Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 236 / 544

Page 13-46
13
G
ENGINE ASSEMBLY
1. Install cylinder head as described in Cylinder Head Installation (See Page 13-19).
2. Insert the flywheel key into the keyway in the crankshaft. Then align the keyway in the flywheel to the
key and push the flywheel and fan assembly onto the crankshaft until it seats.
3. Use a strap wrench (3) to keep the flywheel and fan assembly (1) from turning while tightening the fly-
wheel nut to 60-65 ft.lbs. (81/88 N-m) (Figure 13-100).
4. Install cylinder head shrouds (See Cylinder Shroud, Page 13-8).
5. Install carburetor (See Fuel System - Section 14).
6. Install drive clutch (See Torque Converter - Section 16).
7. Install engine in car, install mounting bolts and tighten to 20-22 ft.lbs. (27/30 N-m) torque.
8. Install drive belt (See Torque Converter - Section 16).
9. Install muffler (See Exhaust System - Section 15).
10. Install starter/generator and belt (See Electrical System - Section 12).
11. Connect starter/generator wires and the spark plug wire (See Electrical System - Section 12).
12. Connect fuel lines (See Fuel System - Section 14).
• 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.
• THE FLYWHEEL NUT HAS RIGHT HAND THREADS. TURN IT CLOCKWISE TO TIGHTEN, OR
COUNTERCLOCKWISE TO LOOSEN.
• BE CAREFUL NOT TO DAMAGE THE FAN BLADES. USE A STRAP WRENCH TO HOLD FLY-
WHEEL. DO NOT PLACE SCREWDRIVER OR PRY BAR BETWEEN FAN BLADES.
FIGURE 13-100 FIGURE 13-101
WARNING
CAUTION
1
3
M
F
34
81
Low
Level
Safe
Level
Full
Level
2
1
3