Club Car DS Villager 4 Maintenance And Service Manual Download Page 78

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Villager 4 - Monsoon Canopy

BODY AND TRIM

2+2 REAR CANOPY SUPPORT INSTALLATION

Figure 4-40

Rear Canopy Support Installation

Install the rear canopy support (3) into the rear underbody

(Figure 4-40)

Install the brackets (2) onto the rear canopy support.

Install the screws (1). Tighten the screws to 80 lb·in (9 N·m).

Page 4-42

2020 Precedent,Villager 2 and 4 Maintenance and Service Manual

Summary of Contents for DS Villager 4

Page 1: ...2020 Precedent Villager 2 and 4 Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Kohler ECH440 Engine Manual Number 86753090004 Edition Code B ...

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Page 3: ... technical representatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commitment to customer support Club Car offers a full line of training and continuing education classes for technicians who want to learn more about our products For more information contact your local dealer or Club Car ...

Page 4: ...Club Car is continually working to further improve its vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or procedures will be forwarded to all Club Car dealers and will when applicable appear in future editions of this manual Club Car reserves the right to change specifications and designs at any time withou...

Page 5: ...following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries Serial Number Decal 2843B Figure 1 Serial Number Decal Cop...

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Page 7: ... 2 4 Transaxle 2 4 Vehicle Weights And Load Capacities 2 5 SECTION 3 Extended Storage 3 1 Electric Vehicle Extended Storage 3 1 Extended Storage Preparation Electric 3 1 Return To Service From Extended Storage Electric 3 2 Gasoline Vehicle Extended Storage 3 4 Extended Storage Preparation Gasoline 3 4 Return To Service From Extended Storage Gasoline 3 5 SECTION 4 Body and Trim 4 1 Cleaning The Win...

Page 8: ...ger Canopy 4 20 Two Passenger Canopy Removal 4 20 Two Passenger Canopy Installation 4 21 Two Passenger Canopy With Visage Display Unit Removal 4 21 Two Passenger Canopy With Visage Display Unit Installation 4 23 Two Passenger Front Canopy Strut Removal 4 25 Two Passenger Front Canopy Strut Installation 4 26 Two Passenger Rear Canopy Support Removal 4 27 Two Passenger Rear Canopy Support Installati...

Page 9: ...Suspension 7 1 General Information 7 1 Steering Wheel 7 1 Steering Wheel Removal 7 1 Steering Wheel Installation 7 2 Steering Column 7 4 Steering Column Removal 7 4 Steering Column Installation 7 5 Rack and Pinion 7 6 Rack and Pinion Inspection 7 6 Rack and Pinion Removal 7 6 Rack and Pinion Installation 7 7 Front Suspension 7 9 Lubrication 7 9 Wheel Alignment 7 9 Front Suspension Components 7 12 ...

Page 10: ...Heavy Duty With Panhard 9 11 Leaf Spring Installation Four Passenger Heavy Duty With Panhard 9 13 SECTION 10 Periodic Maintenance 10 1 General Information 10 1 Pre Operation and Daily Safety Checklist 10 1 10 1 Performance Inspection 10 2 Maintenance 10 3 Periodic Service Schedules 10 4 Periodic Lubrication Schedules 10 8 Air Filter 10 10 Air Filter Removal 10 10 Air Filter Installation 10 10 Engi...

Page 11: ...Totals 11 12 Amp Hours Display 11 13 LIN 11 13 Vehicle Speeds 11 13 Pedal Counters 11 13 Fault Counters 11 13 Fault Count Odometers 11 13 Diagnostics Menu 11 14 Present Errors Folder 11 14 Fault History Folder 11 14 Causes of Faults 11 15 Fault Recovery 11 17 Fault Descriptions 11 18 Incorrect Password OEM Access Level Only 11 18 Max Password Tries OEM Access Level Only 11 18 Throttle Fault 11 18 ...

Page 12: ... 13 Electric Vehicle Electrical Components 13 1 Key Switch 13 1 Testing the Key Switch 13 1 Key Switch Removal 13 1 Key Switch Installation 13 1 Charge Indicator Light 13 2 Testing the Charge Indicator Light 13 2 Charge Indicator Light Removal 13 2 Charge Indicator Light Installation 13 2 USB Port 13 3 USB Port Removal 13 3 USB Port Installation 13 4 Forward Reverse Rocker Switch 13 4 Testing the ...

Page 13: ...er 14 7 Battery Care Vehicles Equipped with the Single Point Watering System 14 8 Battery Care Vehicles Without the Single Point Watering System 14 9 Self Discharge 14 9 Electrolyte Level 14 10 Vibration Damage 14 10 Single Point Watering System SPWS 14 11 Initial Maintenance of the SPWS 14 11 Watering Batteries with the SPWS 14 11 Battery Storage 14 13 Fleet Rotation 14 13 Deep Discharge 14 13 Ea...

Page 14: ...C Cord and Strain Relief Installation 15 28 DC Charging Harness Removal 15 28 DC Charging Harness Installation 15 29 SECTION 16 Electric Vehicle Motor 16 1 General Information 16 1 External Motor Testing 16 1 Motor 16 4 Motor Removal 16 4 Motor Disassembly 16 5 Motor Component Testing and Inspection 16 8 Armature Inspection and Testing 16 8 Motor Frame and Field Windings Inspection 16 10 Motor Bru...

Page 15: ...f Armature 19 9 Commutator Cleaning and Inspection 19 10 Armature Ground Test 19 11 Visual Inspection of Field Coils 19 12 Starter Generator Rework 19 12 Starter Generator Assembly 19 12 Starter Generator Installation 19 15 Belt Tension Adjustment for EFI Engines 19 16 Solenoid 19 18 Solenoid Removal 19 18 Solenoid Installation 19 19 Voltage Regulator 19 20 Voltage Regulator Removal 19 20 Voltage ...

Page 16: ... 36 USB Receptacle Installation 19 36 Oxygen Sensor 19 37 Oxygen Sensor Removal 19 37 Oxygen Sensor Installation 19 37 SECTION 20 Gasoline Vehicle Engine 20 1 General Information 20 1 Before Servicing 20 1 Engine Removal 20 2 Engine Installation 20 5 Snubber 20 8 Snubber Removal 20 8 Snubber Installation 20 8 SECTION 21 Gasoline Vehicle Fuel System 21 1 General Information 21 1 EFI System Features...

Page 17: ...ssembly 23 10 Drive Clutch Installation 23 11 Driven Clutch 23 12 Driven Clutch Removal 23 13 Driven Clutch Disassembly 23 13 Driven Clutch Inspection 23 15 Driven Clutch Assembly 23 16 Driven Clutch Installation 23 18 SECTION 24 Gasoline Vehicle Transaxle 24 1 General Information 24 1 Shifter Lever 24 1 Maintenance Operate Switch 24 1 Governor System 24 2 Transaxle Service 24 2 Lubrication 24 2 T...

Page 18: ... 13 Shifter Cable Installation 24 14 Shifter Cable Adjustment 24 14 SECTION 25 Kohler Engine Service Manual 25 1 SECTION 26 Wiring Diagrams 26 1 General Information 26 1 Engine Harness Wiring Diagram Table 26 2 Index Index 1 Page xvi 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 19: ... If any of the operation or safety decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible property damage personal injury or death Contact your distributor dealer DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death WARNING A WARNING indicates an immediate hazard that could r...

Page 20: ...e in vehicle Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Neutral Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in de...

Page 21: ...starting a gasoline vehicle disconnect the battery and spark plug wire See Disconnect the Battery Gasoline Vehicles on page 1 3 Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component DISABLING THE VEHICLE 1 Park the vehicle on a s...

Page 22: ...e DANGER Batteries disconnected or connected with the Run Tow switch set to RUN can cause a battery explosion and serious personal injury Set the Run Tow switch to TOW before the batteries are disconnected or connected 2 Set the Run Tow switch to TOW 3 Disconnect the negative cable 1 Figure 1 2 Page 1 4 Figure 1 2 Disconnect Electric Vehicle Batteries 4 Disconnect the positive cable 2 5 Wait 90 se...

Page 23: ...n Tow switch to TOW before the batteries are disconnected or connected 1 Set the Run Tow switch to TOW 2 Connect the positive cable 2 Figure 1 3 Page 1 5 Figure 1 3 Connect Electric Vehicle Batteries 3 Connect the negative cable 1 4 Tighten the hardware to 110 lb in 12 4 N m 5 Apply battery terminal protector spray to the battery terminals 2020 Precedent Villager 2 and 4 Maintenance and Service Ma...

Page 24: ...ries but by people who use the batteries as well Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries 1403 Figure 1 4 Dispose of Lead acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using repairing or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries _ 1 Shie...

Page 25: ...cm Wheelbase 65 5 in 166 cm 65 5 in 166 cm 65 5 in 166 cm PERFORMANCE _ DESCRIPTION 2 PASSENGER VILLAGER 2 VILLAGER 4 Forward speed On Level Ground 12 to 15 mph 19 to 24 km h factory setting 19 mph 30 6 km h maximum 19 mph 30 6 km h 12 to 15 mph 19 to 24 km h factory setting 19 mph 30 6 km h maximum Curb To Curb 207 8 in 528 cm 207 8 in 528 cm 207 8 in 528 cm TIRES _ DESCRIPTION 2 PASSENGER VILLAG...

Page 26: ...loss of control of the vehicle and serious personal injury Do not exceed the vehicle load capacities Do not tow when the cargo capacity is exceeded _ VEHICLE WEIGHTS AND LOAD CAPACITIES 2 PASSENGER VILLAGER 2 VILLAGER 4 Vehicle Dry Weight 689 lb 312 3 kg 689 lb 312 3 kg 804 lb 312 3 kg Vehicle Curb Weight 909 lb 412 5 kg 909 lb 412 5 kg 1024 lb 464 5 kg Occupant Capacity 400 lb 181 kg 400 lb 181 k...

Page 27: ... on the vehicle This capacity includes the weight of bed load cargo occupants and optional equipment Vehicle Combination Rated Capacity The vehicle combination rated capacity is the maximum weight on the vehicle with a trailer This capacity includes vehicle rated capacity and the gross trailer weight Maximum Gross Vehicle Weight The maximum gross vehicle weight is the vehicle weight plus the vehic...

Page 28: ...que GASOLINE ENGINE _ DESCRIPTION 2 PASSENGER VILLAGER 2 VILLAGER 4 Horsepower 14 hp 10 4 kw at 3600 rpm per SAE J1940 Fuel Type Gasoline with less than 10 ethanol rating Fuel Capacity 5 6 gal 21 2 l Engine Oil Capacity 39 fl oz 1 1 l 39 fl oz 1 1 l 39 fl oz 1 1 l BATTERY _ DESCRIPTION 2 PASSENGER VILLAGER 2 VILLAGER 4 Battery Type 12V no maintenance Battery Quantity 1 NOISE AND VIBRATION _ DESCRI...

Page 29: ...licable _ TERM DEFINITION Vehicle Dry Weight The vehicle dry weight is the weight of the vehicle with no fuel Vehicle Curb Weight The vehicle curb weight is the weight of the vehicle with the fuel tank filled Occupant Capacity The occupant capacity is the maximum permitted weight for occupants to operate the vehicle safely Cargo Capacity The cargo capacity is the maximum weight of a load that the ...

