Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 218 / 544

Page 13-28
13
G
Connecting Rod Inspection
1. Clean and inspect the bearing surfaces of the connecting rod and cap. Replace parts if scored.
2. Using an inside micrometer or a telescoping gauge, measure the inside diameter of the connecting rod
small bore at several points along its length (Figure 13-53).
3. If the inside diameter exceeds 0.7500 inch (19.050 millimeters), replace the connecting rod.
4. Remount the connecting rod cap to the connecting rod at the large bore end, aligning the pilot groove
on the rod. Screw in the connecting rod bolts and tighten them to 16.5 ft.lbs. (23 N-m).
5. Using a telescoping gauge or an inside micrometer, measure the inside diameter of the large bore at
several points along its length (Figure 13-54).
6. If the inside diameter exceeds 1.4003 inches (35.568 millimeters), replace the connecting rod.
Piston and Connecting Rod Installation - See Page 13-42.
CYLINDER BLOCK
While the engine is disassembled, inspect the cylinder block for cracks, stripped bolt holes, broken fins, or
cylinder wall scoring.
1. Use an inside micrometer or telescoping gauge, together with a micrometer, to measure the cylinder
bore.
• IF THE CONNECTING ROD IS BENT OR TWISTED, IT MUST BE REPLACED.
• WHEN MAKING TESTS OR REPAIRS, 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.
FIGURE 13-53 FIGURE 13-54
NOTE
WARNING
MEASURE
IN 2 PLACES
90
°
APART
A A
2
1
A
A
2
1
MEASURE EACH SIDE
OF OIL GROOVE
IN 2 PLACES
90
°
APART