Page 13-47
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13
13. Connect impulse line of fuel pump to engine.
14. Install air intake hose (See Fuel System - Section 14).
15. Install throttle cable and governor linkages (See Fuel System - Section 14, Engine Control Linkage).
16. Connect wire to the oil sending unit on the crankcase cover.
17. Connect engine kill switch wire.
18. Install oil drain plug in the crankcase. Apply a light film of oil on the seal of a new oil filter and install the
filter on the crankcase. Fill crankcase to the proper level with the correct type of oil. This engine should
be regarded as a new engine for next scheduled oil change (See Periodic Maintenance - Section 4).
19. Install rear body, trim, seatback, etc. (See Body and Trim - Section 5).
20. Check all hardware for proper torque/tightness.
21. Check engine oil level (Figure 13-101).
22. Install a new or cleaned spark plug, gap .027-.031 inch (.686-.787 millimeter), and connect plug wire to
plug.
23. Connect battery cables (positive cable first).
24. Place forward/reverse lever in the NEUTRAL position. Place neutral lock-out cam in SERVICE position.
25. Start engine, and adjust RPM.
26. If initial checks indicate engine is functional, place neutral lock-out cam in OPERATE position.
27. Test drive car to insure all systems are functional and correctly adjusted.
SERVICE SPECIFICATIONS
• BOTH DRAIN PLUGS ARE TO BE TIGHTENED TO 18 - 25 FT. LBS. (24/34 N-M) OF TORQUE.
• ENGINE MUST BE IN LEVEL POSITION. REMOVE OIL LEVEL DIP STICK BY PULLING FROM OIL
FILLER TUBE. WIPE OFF OIL FROM DIP STICK. CHECK OIL BY INSERTING THE DIP STICK
AND FULLY SEATING DIP STICK INTO OIL FILLER TUBE. IF OIL LEVEL IS AT OR BELOW ADD
MARK ON THE DIP STICK, ADD OIL UNTIL LEVEL IS BETWEEN ADD AND FULL (SAFE LEVEL).
DO NOT OVERFILL WITH OIL.
• ENGINE PRODUCES A CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POISON. DO
NOT OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION.
ITEM
SPEC.
SERVICE LIMIT
Crankshaft Axial Play
0.0137 in. (0.35 mm)
Crankshaft Crankpin Journal
O.D. (MIN.)
1.3954 in. (35.444 mm)
Crankshaft PTO-Side Journal
O.D. (MIN.)
1.1783 in. (29.930 mm)
Crankshaft Flywheel-Side Journal
O.D. (MIN.)
1.1783 in. (29.930 mm)
Crankshaft Balancer- Link-Rod Journals
O.D. (MIN.)
1.8474 in. (46.924 mm)
Service Specifications Chart Continued Next Page.
NOTE
CAUTION
DANGER
Summary of Contents for 1996 DS Golf Car Gasoline
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