Page 30: ...Pagination Page 2 Gasoline Vehicle Specifications VEHICLE SPECIFICATIONS Page 2 6 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 31: ...vehicle or during vehicle maintenance disable the vehicle Set the Run Tow switch to TOW Frozen battery acid can cause damage including leaks and explosions If the battery acid freezes replace the battery before charging or use Batteries in a low state of charge will freeze at low temperatures Keep the batteries in a high state of charge CAUTION To avoid exposing electrical components to moisture a...

Page 32: ...at the negative battery cable does not touch the battery terminal The battery charger must stay connected to an electric outlet AC electrical power will be available during storage Battery acid levels will be kept at a sufficient level while in storage 14 If all conditions can be done while in storage do as follows The battery charger must stay connected to an electric outlet AC electrical power w...

Page 33: ...ehicle Extended Storage 3 7 Have a trained technician lubricate the vehicle 8 Do a daily pre operation safety checklist 9 Do a vehicle performance inspection 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 3 3 ...

Page 34: ...rn the key to OFF 5 Remove the key Keep the key in a safe area 6 Put chocks against the wheels NOTE Do not engage the park brake 7 Remove all cargo and personal items 8 Fill the fuel tank 9 Add a fuel stabilizer Refer to the fuel stabilizer manufacturer s instructions 10 Disconnect the fuel vent line from the fuel tank vent nipple 11 Plug the fuel tank vent nipple with a slip on vinyl cap 1 Figure...

Page 35: ...ture antiseize lubricant to the spark plug threads 14 6 Use a spark plug socket to install and tighten the spark plug to 20 lb ft 27 N m 14 7 Connect the spark plug wire 15 Keep the vehicle in a cool and dry area to keep battery self discharge to a minimum 16 Adjust pressure in each tire to recommended tire pressure 17 Clean the vehicle RETURN TO SERVICE FROM EXTENDED STORAGE GASOLINE 1 Clean the ...

Page 36: ... 5 Set the Maintenance Operate switch to MAINTENANCE 6 Start and run the engine NOTE The engine exhaust may smoke for a short time after returning to service 7 Turn the key to OFF 8 Set the Maintenance Operate switch to OPERATE 9 Adjust the pressure in each tire to the recommended tire pressure 10 Have a trained technician lubricate the vehicle 11 Do a daily pre operation safety checklist 12 Do a ...

Page 37: ... the rear beauty panel marked NO STEP Wax will cause these surfaces to become discolored Moisture will cause electrical component damage Do not use a pressure washer or steam cleaner to clean the vehicle Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate Use a commercially available alum...

Page 38: ...e on affected area for approximately 30 minutes Rinse with a water dampened cloth to remove any remaining bleach concentration BODY REPAIR STRESS LINES OR STREAKS Repeatedly flexing the Surlyn body can cause white stress lines or streaks in the finish To remove them 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Slowly wave the heat gun back...

Page 39: ...ghly clean the affected area using a strong non abrasive detergent and hot water then clean with Ultra Kleen Solvent Cleaner to remove any oil based contaminants 2 Lightly buff imperfection with a clean soft cloth or buff pad Do not use any kind of rubbing abrasive compound on body assemblies 3 Wax the entire body part to restore luster and weather protection GOUGES PUNCTURES TEARS LARGE SCRATCHES...

Page 40: ...Seat Bottom Hinge SEAT HINGE REMOVAL 1 Remove the seat bottom 1 from the vehicle Figure 4 1 2 Remove the screws 2 3 Remove the hinge 3 SEAT HINGE INSTALLATION 1 Align the hinge 3 onto the seat bottom 1 Figure 4 1 2 Install the screws 2 Tighten the screws to 75 lb in 8 5 N m Page 4 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 41: ... 3 HIP RESTRAINT INSTALLATION 1 Align the hip restraint 3 onto the seat bottom 1 Figure 4 2 2 Install the screws 2 Tighten the screws to 65 lb in 7 3 N m FRONT BODY See General Warnings on page 1 2 FRONT BODY REMOVAL 1 Remove the four screws 2 and pull the brow cap 1 from the brow and fascia assembly 4 Figure 4 3 Page 4 7 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 5 ...

Page 42: ...the front fascia 6 from the brow 5 FRONT BODY INSTALLATION 1 Install fascia 6 to brow 5 with five screws 7 Tighten screws to 40 in lb 4 5 N m Figure 4 3 Page 4 7 2 Install brow and fascia assembly 4 to front underbody with five screws 8 Tighten screws to 31 in lb 3 5 N m 3 Install front beauty panel 3 over brow 5 Tabs on the forward edge of the front beauty panel should fit into slots between the ...

Page 43: ...BODY AND TRIM Front Body 4 3 8 2 1 5 6 7 4 616 Figure 4 3 Front Body 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 7 ...

Page 44: ... 8 Each bracket is secured in place by two taptite screws 2 tightened to 13 ft lb 17 6 N m The front bumper 3 is attached to the vehicle frame rails by nuts 5 and bolts 4 The nuts are tightened to 13 3 ft lb 18 N m 2 1 2 3 4 5 617 Figure 4 4 Bracket and Front Bumper Page 4 8 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 45: ... horizontal line 15 1 2 inches 39 4 cm above the ground directly in front of the vehicle 3 Turn on headlight Take note where the beam strikes the vertical surface in relation to the marked horizontal line To raise the beam add washers size M6 to the lower mounting screw 1 To lower the beam add washers to both upper screws Tighten screws to 66 in lb 7 5 N m While it is possible to add washers with ...

Page 46: ...n the passenger side INSTRUMENT PANEL INSTALLATION 1 Connect the electrical connector 4 on the passenger side Figure 4 6 2 Install the instrument panel 2 into the dash assembly 3 Make sure that the tabs on the instrument panel engage in the slots on the dash assembly 3 Make sure that electrical wires are not exposed or pinched 4 Install the screws 1 Tighten the screws to 22 lb in 2 5 N m Page 4 10...

Page 47: ...ct the USB receptacle 4 Remove the dash assembly 3 DASH ASSEMBLY INSTALLATION 1 Put the dash assembly 3 on vehicle Figure 4 7 Make sure tabs on the forward edge engage to front underbody 2 Connect the USB receptacle 3 Install the screws 2 Tighten the screws to 8 8 lb ft 12 N m 4 Install the instrument panel 1 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 11 ...

Page 48: ...L 1 Remove the screws 2 Figure 4 8 2 Remove the push rivets 4 3 Carefully pull on floor mat retainer 1 to separate the trim clips from their respective slots Trim clips do not normally need to be removed from the retainer FLOOR MAT RETAINER INSTALLATION 1 Position the floor mat retainer 1 on the vehicle and press firmly to engage the trim clips to the vehicle Figure 4 8 2 Make sure that the floor ...

Page 49: ... AND TRIM Floor Mat and Retainers 4 4 Install the push rivets 4 Figure 4 8 Page 4 12 5 Tighten the two screws 2 to 4 4 lb ft 6 0 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 13 ...

Page 50: ...el Tool NOTE Refer to the Illustrated Parts Catalog for service tool part numbers Figure 4 9 Kick Plate and Charger Receptacle Bezel Removal 1 Use the charger bezel tool to remove charger receptacle bezel 1 from the kick plate 2 Figure 4 9 Page 4 14 2 Remove the floor mat 3 Remove three screws 3 and washers 4 4 Remove the two front screws 5 Page 4 14 2020 Precedent Villager 2 and 4 Maintenance and...

Page 51: ...TALLATION Figure 4 10 Kick Plate and Charger Receptacle Bezel Installation 1 Install the kick plate 3 2 Make sure that the front lower edge of the rear beauty panel mates with the kick plate 3 Install the three screws 1 and washers 2 Tighten the screws to 3 3 lb ft 4 5 N m 4 Install the two front screws 5 Tighten screws to 3 7 lb ft 5 N m 5 Install the floor mat 6 Install the charger receptacle be...

Page 52: ...orward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate 5 Remove the kick plate 3 from vehicle KICK PLATE INSTALLATION 1 Install the kick plate 3 2 Install the three screws 1 and washers 2 Tighten the screws to 3 3 lb ft 4 5 N m 3 Install two front screws 4 Tighten the screws to 3 7 lb ft 5 N m 4 Install the floor mat Page 4 16 2020 Precedent Vi...

Page 53: ...NEL REMOVAL 1 Remove the two push rivets 1 Figure 4 12 2 Remove the access panel 2 ACCESS PANEL INSTALLATION 1 Install the access panel 2 onto the rear underbody Figure 4 12 2 Install the two push rivets 1 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 17 ...

Page 54: ...Overhead Basket 2 Release the tab 2 and remove the overhead basket 3 OVERHEAD BASKET INSTALLATION 1 Align the overhead basket 3 with the display unit support Figure 4 13 Page 4 18 2 Push the overhead basket forward until the tab 2 locks 3 Install the screw 1 Tighten the screw to 17 7 lb in 2 0 N m Page 4 18 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 55: ...er basket 3 3 Disconnect the electrical connector 4 OVERHEAD SPEAKER BASKET INSTALLATION 1 Connect the electrical connector 4 Figure 4 14 Page 4 19 2 Align the overhead speaker basket 3 with the display unit support 3 Push the overhead speaker basket forward until the tab 2 locks 4 Install the screw 1 Tighten the screw to 17 7 lb in 2 0 N m 2020 Precedent Villager 2 and 4 Maintenance and Service M...

Page 56: ...m the vehicle without first removing the canopy Figure 4 15 Two Passenger Canopy Removal 1 Remove the nuts 1 washer 2 and bolts 3 from the canopy 4 and each front canopy strut Figure 4 15 2 Remove the nuts 6 washer 7 and bolts 8 from the canopy and each rear canopy support 3 Remove the canopy Page 4 20 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 57: ... the rear supports 2 Install the bolts 3 washers 2 and nuts 1 Tighten the hardware to 50 lb in 5 6 N m 3 Install the bolts 8 washers 7 and nuts 6 Tighten the hardware to 50 lb in 5 6 N m TWO PASSENGER CANOPY WITH VISAGE DISPLAY UNIT REMOVAL CAUTION To prevent damage to the canopy do not remove the canopy supports from the vehicle without first removing the canopy 1 Remove the overhead baskets See ...

Page 58: ...support 4 Remove the canopy 7 5 Disconnect the canopy harness 8 6 Remove the screws 9 Figure 4 18 Page 4 22 Figure 4 18 Visage Display Unit Removal 7 Remove the Visage display unit VDU 10 from the display unit support 8 Disconnect the display unit harness 11 9 Remove the display unit support 12 Page 4 22 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 59: ... 4 19 Visage Display Unit Installation 2 Install the display unit support onto the front canopy struts 3 Connect the display unit harness 11 4 Install the Visage display unit VDU 10 onto the display unit support 5 Install the screws 9 Tighten the screws to 24 lb in 2 7 N m 6 Make sure that the strut harness is routed correctly 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 2...

