutches359
- General Information359
- Troubleshooting359
- Drive Belt361
  - Drive Belt Removal361
  - Drive Belt Installation361
- Drive Clutch362
- Driven Clutch371
SECTION 24 - Gasoline Vehicle - Transaxle377
- General Information377
- Rear Hubs380
  - Rear Hub Removal380
  - Rear Hub Installation380
- Axle Tubes, Axle Shafts and Wheel Bearings382
- Transaxle Removal385
- Transaxle Installation388
- Forward/Reverse Handle389
  - Forward/Reverse Handle Removal389
  - Forward/Reverse Handle Installation389
- Shifter Cable389
SECTION 25 - Wiring Diagrams391
- General Information392
- Electric: Accessory Wiring Diagram393
Index405

Brand	Club Car
Model	Precedent Villager 2
Category	Golf Cars
Language	English

Club Car Precedent Villager 2 User Manual

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Club Car Precedent Villager 2 Specifications

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