Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 215 / 544

Page 13-25
G
13
Removal (Figure 13-44)
1. Turn the engine upside down to keep the tappets (1) from catching the cam lobes.
2. Take the camshaft out of the engine block. Pull both tappets out.
Inspection
1. Inspect the camshaft for wear or broken gear teeth.
2. Measure the camshaft journals and camlobes with a micrometer at the points shown (Figures 13-45
and 13-46).
3. If the camshaft journal diameter is less than 0.9026 inch (22.927 millimeters) at either end of the shaft,
replace the camshaft.
4. If the lobe height is less than 1.287 inches (32.690 millimeters) for either lobe, replace the camshaft.
Installation - See Page 13-44
PISTON/CONNECTING ROD
Removal
1. Turn crankshaft to expose the two connecting rod cap bolts (1) (Figure 13-47, Page 13-26).
2. Loosen the cap bolts and take them out together with the connecting rod cap (2).
3. Push the piston/connecting rod assembly out of the cylinder.
PISTON
Inspection and Repair
1. Remove all deposits from the piston.
2. Clean the carbon from the piston ring grooves.
• WHEN MAKING TESTS OR REPAIRS, ALWAYS:
- ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE KEY.
- DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST.
- DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
- REMOVE SPARK PLUG WIRE.
• BEFORE REMOVAL AND DISASSEMBLY, CLEAN THE ENGINE.
• SEE SAFETY WARNINGS, PAGE 13-1.
• THE CONNECTING ROD AND CAP MUST STAY TOGETHER AS A SET. DO NOT MIX WITH
PARTS FROM ANY OTHER ENGINE.
• NEVER CLEAN THE PISTON HEAD WITH THE ENGINE ASSEMBLED. CARBON PARTICLES
WILL FALL BETWEEN THE PISTON AND CYLINDER WALL, AND MAY CAUSE SEVERE CYLIN-
DER WEAR.
WARNING
NOTE
CAUTION