Page 60: ... 8 Install the canopy 7 on top of the front and rear canopy supports 9 Install the bolts 3 washers 2 and nuts 1 Tighten the hardware to 50 lb in 5 6 N m 10 Install the bolts 6 washers 5 and nuts 4 Tighten the hardware to 50 lb in 5 6 N m 11 Install the overhead baskets See Display Unit Overhead Basket Page 4 24 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 61: ...d the bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components Figure 4 21 Front Canopy Strut Removal 1 Remove the canopy 2 Remove the screw 1 Figure 4 21 3 Slide the front canopy strut cover 2 up the front canopy strut 3 4 Remove the screws 4 and the front canopy strut 2020 Precedent Villager 2 and 4 Maintenance and...

Page 62: ...the front canopy strut 3 onto the vehicle Figure 4 22 2 Install the front canopy strut cover 2 onto the front canopy strut 3 Install the screws 4 Tighten the screws to 18 4 lb ft 25 N m 4 Install the screw 1 Tighten the screw to 31 lb in 4 6 N m 5 Install the canopy Page 4 26 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 63: ...removing the canopy Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components Figure 4 23 Rear Canopy Support Removal 1 Remove the canopy 2 Remove the screw 1 Figure 4 23 3 Remove the rear canopy support 2 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 27 ...

Page 64: ...ew to 88 lb in 10 N m 3 Install the canopy TWO PASSENGER REAR BODY UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module SAM includes two mounting locations on both the driver side and the passenger side These serve as common attachment points for various accessories Accessories that can be mounted on the SAM include single or dual sand bottles sand bucket and the club cleaner Page 4 28 202...

Page 65: ...icle has a canopy remove the rear canopy supports from the SAM 2 Figure 4 25 2 Remove the four bolts 1 SAM Installation 1 Position the SAM 2 over its mounting holes Figure 4 25 2 Install the four screws 1 Tighten the screws to 71 lb in 8 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 29 ...

Page 66: ...al 1 Remove the two screws 1 Figure 4 26 2 Remove the seat back 2 from the SAM 3 Seat Back Installation 1 Put the seat back 2 on the SAM 3 Figure 4 26 2 Install the two screws 1 Tighten the screws to 51 lb in 5 8 N m Page 4 30 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 67: ...oval 1 Remove the two screws 1 Figure 4 27 2 Remove the bag rack 2 from the SAM 3 Bag Rack Installation 1 Install the bag rack 2 onto the SAM 3 Figure 4 27 2 Install the two screws 1 Tighten the screws to 53 lb in 6 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 31 ...

Page 68: ...rivets 1 and screw 2 Figure 4 28 2 Remove the bag strap 3 from the bag rack 4 Bag Strap Installation 1 Install the bag strap 3 onto the bag rack 4 Figure 4 28 2 Install the push rivets 1 and screw 2 Tighten the screw to 31 lb in 3 5 N m Page 4 32 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 69: ...e the three screws 1 Figure 4 29 2 Remove the sweater basket 2 from the bag rack 3 Sweater Basket Installation 1 Install the sweater basket 2 onto the bag rack 3 Figure 4 29 2 Install the three screws 1 Tighten the screws to 31 lb in 3 5 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 33 ...

Page 70: ...ody clips 4 of the rear beauty panel 5 from the slots in the rear underbody 6 7 Remove the rear beauty panel from vehicle Rear Beauty Panel Installation 1 Install the rear beauty panel 5 onto vehicle Figure 4 30 2 Make sure that the two body clips 4 engage the slots in the rear underbody 6 3 Install the four screws 3 Tighten the screws to 44 lb in 5 N m 4 Install the Forward Neutral Reverse contro...

Page 71: ...Remove remove the four screws 1 Figure 4 31 4 Lift the rear edge of the rear underbody 2 until the front portion slides out from beneath the front underbody Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install the rear underbody 2 onto the vehicle Figure 4 31 2 Install the four screws 1 Tighten the screws to 71 lb in 8 N m 2020 Precedent Villager 2 and 4 Maintenance and...

Page 72: ...emove the four bolts 1 Figure 4 32 2 Remove the rear crossmember 2 Rear Crossmember Installation 1 Install the rear crossmember 2 onto the vehicle Figure 4 32 2 Make sure that the J clips 3 are installed on the inside of the frame rail 3 Install the four bolts 1 Tighten the bolts to 56 lb in 6 35 N m Page 4 36 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 73: ...orts from the vehicle without first removing the canopy 1 Remove the nuts 1 washers 2 and bolts 3 from the front canopy strut 4 Figure 4 33 Figure 4 33 Canopy Removal Front Canopy Strut 2 Remove the screws 5 Figure 4 34 3 Remove the canopy 6 Figure 4 34 Canopy Removal Rear Canopy Support 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 37 ...

Page 74: ...l the screws 5 Tighten the screws to 80 lb in 9 N m Figure 4 35 Canopy Installation Rear Canopy Support 3 Install the bolts 3 washers 2 and nuts 1 to secure the front canopy strut 4 Figure 4 36 Tighten the hardware to 80 lb in 9 N m Figure 4 36 Canopy Installation Front Canopy Strut Page 4 38 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 75: ...he bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components Figure 4 37 Front Canopy Strut Removal 1 Remove the canopy 2 Remove the screw 1 Figure 4 37 3 Slide the front canopy strut cover 2 up the front canopy strut 3 4 Remove the screws 4 and the front canopy strut 2020 Precedent Villager 2 and 4 Maintenance and Se...

Page 76: ... front canopy strut 3 onto the vehicle Figure 4 38 2 Install the front canopy strut cover 2 onto the front canopy strut 3 Install the screws 4 Tighten the screws to 18 4 lb ft 25 N m 4 Install the screw 1 Tighten the screw to 31 lb in 4 6 N m 5 Install the canopy Page 4 40 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 77: ...he canopy Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components Figure 4 39 Rear Canopy Support Removal 1 Remove the canopy 2 Remove the screws 1 and brackets 2 Figure 4 39 3 Remove the rear canopy support 3 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 41 ...

Page 78: ... Rear Canopy Support Installation 1 Install the rear canopy support 3 into the rear underbody Figure 4 40 2 Install the brackets 2 onto the rear canopy support 3 Install the screws 1 Tighten the screws to 80 lb in 9 N m Page 4 42 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 79: ...k Removal Figure 4 41 Seat Back Removal 1 Remove the screws 1 from the front seat back 2 Figure 4 41 2 Remove the front seat back 3 Remove the screws 3 from the rear seat back 4 4 Remove the rear seat back 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 43 ...

Page 80: ...port tab 3 is installed in the front seat back Figure 4 42 2 Install the screws 4 Tighten the screw to 4 4 lb ft 6 N m 3 Install the rear seat back 5 onto the seat support 6 Make sure the seat support tab 7 is installed in the rear seat back 4 Install the screws 8 Tighten the screw to 4 4 lb ft 6 N m Page 4 44 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 81: ... the screws 1 Figure 4 43 2 Lift and remove the rear seat bottom 2 Fixed Rear Seat Bottom Installation 1 Install the rear seat bottom tabs into the seat supports Lower the rear seat bottom 2 onto the seat supports Figure 4 43 2 Install the screws 1 Tighten the screws to 4 4 lb ft 6 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 45 ...

Page 82: ...ove the rear seat bottom 2 Remove the screws 1 Figure 4 44 3 Remove the hinge 2 Fixed Rear Seat Hinge Installation 1 Install the hinge 2 onto the rear seat bottom Figure 4 44 2 Install the screws 1 Tighten the screws to 4 4 lb ft 6 N m Page 4 46 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 83: ... 3 4 Lift and remove the hip restraint 4 Fixed Rear Seat Hip Restraint Installation 1 Install the rear hip restraint 4 onto the foot deck 2 Install the screws 3 Tighten the screws to 4 4 lb ft 6 N m Figure 4 45 3 Install the strut angle 2 on the rear hip restraint 4 Install the screws 1 Tighten the screws to 4 4 lb ft 6 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 47 ...

Page 84: ...Rear Seat Bottom 1 Remove the screws 1 Figure 4 46 2 Remove the rear seat bottom 2 from the fold down hinge 3 Fold Down Rear Seat Bottom Installation 1 Put the rear seat bottom 2 onto the fold down hinge 3 Figure 4 46 2 Install the screws 1 Tighten the screws to 6 6 lb ft 9 N m Page 4 48 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 85: ...4 Remove the rear seat assembly 7 Fold Down Rear Seat Assembly Installation 1 Put the rear seat assembly 7 onto the vehicle Figure 4 47 2 Install the screws 1 Tighten the screws to 13 lb ft 17 5 N m 3 Install the bolts 2 and nuts 3 Tighten the nuts to 13 lb ft 17 5 N m 4 Install the bolts 4 washers 5 and nuts 6 Tighten the bolts to 8 5 lb ft 11 5 N m 2020 Precedent Villager 2 and 4 Maintenance and...

Page 86: ...ws 3 4 Lift and remove the hip restraint 4 Fold Down Rear Seat Hip Restraint Installation 1 Install the rear hip restraint 4 onto the foot deck Figure 4 48 2 Install the screws 3 Tighten the screws to 4 4 lb ft 6 N m 3 Install the strut angle 2 on the rear hip restraint 4 Install the screws 1 Tighten the screws to 4 4 lb ft 6 N m Page 4 50 2020 Precedent Villager 2 and 4 Maintenance and Service Ma...

Page 87: ...ut 4 and bolt 5 3 Remove the side frame 6 Side Frame Installation 1 Install the side frame 6 onto the foot deck Figure 4 49 2 Install the nut 4 and bolt 5 Tighten the bolt to 8 5 lb ft 11 5 N m 3 Install the nut 1 washers 2 and bolt 3 Tighten the bolt to 8 5 lb ft 11 5 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 51 ...

Page 88: ...ws 1 Figure 4 50 5 Remove the screw 2 6 Remove the seat support 3 Seat Support Installation 1 Install the seat support 3 onto the vehicle Figure 4 50 2 Install the screw 2 Tighten the screw to 13 lb ft 17 5 N m 3 Install the screws 1 Tighten the screws to 7 lb ft 10 N m 4 Install the rear seat bottom assembly 5 Install the hip restraints 6 Install the seat backs Page 4 52 2020 Precedent Villager 2...

Page 89: ... deck procedures Foot Deck Removal Figure 4 51 Foot Deck 2 2 Removal 1 Support the foot deck 2 Remove the screws 1 Figure 4 51 3 Remove the screws 2 4 Remove the bolts 3 and the foot deck 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 53 ...

Page 90: ...Deck 2 2 Disassembly 1 Remove the push rivets 1 Figure 4 52 2 Remove the floormat 2 3 Remove the screws 3 4 Remove the foot deck 4 5 Remove the screws 5 6 Remove the handrail 6 from the foot deck support 7 Page 4 54 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 91: ... 2 Install the handrail 3 into the foot deck support 3 Install the screws 4 Tighten the bolts to 5 5 lb ft 7 5 N m 4 Install the foot deck 5 onto the foot deck support 5 Install the screws 6 Tighten the screws to 6 lb ft 8 N m 6 Install the floormat 7 onto the foot deck 7 Install the push rivets 8 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 4 55 ...

