Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 261 / 544

Page 14-21
G
14
FUEL PUMP ASSEMBLY
1. Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 14-14).
2. Install the valve assembly in the pumping chamber (Figure 14-14) .
3. Install the pumping chamber (30) on top of the fuel diaphragm. Be sure that the fuel inlet and the fuel
outlet align with the arrows on the back of the back cover (Figure 14-14).
4. Install the gasket (29), clear impulse diaphragm (28), and the paper impulse gasket (27) to the pumping
chamber (Figure 14-14).
5. Install the front cover (Item 26) and then the four screws (24) and lock washers (25) on the assembly
(Figure 14-14). Be sure that the arrows on the front cover point from the fuel inlet to the fuel outlet.
Tighten the screws to 26 in.lbs. (3.0 N-m) (Figure 14-15).
FUEL PUMP INSTALLATION
1. Connect to the fuel pump the fuel line (18) that comes from the primary fuel filter (17). Install a new
clamp (16) (Figure 14-13, Page 14-18). See Page 14-18 for proper routing of fuel lines.
2. Connect the fuel line (23), that goes to the carburetor, to the output side of the fuel pump (Figure 14-
13, Page 14-18).
3. Connect the impulse line (21) to the bottom nipple on the fuel pump. Use a new clamp (20) (Figure 14-
13, Page 14-18).
4. Install the fuel pump on the fuel tank and tighten the mounting bolts to 16-21 in.lbs. (1.8/2.4 N-m) (Fig-
ure 14-13, Page 14-18).
5. Connect the fuel lines to the primary filter (Figure 14-13, Page 14-18).
6. Place the forward and reverse lever in the NEUTRAL position and place the neutral lockout cam in the
SERVICE position. Start the engine and check for fuel leaks. If the fuel pump leaks, a rebuild kit must
be installed to replace all gaskets and diaphragms.
7. Place the neutral lockout cam in the OPERATE position.
• IF THE VALVE ASSEMBLY IS NOT INSTALLED EXACTLY AS SHOWN, THE IMPULSE FUEL
PUMP WILL NOT OPERATE PROPERLY.
• BE SURE TO CONNECT THE FUEL LINE (18), THAT COMES FROM THE PRIMARY FUEL FIL-
TER (17), TO THE INLET NIPPLE ON THE PUMP. THE DIRECTION OF FUEL FLOW IS INDI-
CATED BY THE ARROWS ON THE FUEL PUMP (FIGURE 14-13, PAGE 14-18) (SEE FIGURE 14-
15).
• THE ENGINE PRODUCES CARBON MONOXIDE, WHICH IS AN ODORLESS, DEADLY POISON.
DO NOT OPERATE THE ENGINE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION.
• CORRECT ANY FUEL LEAKS BEFORE USING THE VEHICLE.
CAUTION
NOTE
DANGER