Page 92: ...ation 1 Support the foot deck 2 Install the bolts 3 Figure 4 54 Tighten the bolts to 22 lb ft 30 N m 3 Install the screws 2 Tighten the screws to 13 lb ft 18 N m 4 Install the screws 1 Tighten the screws to 7 lb ft 10 N m Page 4 56 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 93: ...s 2 under the rear of the beauty panel 3 from the slots in the rear underbody 4 6 Remove the rear beauty panel from the rear underbody Rear Beauty Panel Installation 1 Install the rear beauty panel 3 on the rear underbody 4 Make sure body clips 2 on the rear of the beauty panel engage the slots in the rear underbody Figure 4 55 2 Install the screws 1 Tighten the screws to 44 lb in 5 N m 3 Install ...

Page 94: ...dge of the rear underbody 2 until the front portion slides out from beneath the front underbody Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install the rear underbody 2 on the vehicle Figure 4 56 2 Install the screws 1 Tighten the screws to 71 lb in 8 N m 3 Install the access panel 4 Install the rear beauty panel Page 4 58 2020 Precedent Villager 2 and 4 Maintenance an...

Page 95: ...r mat 2 over the pedal group to gain access to the pedal group hardware 1 2 3 629 Figure 5 1 Pedal Group Access 4 Remove fastener 10 and lift off cover plate 7 Figure 5 2 Page 5 2 5 Loosen jam nuts 4 and 5 on each side of turnbuckle 6 NOTE Nut 4 has a left hand thread 6 Loosen turnbuckle 6 until the threaded rod 8 from the pedal group 11 is free of the turnbuckle Figure 5 2 Page 5 2 7 Remove two s...

Page 96: ...al Group Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP 7 10 2 1 3 6 4 5 11 9 8 13 12 2518 Figure 5 2 Pedal Group Electric Vehicle Page 5 2 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 97: ...ecure with two screws 2 on the driver side and two screws 1 on the passenger side Tighten driver side screws 2 to 97 in lb 11 N m Tighten passenger side screws 1 to 18 in lb 2 N m 3 Remove the turnbuckle 6 and apply Loctite 242 to the threaded ends of both the rod from the pedal group 8 and the brake actuator rod 9 Connect the rods using the turnbuckle 6 4 Adjust the brake cable equalizer tension ...

Page 98: ...Loosen jam nuts 4 and 5 on each side of turnbuckle 6 NOTE Nut 4 has a left hand thread 6 Loosen turnbuckle 6 until the threaded rod 8 from the pedal group 11 is free of the turnbuckle Figure 5 4 Page 5 5 1 2 3 629 Figure 5 3 Pedal Group Access 7 Loosen two nuts 9 on the accelerator cable and lift the cable from its mounting bracket 8 Remove two screws 2 on the driver side of the pedal group and tw...

Page 99: ...edal assembly The throttle position sensor detects the position of the accelerator pedal and sends a voltage to the solenoid and forward reverse limit switches The throttle position sensor itself is not intended to be replaced If sensor is determined to need replacing through test procedures found in this manual the accelerator pedal assembly must be replaced See Accelerator Pedal Removal on page ...

Page 100: ...stall the floor mat 2 over the pedal group Make sure tabs on floor mat sides are beneath the sill 3 Tighten screws 1 to 53 in lb 6 N m Figure 5 3 Page 5 4 8 Connect battery and spark plug wire s See Connect the Battery Gasoline Vehicles on page 1 4 DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group Both shie...

Page 101: ... 5 Figure 5 5 Page 5 8 3 Remove four screws 12 securing brake pedal assembly 8 to pedal group mounting plate and pull brake pedal assembly through bottom of pedal group mounting plate BRAKE PEDAL INSTALLATION 1 Insert brake pedal assembly 8 through bottom of pedal group mounting plate and secure with four screws 12 Figure 5 5 Page 5 8 2 Tighten screws 12 to 100 in lb 11 3 N m 3 Install debris shie...

Page 102: ...5 Brake Pedal Installation ACCELERATOR AND BRAKE PEDAL GROUP Figure 5 5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5 8 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 103: ...eel BRAKE SHOE REMOVAL CAUTION Worn or damaged brake drums cannot be machined to refinish them Replace as necessary 1 Disable the vehicle 2 Electric Vehicle Disconnect the batteries and discharge the controller Gasoline Vehicle Disconnect battery and spark plug wire 3 Loosen the lug nuts on the rear wheels 4 Lift the rear of the vehicle WARNING Lift only one end of the vehicle at a time Use a suit...

Page 104: ...s 10 Remove the rear wheels 11 If the brake drums can be easily removed 11 1 Remove the brake drums 11 2 Electric Vehicle Remove the axle shaft Gasoline Vehicle Remove the wheel hub assembly 11 3 Using needle nose pliers turn the retainer pin 6 90 to remove the shoe retainer clip 7 Figure 6 2 CAUTION The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed ...

Page 105: ...trated Figure 6 3 NOTE This will release the shoes from the backing plate allowing them to pivot away from the inside of the brake drum 10 which should then allow the brake drum to be pulled free NOTE It may be necessary to remove the sealant material around the head of each pin 1400 18100 10220C Figure 6 3 Shoe Retainer Pins 13 Grasp both brake shoes and pull them together with the springs out of...

Page 106: ...WHEEL BRAKE ASSEMBLIES 14 Remove adjuster wheel 11 with two washers 12 and 13 from the backing plate Figure 6 5 2732B Figure 6 5 Remove Adjuster Wheel Page 6 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 107: ...er 2 from backing plate and wipe with a clean damp cloth 2 1 1400 18100 10220B Figure 6 6 Backing Plate and Dust Cover 3 Lubricate the slide 3 with dry moly lubricant Figure 6 7 2733B Figure 6 7 Lubricate Slide 4 Make sure that the slide can easily move back and forth 5 Install the dust cover onto the backing plate 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 6 5 ...

Page 108: ... small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on the raised bosses 4 on the brake backing plate Figure 6 8 2734C Figure 6 8 Apply Grease On Bosses 7 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe m...

Page 109: ...to the brake adjuster assembly adjuster wheel shoe slots and the shaft of the adjuster wheel as shown Figure 6 10 2735 Figure 6 10 Apply Grease To Brake Adjuster 9 Install the adjuster wheel 5 and two washers 6 and 7 into the adjuster assembly Figure 6 11 2732C Figure 6 11 Install Adjuster Wheel 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 6 7 ...

Page 110: ... of the brake assembly NOTE The trailing shoe has 17T stamped into the shoe flange The trailing shoe is toward the front of the vehicle 2736B Figure 6 12 Install Adjuster Wheel Trailing Shoe 3 If the retainer pins 5 were sheared during removal replace the retainer pins Figure 6 13 4 Use pliers to compress and install the shoe retainer clip 6 while turning the retainer pin into position 2737B Figur...

Page 111: ... the stamped end of the shoe is on the top of the brake assembly NOTE The leading shoe has 17L stamped into the shoe flange The leading shoe is toward the rear of the vehicle 7 Install the leading shoe 9 in the slots in the shoe mounting block A and the adjuster assembly B Figure 6 15 646B Figure 6 15 Install Leading Shoe 8 Use pliers to compress and install the shoe retainer clip while turning th...

Page 112: ...7 Set Adjusting Wheel 11 Turn the adjusting wheel upward until it stops 12 Remove the screwdriver 13 Electric Vehicle Install the axle shaft Gasoline Vehicle Install the wheel hub assembly 14 Install the brake drum Make sure that the brake drum is properly seated NOTE If drum installation is difficult the brake shoes may need to be adjusted vertically in the mounting slots 15 Make sure that the ax...

Page 113: ...brake actuator rod 14 20 Install the turnbuckle Make sure that the brake cables 15 are installed in the brake equalizer 16 636E Figure 6 18 Turnbuckle Installation 21 Adjust the brake cable equalizer 22 Electric Vehicle Connect the batteries Gasoline Vehicle Connect battery and spark plug wire 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 6 11 ...

Page 114: ...reads for both front and rear jam nuts WARNING Reduced braking force could result if the jam nuts are not tightened in the proper sequence 5 Tighten the rear jam nut first to 208 lb in 23 5 N m then tighten the front jam nut to 208 lb in 23 5 N m For optimal performance drive the vehicle and apply the brakes approximately 20 times to burnish the shoes center the clusters and adjust the brake mecha...

Page 115: ...remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 5 Remove the floor mat 6 Remove the pedal access panel 7 Loosen the left hand thread jam nut 1 and right hand thread jam nut 3 1 2 inch 12 7 mm away from the turnbuckle 2 Figure 6 20 2 3 4 1 5 636 Figure 6 20 Loosen Turnbuckle 8 Loosen the turnbuckle to release tension on the eq...

Page 116: ...ide of the brake drum 8 which should then allow the brake drum to be pulled free NOTE It may be necessary to remove the sealant material around the head of each pin 1400 18100 10220D Figure 6 21 Shoe Retainer Pins 13 Electric Vehicle Remove the axle shaft Gasoline Vehicle Remove the wheel hub assembly 14 Remove the brake shoes 15 Remove and discard the bow tie locking pin 9 Figure 6 22 2731C Figur...

Page 117: ...le shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area 1 Install the brake back plate 1 onto the transaxle Figure 6 23 2731D Figure 6 23 Brake Cluster Installation 2 Install new bolts 2 and lock nuts 3 Tighten the bolt heads to 30 lb ft 40 6 N m 3 Install the clevis pin 4 4 Install the new bow tie locking pin 5 2020 Precedent Villager 2 and 4 Maintenance a...

Page 118: ...stall Shoe Retainer Clip 6 Electric Vehicle Install the axle shaft Gasoline Vehicle Install the wheel hub assembly 7 Install the brake drum 8 Install the rear wheels 9 Lower the rear of the vehicle 10 Adjust the brake cable equalizer 11 Install the pedal access panel 12 Install the floor mat 13 Electric Vehicle Connect the batteries Gasoline Vehicle Connect the battery and spark plug wire Page 6 1...

Page 119: ...oor mat 4 Remove the pedal access panel 5 Loosen the left hand thread jam nut 1 and right hand thread jam nut 3 1 2 inch 12 7 mm away from the turnbuckle 2 Figure 6 25 6 Remove the turnbuckle from the brake actuator rod 4 7 Lift the brake actuator rod and equalizer bracket 5 8 Remove the brake cables 6 from the equalizer bracket 2 3 1 6 4 636C Figure 6 25 Remove Turnbuckle 9 Remove the nut 7 Figur...

Page 120: ...tool to compress the retaining clips 10 on the end of the cable housing enough to slide the cable end out of the hole in the frame Figure 6 27 650D Figure 6 27 Retaining clips 12 Remove and discard the bow tie locking pin 11 Figure 6 28 Page 6 18 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 121: ...ch wheel and pull the clevis 13 away from the lever 14 Discard the clevis pin 15 Use a brake cable release tool to compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket 14 and remove the brake cable from the vehicle 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 6 19 ...

Page 122: ...sert the end of the new brake cable through the hole in the frame Figure 6 29 Push on the cable housing so the clips on the housing ends secure the housing in the hole 650C Figure 6 29 Cable Through Frame 2 Hold the brake actuator rod 1 and the equalizer bracket 2 in the upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position t...

Page 123: ...new clevis pin 4 and new bow tie locking pin 5 5 4 3 651B Figure 6 31 Connect Cables at Rear Brakes 5 Place the tab 6 on cable housing over the forward leaf spring mounting bolt 7 Figure 6 32 8 7 6 652B Figure 6 32 Brake Cable Mounting Tab 6 Install the nut 8 Tighten the nut to 18 4 lb ft 25 N m 7 Adjust the brake cable equalizer 8 Electric Vehicle Connect the batteries Gasoline Vehicle Connect th...

Page 124: ...Pagination Page 6 Brake Cable WHEEL BRAKE ASSEMBLIES Page 6 22 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 125: ...ting mechanism is incorporated into the assembly STEERING WHEEL STEERING WHEEL REMOVAL Special Tools Needed _ Steering Wheel Puller Tool NOTE Refer to the Illustrated Parts Catalog for service tool part numbers 1 Disable the vehicle 2 Electric Vehicle Disconnect the batteries and discharge the controller Gasoline Vehicle Disconnect battery and spark plug wire 3 Rotate steering wheel to a straight ...

Page 126: ...il the base plate contacts the bottom of the steering wheel at the steering column 8 Figure 7 2 8 7 2520B Figure 7 2 Steering Wheel Puller 10 Use a 1 2 inch drive air impact wrench to tighten the anvil screw until the steering wheel releases from the steering shaft 11 Remove the steering wheel from the steering column STEERING WHEEL INSTALLATION 1 Apply a small amount of oil or anti seize compound...

Page 127: ...eering Wheel Installation 3 Install steering wheel retaining bolt 3 Tighten the bolt to 37 lb ft 50 N m 4 Put the cover 4 on the steering wheel 5 Install the screws 5 Tighten the screws to 15 lb in 1 7 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 7 3 ...

Page 128: ...onnect the batteries and discharge the controller Gasoline Vehicle Disconnect battery and spark plug wire 3 Remove the steering wheel 4 Remove the dash insert instrument panel dash assembly and front bumper 5 Remove the bolt 1 Figure 7 4 6 Remove the bolts 2 7 Remove the steering column 3 from the vehicle Page 7 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 129: ...he bolt 4 Install the steering column mounting bracket 4 on the vehicle frame 5 Install the bolts 5 Tighten the bolts to 18 4 lb ft 25 N m 6 Tighten the bolt 3 to 18 4 lb ft 25 N m 7 Make sure that the upper universal joint bolt 6 is tighten to 18 4 lb ft 25 N m 8 Install front bumper dash assembly dash insert and instrument panel 9 Install the steering wheel 10 Electric Vehicle Connect the batter...

Page 130: ...stem fully assembled and all four tires on the ground floor turn the steering wheel from stop to stop While turning feel for any binding clunking or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found 4 In the event of an known impact and obvious visible damage is not found in the method described above disconnect the tie rods and or drag links fr...

Page 131: ...Apply a light coat of anti seize lubricating compound to the pinion shaft 7 Figure 7 7 2 Install the universal joint 6 onto the pinion shaft 3 Install the screws 4 Tighten the screws to 22 lb ft 30 N m 4 Install the bolt 5 Tighten the bolt to 18 4 lb ft 25 N m 5 Install the tie rod ends 2 into the spindle tabs 3 6 Install the retaining nuts 1 WARNING Do not operate vehicle until toe in is adjusted...

Page 132: ...7 Rack and Pinion STEERING AND FRONT SUSPENSION 9 Test drive the vehicle before returning it to service Page 7 8 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 133: ...ngs on page 1 2 WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe in of the front wheels CAUTION Prior to making any front suspension adjustments inspect components for wear or damage and repair or replace as necessary Camber Adjustment 1 Park the vehicle on a solid level surface 2 Check each front wheel with a framing square At the flo...

Page 134: ...10 lb ft 13 5 N m Toe in Adjustment 1 Park the vehicle on a solid level surface 2 Roll the vehicle forward then stop the vehicle 3 Make sure the front wheels are pointed straight ahead CAUTION Do not turn the steering wheel again during this procedure 4 On each front tire mark as closely as possible the center of the tread face that is toward the rear of the vehicle The marks should be even with t...

Page 135: ...cessary 9 1 Loosen the jam nuts on both ends of each drag link Figure 7 11 2376 Figure 7 11 Loosen Jam Nuts 9 2 To increase the toe in rotate both drag links equally counterclockwise 9 3 To decrease the toe in rotate both drag links equally clockwise 9 4 Maintain an equal distance from the ball joint to the end of the threads on each drag link Figure 7 12 2064 Figure 7 12 Adjust Both Drag Links To...

Page 136: ...gure 7 13 1 4 3 2 1311B Figure 7 13 Tie Rod End Removal 4 Remove the retaining nuts 2 5 Lift the tie rod 3 from the hole in the spindle tab 6 Remove the tie rod ends from the drag link 7 Apply a light coat of anti seize lubricating compound to the threads 4 TIE ROD INSTALLATION 1 Install tie rod ends 3 onto the drag link 4 to a depth of 1 2 inch 12 5 mm Figure 7 14 WARNING The tie rod ends must be...

Page 137: ...Adjust the wheel toe in 5 Electric Vehicle Connect the batteries Gasoline Vehicle Connect the battery and spark plug wire LEAF SPRING REMOVAL 1 Disable the vehicle 2 Electric Vehicle Disconnect the batteries and discharge the controller Gasoline Vehicle Disconnect the battery and spark plug wire 3 Remove the front wheels 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 7 13 ...

Page 138: ...all the urethane bushings 6 and steel sleeves 7 into leaf spring eyes Figure 7 16 2 1 5 7 6 4 3 1312B Figure 7 16 Leaf Spring Installation 2 Install the leaf spring 5 bottom spring plate 4 and four bolts 3 Tighten the bolts in a crisscross pattern to 37 lb ft 50 N m 3 Install the kingpins 2 on the leaf spring with the bolts 1 Tighten the bolts to 30 lb ft 41 N m 4 Install the front wheels 5 Adjust...

Page 139: ...e tabs 4 on the spindles 7 Remove the nut 5 from the top of the kingpin 6 8 Raise the upper clevis from the kingpin 9 Slide the spindle 7 off the kingpin 10 Remove the wave washer 8 11 Inspect the wave washer 11 1 If the wave washer is broken replace the washer 11 2 If the wave washer bottom to crest height dimension is less than 0 040 inch 1 mm replace the washer 12 Remove the bolt 9 and the king...

Page 140: ... and Steering Spindle Installation 3 Install the bolts 2 Tighten the bolt to 30 lb ft 41 N m 4 Install the wave washers 3 on the kingpin 5 Install the steering spindles 4 on the kingpins 6 Put the upper clevis over the kingpin threads and install nuts 5 Tighten the nuts to 70 lb ft 95 N m 7 Install the tie rod ends 6 to the spindle tabs 7 8 Install the nuts 8 Tighten the nuts to 70 lb ft 95 N m 9 ...

Page 141: ...Vehicle Disconnect the battery and spark plug wire 3 Remove the front wheels 4 Remove the bolts 1 5 Move the rack and pinion 2 to allow clearance for the control arm bolts Figure 7 19 1 2 1383C Figure 7 19 Move Rack and Pinion 6 Remove the bolts 3 and 4 Figure 7 20 3 4 1312E Figure 7 20 Control Arm Bolt Removal 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 7 17 ...

Page 142: ...t the bushings 6 and sleeves 7 and 8 in the control arm Replace as necessary CONTROL ARM INSTALLATION 1 Put the control arm into position on the vehicle 2 Install the bolts 1 and 2 Figure 7 22 Tighten the bolts to 30 lb ft 41 N m 1 2 1312F Figure 7 22 Control Arm Bolt Installation Page 7 18 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 143: ...heels 5 Adjust the camber and toe in 6 Electric Vehicle Connect the batteries Gasoline Vehicle Connect the battery and spark plug wire FRONT SHOCK ABSORBER INSPECTION 1 Examine the area 1 where the shaft enters the shock absorber body Figure 7 24 1 1 If there is fluid leakage replace the shock absorber 1 1311D Figure 7 24 Shock Absorber Inspection 2020 Precedent Villager 2 and 4 Maintenance and Se...

Page 144: ...soline Vehicle Disconnect the battery and spark plug wire 3 Remove the upper bolt 1 Figure 7 25 1 2 3 1312G Figure 7 25 Shock Absorber Removal 4 Remove the lower bolt 2 5 Remove the shock absorber 3 FRONT SHOCK ABSORBER INSTALLATION 1 Make sure that the front shock absorbers 3 have the same part number Figure 7 26 Page 7 20 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 145: ...ck Absorber Installation 2 Install the shock absorber 3 Install the bolts 1 and 2 Tighten the bolts to 16 lb ft 21 N m 4 Electric Vehicle Connect the batteries Gasoline Vehicle Connect the battery and spark plug wire 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 7 21 ...

Page 146: ...he spindle 5 If the wheel and hub move on the spindle replace the hub assembly FRONT WHEEL HUB REMOVAL 1 Disable the vehicle 2 Set the Run Tow Stow switch to TOW STOW 3 Remove the high voltage interlock fuse See Remove The High Voltage Interlock Fuse 4 Remove the front wheels 5 Remove the dust cap 1 Figure 7 27 4 2 3 1 678B Figure 7 27 Front Wheel Hub Removal 6 Remove and discard the lock nut 2 7 ...

Page 147: ...ndle shaft 3 Install the hub assembly 3 onto the spindle shaft 4 Install the new lock nut 2 Tighten the lock nut to 50 lb ft 68 N m 5 Rotate the hub The hub should rotate smoothly without binding side play or any indication of rough spots 6 Install the dust cap 1 7 Install the front wheels 8 Electric Vehicle Connect the batteries Gasoline Vehicle Connect the battery and spark plug wire 2020 Preced...

Page 148: ...Pagination Page 7 Front Wheel Hubs STEERING AND FRONT SUSPENSION Page 7 24 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 149: ... 1 4 Gasoline Vehicle Disconnect battery and spark plug wire s See Disconnect the Battery Gasoline Vehicles on page 1 3 2 Slightly loosen the lug nuts on the wheel to be removed 3 Raise the end of the vehicle from which the wheel is to be removed Make sure that the wheels are off the ground See General Warnings on page 1 2 4 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install whe...

Page 150: ... use excessive force when starting the bead over the edge of the rim 4 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 5 Once the lower bead is started over the rim flange the tire can be removed f...

Page 151: ...beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats 6 Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 to 35 psig 207 to 242 kPa The thr...

Page 152: ...8 Tires WHEELS AND TIRES 680 Figure 8 2 Inflate Tire Page 8 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 153: ...by two shock absorbers mounted between the springs and the vehicle frame SHOCK ABSORBERS The following procedures are the same for all vehicles REAR SHOCK ABSORBER INSPECTION Examine the area 1 where the shaft enters the shock absorber body Figure 9 1 Page 9 1 1 If there is fluid leakage replace the shock absorber Figure 9 1 Rear Shock Absorber Inspection 2020 Precedent Villager 2 and 4 Maintenanc...

Page 154: ... the controller Gasoline Vehicle Disconnect battery and spark plug wire 3 Remove the nut 1 cup washer 2 and rubber bushing 3 from the top of the shock absorber Figure 9 2 Page 9 2 4 Remove the nut 4 cup washer 5 and rubber bushing 6 from bottom of the shock absorber 5 Compress and remove the shock absorber 7 Page 9 2 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 155: ...ll the top stem of the shock absorber into the frame shock mount 5 4 Install the rubber bushing 6 cup washer 7 and nut 8 onto the top of the shock absorber 5 Install the rubber bushing 9 cup washer 10 and nut 11 onto the top of the shock absorber 6 Tighten the nuts until the rubber bushings expand to the size of the cup washer 7 Electric Vehicle Connect the batteries Gasoline Vehicle Connect batte...

Page 156: ...e the panhard 2 5 Remove the bolts 3 and nuts 4 6 Remove the bracket 5 PANHARD AND BRACKET INSTALLATION 1 Put the bracket 5 into position on the frame Figure 9 4 Page 9 4 2 Install the bolts 3 and nuts 4 Tighten the bolts to 18 5 lb ft 25 N m 3 Put the panhard 2 into position on the vehicle 4 Install the bolts 1 Tighten the bolts to 92 lb ft 125 N m 5 Electric Vehicle Connect the batteries Gasolin...

Page 157: ... brakes 1 Disable the vehicle 2 Electric Vehicle Disconnect the batteries and discharge the controller Gasoline Vehicle Disconnect the battery and spark plug wire 3 Lift the rear of the vehicle 4 Put a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them 5 Remove the tire an...

Page 158: ... the spring to the transaxle 11 Remove the shock mount bracket 10 and the U bolt 12 Remove the nut 11 and bolt 12 from the rear of the leaf spring 13 13 Remove the nut 14 and bolt 15 from the front of the leaf spring and remove the leaf spring 14 Examine the bushings 16 and sleeves 17 in the spring eyes 14 1 If the bushings or sleeves are worn or have damage replace them Page 9 6 2020 Precedent Vi...

Page 159: ...stall the bolt 2 and nut 3 Tighten the nut to 18 5 lb ft 25 N m 3 Install the rear of the leaf spring onto the shackle 4 Install the bolt 4 and nut 5 Tighten the nut to 18 5 lb ft 25 N m 5 Install the shock mount bracket 6 U bolt 7 and nuts 8 Tighten the nuts to 25 lb ft 34 N m 6 Install the bottom stem of the shock absorber into the shock mount bracket 7 Install the rubber bushing 9 cup washer 10...

Page 160: ...minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 1 Disable the vehicle 2 Electric Vehicle Disconnect the batteries and discharge the controlle...

Page 161: ... and rubber bushing 7 from the bottom stem of the shock absorber Figure 9 10 Page 9 9 Figure 9 10 Leaf Spring Removal Four Passenger 10 Remove the nuts 8 and the U bolt 9 securing the spring to the transaxle 11 Remove the shock mount bracket 10 jounce bumper 11 and the U bolt 12 Remove the nut 12 and bolt 13 from the rear of the leaf spring 14 2020 Precedent Villager 2 and 4 Maintenance and Servic...

Page 162: ...9 11 Page 9 10 Figure 9 11 Leaf Spring Installation Four Passenger 2 Install the bolts 2 and nut 3 Tighten the nut to 18 5 lb ft 25 N m 3 Install the rear of the leaf spring onto the shackle 4 Install the bolt 4 and nut 5 Tighten the nut to 18 5 lb ft 25 N m 5 Install the shock mount bracket 6 jounce bumper 7 U bolts 8 and nuts 9 Tighten the nuts to 45 lb ft 60 N m 6 Install the bottom stem of the...

Page 163: ...ting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 1 Disable the vehicle 2 Electric Vehicle Disconnect the batteries and discharge the controller Gasoline ...

Page 164: ...om the lower mounting stem of the shock absorber Figure 9 14 Figure 9 14 Leaf Spring Removal Four Passenger Heavy Duty With Panhard 10 Remove the nuts 8 U bolts 9 and shock mount bracket 11 11 Remove the bolt 12 and nut 13 attaching the rear of the 10 leaf spring to the shackle 12 Remove the nut 14 and bolt 15 attaching the front of the leaf spring to the vehicle frame and remove the spring Page 9...

Page 165: ...Figure 9 15 Figure 9 15 Leaf Spring Installation Four Passenger Heavy Duty With Panhard 2 Install the bolt 2 and nut 3 Tighten the nut to 18 5 lb ft 25 N m 3 Install the rear of the leaf spring onto the shackle 4 Install the bolt 4 and nut 5 Tighten the nut to 18 5 lb ft 25 N m 5 Install the shock mount bracket 6 U bolts 7 and nuts 8 Tighten the nuts to 45 lb ft 60 N m 6 Install the bottom stem of...

Page 166: ...ble end 13 onto the brake lever 10 Install the clevis pin 14 and the bow tie locking pin 15 11 Lower and remove the floor jack under the transaxle 12 Install the tire and wheel assembly 13 Lower the rear of the vehicle 14 Electric Vehicle Connect the batteries Gasoline Vehicle Connect the battery and spark plug wire Page 9 14 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 167: ...b Car distributor dealer or a trained technician Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions All Vehicles General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Safety and informatio...

Page 168: ...nce Have a Club Car distributor dealer or a trained technician investigate anything unusual Electric Vehicles Accelerator With the key switch in the ON position and the Forward Neutral Reverse switch in the FORWARD position as the accelerator pedal is pressed the motor should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original ...

Page 169: ...from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic service WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make ...

Page 170: ...lowed to keep vehicle in optimum operating condition _ PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Pre Operation and Daily Safety Checklist See Pre Operation and Daily Safety Checklist on page 10 1 Performance Inspection See Performance Inspection on page 10 2 Daily service by owner Batteries Charge batteries after each daily use only Weekly service by owner Batteries For ...

Page 171: ... or 100 rounds of golf Front wheel alignment and camber Check and adjust as required See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Batteries For vehicles equipped with the Single Point Watering System Manually check battery electrolyte levels of all cells to verify correct valve operation See page Annual service by owner or trained technician every 1...

Page 172: ...d technician General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Battery Clean terminals and wash dirt from casing Apply Battery Terminal Protector Spray to battery terminals Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and conne...

Page 173: ...heck hose for cracks Pedal group Lubricate all rotating joints See Periodic Lubrication Schedules on page 10 8 General vehicle Check for loose hardware tighten if necessary Refer to the appropriate maintenance and service manual Annual service by trained technician only every 100 hours of operation or every 200 rounds of golf Safety decals Check safety decals Replace if damaged or illegible Two ye...

Page 174: ...iannually by owner or trained technician every 50 hours of operation or 100 rounds of golf Front suspension two fittings Chassis Lube EP NLGI Grade 2 Check fill transaxle to plug level 22 fl oz 0 67 L SAE 30 WT API Class SE SF or SG Oil or higher Annually by trained technician only every 100 hours of operation or 200 rounds of golf Pedal group as required Dupont Performance Dry Multi Use Lubricant...

Page 175: ...Front suspension two fittings Chassis Lube EP NLGI Grade 2 Transaxle Check fill to plug level 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Annually by trained technician only every 100 hours of operation or every 200 rounds of golf Pedal group as required Dupont Performance Dry Multi Use Lubricant First change 100 hours additional change every 200 hours of operation or annually whichever comes first C...

Page 176: ...e air cleaner cover 2 3 Remove the air filter 3 AIR FILTER INSTALLATION 1 Use a wet lint free cloth to clean the inside of the air filter container 2 Install the air filter 3 Figure 10 3 Page 10 10 3 Install the air cleaner cover 2 4 Engage the latch 1 ENGINE OIL ENGINE OIL VISCOSITY Select the engine oil viscosity for your environmental conditions Page 10 10 2020 Precedent Villager 2 and 4 Mainte...

Page 177: ...Figure 10 5 Page 10 11 Figure 10 5 Dipstick 2 Make sure that there is oil on the dipstick 3 Install the dipstick 4 Start and operate the engine for three minutes If the low oil warning light stays on turn off the engine immediately 5 Turn off the engine 6 Wait two minutes 7 Remove and clean the dipstick 8 Install the dipstick 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 10 1...

Page 178: ...e ENGINE OIL REPLACEMENT CAUTION Hot engine oil will cause skin burns Do not change the engine oil when the engine is hot Let the engine temperature decrease before the oil is changed CAUTION Too much engine oil can decrease engine performance and damage the engine Do not exceed the recommended engine oil capacity Before the engine oil is replaced Disable the vehicle Disconnect the battery To repl...

Page 179: ... Drain Plug 3 Put a drain pan below the oil drain plug 4 Remove the oil drain plug 5 Drain the oil fully 6 Clean the oil drain plug 7 Examine the gasket on the oil drain plug for damage Replace if necessary 8 Install the oil drain plug and tighten to 13 lb ft 18 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 10 13 ...

Page 180: ...ADD ENGINE OIL CAUTION Do not remove the dipstick while the engine is on CAUTION Too much engine oil can decrease engine performance and damage the engine Do not exceed the recommended engine oil capacity Before engine oil is added Disable the vehicle To add engine oil 1 Remove the dipstick 1 Figure 10 7 Page 10 13 Page 10 14 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 181: ...Dipstick 2 Add engine oil until the oil level is between the maximum 1 and minimum 2 indicators Figure 10 11 Page 10 15 Figure 10 11 Dipstick Indicators 3 Install the dipstick 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 10 15 ...

Page 182: ...Pagination Page 10 Engine Oil PERIODIC MAINTENANCE Page 10 16 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 183: ...e CDT to troubleshoot the vehicle and to adjust controller parameters that affect vehicle behavior The Excel controller with OS version 34 or version 35 The OS version can be viewed in the System Info menu of the CDT See System Info on page 11 5 1 7 8 3 4 5 6 12 2 11 10 9 1 Display Screen 5 Help Button 9 Favorites Button 2 Softkeys 6 Main Menu Button 10 Power Button 3 Key 7 System Port 11 Arrow Ke...

Page 184: ...lt are also provided Help function Help screens give descriptions of adjustable parameters monitored variables and faults PC interface Files can be downloaded from a PC onto an Secure Digital SD card or into the programmer directly through its USB connector for installation into the controller Plot and Log The plot and log programs allow you to look at variables over time either in graphical forma...

Page 185: ...mediately after the CDT is connected to the vehicle it begins loading controller information During this time the loading status is shown as a percentage the CDT s software version is given and status information icons appear in the upper right corner Once loading is complete the screen displays the Main Menu NOTE If the Power button is used to turn ON the handset and the handset is not connected ...

Page 186: ...rror Lockout Fault This is a symptom not a cause Inspect and test the charger interlock circuit If no problems are found in the charger interlock circuit replace the controller Overvoltage Controller reads 72 volts or more it s a symptom not a cause See other faults that accompany OV Low Battery Voltage Check Battery Voltage Under a Load less than 34 volts could be a symptom not a cause Speed Sens...

Page 187: ...ee following NOTE NOTE This manual covers hardware version 5 PROTOCOL VERSION Displays the controller protocol version PARAM BLOCK VERSION Displays a number that represents the default parameter settings at time of manufacture MFG DATE CODE Displays the date the controller was manufactured OS VERSION Displays the controller operating system software version See following NOTE NOTE This manual span...

Page 188: ...ting of 4 cannot be selected with the speed setting menu item For additional information on speed setting 4 refer to Code A Code B and Code C See Code A Code B and Code C on page 11 8 _ SPEED SETTING DESCRIPTION VEHICLE SPEED 1 Commercial speed 8 0 mph 12 9 km h 2 Slow golf speed 11 4 mph 18 3 km h 3 Normal golf speed Typical 14 8 mph 23 8 km h See S3 FWD Speed on page 11 7 4 Private speed mode 19...

Page 189: ...d 23 8 km h respectively The default s3 fwd speed is 14 8 mph 23 8 km h The s3 fwd speed may be adjusted with the handset from 11 4 to 14 8 mph 18 3 to 23 8 km h in 0 1 mph 0 16 km h increments The speed value chosen for s3 fwd speed may also be observed in the monitor menu See Vehicle Speeds on page 11 13 To fine tune vehicle top speed in normal golf speed range 12 4 to 14 8 mph 20 0 to 23 8 km h...

Page 190: ...more aggressive braking action WalkAway Deterrent The walkaway deterrent menu item allows the user to turn this function ON or OFF Walkaway deterrent is triggered by the High Speed WalkAway fault With it ON the reverse buzzer will sound immediately upon the key switch being turned OFF at speeds above 2 mph With it OFF the buzzer will cycle on and off at a higher frequency 7 5 Hz vs 2 5 Hz Battery ...

Page 191: ...O 67 C 80 P 68 D 81 Q 69 E 82 R 70 F 83 S 71 G 84 T 72 H 85 U 73 I 86 V 74 J 87 W 75 K 88 X 76 L 89 Y 77 M 90 Z Vehicle Date of Manufacture Four digit number programmed by vehicle manufacturer Example 1401 represents Model Year 2014 week 1 Vehicle S N Six digit number programmed by vehicle manufacturer Vehicle Decal Decal number ranging from 0 to 999 and programmed by vehicle manufacturer MONITOR ...

Page 192: ... or the current being returned to the batteries during regenerative motor braking It has a range from negative 300 amps to positive 300 amps BDI PERCENT Battery Discharge Indicator BDI Percent displays the current battery state of charge as a percent It is based on several parameters monitored by the controller SPEED Vehicle speed in mph THROTTLE Indicates the position of the accelerator pedal fro...

Page 193: ...he Forward Reverse switch in the NEUTRAL or REVERSE position the handset should indicate that the forward input is off When the Forward Reverse switch is placed in the FORWARD position the handset should indicate that the forward input is on REVERSE INPUT With the Forward Reverse switch in the NEUTRAL or FORWARD position the handset should indicate that the reverse input is off When the Forward Re...

Page 194: ...o adjusting correction factor for estimating state of charge based upon the difference between the currently estimated state of charge and the Load Line SOC Open Circuit Voltage Start Open Circuit Voltage Start is the voltage as determined by the controller following a cycle of the Run Tow switch or coming out of sleep mode Open Circuit SOC Start Open Circuit SOC Start is the estimated state of ch...

Page 195: ... amp hours removed from batteries since trip amp hours was reset See Reset Trip Amp Hours on page 11 8 Trip Regen Amp Hours Displays amp hours returned to the batteries from regenerative braking since trip amp hours was reset LIN Relates to communication between the controller and the Guardian Visage device if equipped Charger Additional VEHICLE SPEEDS Press right arrow to display programmed speed...

Page 196: ...s or locations where a problem with vehicle performance has been reported See following WARNING WARNING The vehicle operator should not monitor the handset while the vehicle is in motion A technician can monitor the handset while traveling as a passenger in the vehicle Failure to heed this warning could result in severe personal injury or death PRESENT ERRORS FOLDER The Fault History folder displa...

Page 197: ...is detected the controller responds to the fault by limiting the vehicle speed to 1 2 of its normal top speed If the technician reaches the conclusion that the vehicle is running slowly because batteries are heavily discharged he has made an improper diagnosis of the problem The controller should be checked for fault codes before any service is performed After detecting a fault the controller will...

Page 198: ... a stop OVERVOLTAGE A B G Vehicle slows and beeps LOW BATTERY VOLTAGE E Top speed is reduced THERMAL CUTBACK E Top speed is reduced MOTOR STALL J None MAIN DROPOUT 1 and 2 A C Vehicle comes to a stop MAX PASSWORD TRIES L Vehicle continues to only reach a top speed determined by the Speed Setting INCORRECT PASSWORD J None MAIN DRIVER OVERCURRENT A B Vehicle comes to a stop CURRENT SENSE FAULT A B C...

Page 199: ...ondition clears SPEED SENSOR When condition clears MAIN WELDED When condition clears MAIN DRIVER ON When condition clears MAIN DRIVER OFF When accel pedal is cycled MAIN COIL OPEN When accel pedal is cycled FIELD MISSING When accel pedal is cycled HPD When accel pedal is cycled OVERVOLTAGE When condition clears LOW BATTERY VOLTAGE When condition clears THERMAL CUTBACK When condition clears MOTOR S...

Page 200: ...t What it means If the voltage seen by the controller coming out of the MCOR is not within specified limits this fault occurs and the controller de energizes the solenoid coil Perform additional diagnostic if vehicle is running What to do Replace MCOR See following NOTE NOTE Newer controllers may infrequently read voltages above or below limits and give a false fault LOW BATTERY VOLTAGE UNDERVOLTA...

Page 201: ...s switched on This is a safety control and the controller must see the pedal engaged last in the following sequence key switch first FNR second and then pedal last What to do Check throttle percentage and if at 0 issue is driver error MAIN DRVR OVERCURRENT If the current on the relay driver exceeds 120 mA or the current on the solenoid driver exceeds 6 A a main driver overcurrent fault is detected...

Page 202: ...o the motor a speed sensor fault is detected What it means Speed sensor is not working Check connection What to do Replace speed sensor MAIN DRIVER ON If the field effect transistor FET that controls the closing of the solenoid contacts is found to be energized when it should not be a main driver on fault is detected by the speed controller What it means The controller FET controlling the energizi...

Page 203: ...s registered What to do In most cases this is an operator issue holding the vehicle on an incline with the accelerator pedal not the brake pedal See following NOTE NOTE In rare cases it could be a controller or drivetrain issue If the vehicle rolls the drivetrain is okay Check to see if Armature Current spikes to 250 amps when accelerator pedal is pressed If so replace controller MAIN DRIVER OFF I...

Page 204: ...s in the fault history menu the trained technician should attempt to determine when and where the fault has occurred For example if the motor stall fault is present in the fault history the trained technician may be able to determine the location on the course where an operator has held the vehicle on a hill by using the accelerator pedal CLEAR FAULT HISTORY After a repair has been made the fault ...

Page 205: ...dd a ready made folder from the Parameters or Monitor menu the folder icon will appear in the Favorites menu with a star on it Although you can rename a ready made folder you are not allowed to rename any of the items within that folder You can also create folders of your own to hold specific sets of items these folders will be indicated with the usual folder icon You may want to create a folder f...

Page 206: ... Yes Text for save as When you create a new cpf file the field at the top of the keyboard screen is either blank No text or is automatically filled with the date and time in this format YYYY_MM_DD_HHMM Date Time Keyboard help text When set to On every time you enter the keyboard screen a pop up explains how to use the keyboard When set to Off no pop up appears as you enter the keyboard screen but ...

Page 207: ...ors for specific variables use the Move Down and Move Up softkeys to achieve the desired combinations Use the left arrow key to return to the Plot Log menu To open the plotting program highlight Plot and press the right arrow key The vertical axis is always used for the variables being plotted and the horizontal axis is always used for time For On Off items On 1 and Off 0 on the plot Press the Sta...

Page 208: ...t under HHP Settings menu Controller is in power down mode vehicle unused and not charged for 72 hours Connect charger or drive the vehicle a short distance and reconnect the handset to the vehicle Charger has been connected and charging for more than 10 minutes Disconnect charger wait 30 seconds and reconnect charger Loose vehicle wire harness connections Test Procedure 3 CDT Ports on page 11 28 ...

Page 209: ...uld result in vehicle malfunction property damage personal injury or death Index of Test Procedures 1 Handset Cord 2 Handset Cord Adaptor 3 CDT Ports TEST PROCEDURE 1 Handset Cord See General Warnings on page 1 2 1 Using a multimeter set for 200 ohms place the red probe into one of the terminals on the end of the cord with the square plug 2 Place the black probe on each of the pins one at a time o...

Page 210: ...Warnings on page 1 2 3 Check the CDT port mounted under the instrument panel 3 1 Remove the three screws 1 that secure the instrument panel assembly 2 to the dash assembly 3 Figure 11 3 Page 11 28 3 1 2 4 5 700 Figure 11 3 Instrument Panel Assembly Removal and CDT Port Connection 3 2 Disconnect the four pin connectors 4 and 5 and visually inspect the contacts for damage and corrosion Inspect the C...

Page 211: ...he vehicle batteries positive cable first 4 3 5 If the handset functions when connected directly to the controller the adapter plug or vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cord Adaptor on page 11 27 Section 12 Electric Vehicle Troubleshooting and Electrical System 4 4 Replace electronics module cover See Speed Controller Installation Section 13 Page 13 12 4...

Page 212: ...Pagination Page 11 Connection Tests CONTROLLER DIAGNOSTIC TOOL CDT Page 11 30 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 213: ...HT Excel vehicles with ERIC Charging system feature a dash mounted charge indicator light below the steering column that serves two functions 1 Battery low state of charge warning and 2 Charging confirmation The charge indicator light is controlled by pin 11 of the controller Battery Low State of Charge Warning The light comes on and remains solid when the battery state of charge falls below 20 Th...

Page 214: ... charge cycle begins and when the battery pack has reached a low state of charge New instrument panel wire harness not compatible with vehicles using PowerDrive chargers A new controller is used that has data collecting functions previously performed by the OBC Pin 11 in the 16 pin connector is now utilized to operate the charge indicator light in the instrument panel In addition the controller ha...

Page 215: ...le motor acts as a generator slowing the vehicle as it creates energy that is used to charge the batteries Tow Run Switch When the Tow Run switch is in the RUN position the vehicle will function normally When the switch is in the TOW position power to the controller is shut off disabling the vehicle operating circuit and walk away braking allowing the vehicle to be towed Motor Protection Circuit T...

Page 216: ...gram ELECTRIC VEHICLE TROUBLESHOOTING AND ELECTRICAL SYSTEM BATTERY WIRING DIAGRAM WD_6x8V_Batteries_ERIC_Charging Figure 12 1 Battery Wiring Diagram Page 12 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 217: ... SYSTEM Sonic Weld Fuse and 10k Ohm Resistor Locations 12 SONIC WELD FUSE AND 10K OHM RESISTOR LOCATIONS 2783 Figure 12 2 Sonic Weld and 10k Ohm Resistor Locations Approximate 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 12 5 ...

Page 218: ...et is unavailable the technician should proceed to Troubleshooting Guide 2 TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an CDT handset See following NOTE NOTE Before troubleshooting the vehicle check the diagnostic history from the Special Diagnostics Menu Note any fault codes _ TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disco...

Page 219: ...r disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Monitor Menu FORWARD INPUT and or REVERSE INPUT does not indicate the correct reading Failed Forward Reverse rocker switch Test Procedure 6 Forward Reverse Rocker Switch on page 12 18 Speed controller logic malfunction Disconnect the batteries and allow the speed co...

Page 220: ...page 1 2 Reconnect the batteries and see if the symptom returns Diagnostic Menu MAIN DRIVER ON or MAIN DRIVER OFF fault code Failure of the FET that controls the solenoid coil Replace the speed controller See Speed Controller Removal on page 13 12 Diagnostic Menu MAIN COIL FAULT fault code or Diagnostic Menu MAIN DROPOUT 1 or 2 fault code Solenoid coil has failed in an open condition Replace solen...

Page 221: ...BLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1 use Troubleshooting Guide 2 If an CDT handset is unavailable use Troubleshooting Guide 2 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 12 9 ...

Page 222: ...rocker switch Test Procedure 6 Forward Reverse Rocker Switch on page 12 18 Solenoid loose wires Test Procedure 7 Solenoid Activating Coil on page 12 20 Solenoid failed coil Test Procedure 7 Solenoid Activating Coil on page 12 20 Speed controller thermal cutback Allow controller to cool and ensure that vehicle is not over loaded before returning to operation 16 pin connector at speed controller Che...

Page 223: ...here it does not maintain speed nor accelerate MCOR malfunction Test Procedure 11 MCOR Voltage on page 12 23 Vehicle reaches top speed before 100 pedal travel is reached Speed controller failed throttle resistor s Replace speed controller See Speed Controller Removal on page 13 12 Wiring improperly wired Check vehicle wiring Vehicle operates but motor braking function does not Speed sensor disconn...

Page 224: ...ehicle without the cover properly installed Do not direct a water stream in area of the cover TESTING BASICS To use the CDT the Tow Run switch must be in the RUN position The Tow Run switch provides power to the logic board and power board inside the controller Battery Pack Voltage BPV will be referenced throughout the test procedures BPV is accessed in Test Procedure 1 Batteries Voltage Check BPV...

Page 225: ...x of Test Procedures 1 Batteries Voltage Check BPV 2 48 Volt Battery Pack Voltage Under Load 3 Tow Run Switch 4 15 Amp Fuse 5 Key Switch and MCOR Limit Switch Circuit 6 Forward Reverse Rocker Switch 7 Solenoid Activating Coil 8 Pre Charge Resistor 9 Solenoid Continuity 10 Charger Interlock 11 MCOR Voltage 12 Motor Speed Sensor 13 A1 and A2 Motor Voltage 14 Voltage at Charger Receptacle Red Wire So...

Page 226: ... red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 6 Figure 12 3 Page 12 14 3 The multimeter should indicate at least 48 volts If not check for loose battery connections or a battery installed in reverse polarity Refer to Electric Vehicle Batteries on page 14 1 for further details on battery testing 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500...

Page 227: ...eading while under load provides a more accurate diagnosis of the condition of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if one or more batteries in the set have failed Testing battery voltage while the batteries are not under load will not always indicate the true condition of the batteries For more information about the...

Page 228: ...g Basics on page 12 12 2 Access the Tow Run switch but do not disconnect wires 3 With the Tow Run switch in the RUN position 3 1 The pink wire should show BPV coming to the switch 3 2 The light green wire should also show BPV If it shows less than 5 volts the switch has failed OPEN and must be replaced 4 With the Tow Run switch in the TOW position 4 1 The light green wire should show less than 5 v...

Page 229: ...to the following procedure Key Switch and MCOR Limit Switch Circuit Test without the CDT Handset If the key switch functions as described proceed to the following step See following NOTE NOTE The key switch MUST function properly in order to test the MCOR limit switch with the CDT handset 5 Test the MCOR limit switch 5 1 Select FOOT INPUT on the Monitor menu by using the SCROLL DISPLAY buttons on ...

Page 230: ...OT INPUT Remove floormat and cover plate to access the MCOR See Pedal Group Removal on page 5 4 6 1 With the key switch in the ON position With an insulation piercing probe check voltage of the blue wire in the MCOR 2 pin connector It should show BPV coming to the MCOR If not check wiring With an insulation piercing probe check voltage of the green wire in the MCOR 2 pin connector It should show z...

Page 231: ...Forward Reverse switch in each position 4 1 Orange Wire The orange wire provides power to the switch and should show BPV coming to the switch in all three positions If the orange wire does not show BPV check the 15 amp fuse Tow Run switch red to pink wire spade terminal connection and related wiring 4 2 Brown Wire The brown wire should show BPV in FORWARD The brown wire should show zero 0 volts in...

Page 232: ... factory installed solenoids Figure 12 6 Page 12 20 If not replace the solenoid A reading of 180 to 190 ohms should be obtained for service replacement solenoids Figure 12 7 Page 12 20 If not replace the solenoid 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k ...

Page 233: ...nd lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 2 3 Disconnect the batteries and discharge the controller See Disconnect the Batteries Electric Vehicles on page 1 4 4 Disconnect the 6 gauge yellow wire and pre charge resistor from large post of s...

Page 234: ...the circuit once the DC cord plug is inserted into the charger receptacle 1 With batteries connected place the Tow Run switch in the RUN position 2 Remove electronics module cover See Electronics Module Cover Removal Section 13 Page 13 6 3 Check 15 amp fuse See Test Procedure 4 15 Amp Fuse on page 12 16 4 Check power Using a multimeter set to 200 volts DC place red probe with insulation piercing p...

Page 235: ... following WARNING WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 Connect the CDT to the vehicle 3 Access the Monitor menu and select THROTTLE by using the SCROLL DISPLAY buttons 4 The CDT should indicate 0 with the pedal not pressed While monitoring the CDT display screen slowly press the accelerator pedal As the pedal is p...

Page 236: ...ose to the three pin connector at the MCOR The reading should be approximately 4 65 volts 5 If reading is zero volts check the white wire continuity from the three pin connector at the MCOR to the 16 pin connector at the speed controller Check terminal positions in three pin connector at the MCOR and the 16 pin connector If all of the continuity readings are correct and the connectors are wired co...

Page 237: ...witch in the NEUTRAL position 2 Connect the CDT to the vehicle 3 Access the Monitor menu and select SPEED PULSES by using the SCROLL DISPLAY buttons The CDT should indicate OFF when the vehicle is at rest 4 While monitoring the CDT display screen slowly push the vehicle a short distance about 3 feet 1 meter The CDT should indicate ON for speed sensor pulses while the wheels are in motion 5 If the ...

Page 238: ...no 6 6 x 8 Volt battery set negative post and place the red probe with insulation piercing probe on the green wire between the three pin connector and the motor speed sensor 6 1 Raise one rear wheel off ground Slowly turn the rear wheel to rotate the motor armature As the armature rotates the voltage reading should alternate from zero to approximately 4 85 volts The voltage reading will fluctuate ...

Page 239: ... 1 4 4 3 Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts Also check continuity of all motor wires Section 16 Electric Vehicle Motor TEST PROCEDURE 14 Voltage at Charger Receptacle Red Wire Socket See General Warnings on page 1 2 NOTE This is a voltage test 1 If necessary see Testing Basics on page 12 12 2 Probe the charger receptacle socket c...

Page 240: ...erminals until they are firmly seated in the 16 pin connector After each terminal has been pushed into the housing gently pull on the wire to ensure it is locked into place 3 Check wires in the plug to make sure none are broken at the terminal pin crimp Repair or replace as required 4 Check the wire colors of each wire and make sure that the colors for each pin position match the wire colors as sh...

Page 241: ...he following information What function the wire performs Whether or not the 16 pin connector must remain connected during the test The appropriate test result for each pin If results differ from those described in the procedure check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures See Index of Test Procedures Testing Controller...

Page 242: ...ES BACK PROBE TO TEST TEST PROCEDURE THROTTLE OUTPUT Pin 1 White Supplies approximately 5 volts in MCOR 3 pin circuit Yes 4 to 5 volts measured between pin 1 and B terminal on controller Key switch either ON or OFF CHARGE INDICATOR LIGHT OUTPUT Pin 11 Blue Yellow Supplies a positive controlled current source to power the charge indicator light on the instrument panel Yes Do not back probe for this...

Page 243: ...tage 8 1 If the voltage reading is correct replace the reverse buzzer 8 2 If reading is zero volts check orange white wire continuity and connection at Pin 7 in 16 Pin connector 8 3 If there is no continuity in the orange white wire or the pin 7 terminal in the 16 pin connector is not properly seated repair or replace as required 8 4 If the orange white wire continuity and 16 Pin connector are cor...

Page 244: ...12 9 Page 12 32 and pin 3 purple white wire of the 16 pin connector It should indicate continuity If not check sonic welds no 1 and no 2 3 Probe pin 2 red white wire It should show BPV If not check 2 amp fuse See following NOTE NOTE The red white wire has BPV with the Run Tow switch in either position 4 Probe pin 4 white black wire It should show approximately 13 volts supplied by the controller I...

Page 245: ... push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the outside of the instrument panel Figure 13 2 Page 13 2 KEY SWITCH INSTALLATION 1 Position the key switch and flat washer 9 in the instrument panel then install and tighten the switch retaining nut 6 to 40 in lb 4 5 N m Install key switch ca...

Page 246: ...discharge the controller See Disconnect the Batteries Electric Vehicles on page 1 4 2 Remove instrument panel See Key Switch Removal on page 13 1 3 Disconnect the wires at the warning light 4 Press the two retaining tabs 1 and remove the light from the center dash Figure 13 3 Page 13 3 CHARGE INDICATOR LIGHT INSTALLATION 1 Install in reverse order of removal 2 Place the Tow Run switch in the TOW p...

Page 247: ...recharge portable devices The USB port is not designed for the transfer of data Figure 13 4 USB Port USB PORT REMOVAL 1 Remove the instrument panel to access the USB port wires and lock tabs Figure 13 5 Page 13 4 2 Disconnect the USB port wires 3 Push the lock tabs on both sides and remove the USB port 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 13 3 ...

Page 248: ...minal 6 Vehicles without a battery condition indicator Attach the extra wires 3 4 to the instrument panel harness with a plastic tie 7 Install the instrument panel FORWARD REVERSE ROCKER SWITCH See General Warnings on page 1 2 TESTING THE FORWARD REVERSE ROCKER SWITCH See Test Procedure 6 Forward Reverse Rocker Switch on page 12 18 FORWARD REVERSE ROCKER SWITCH REMOVAL 1 Disconnect the batteries a...

Page 249: ...2 3 N m 4 Place the Tow Run switch in the TOW position and connect the batteries See Connect the Batteries Electric Vehicles on page 1 5 5 Place the Tow Run switch in the RUN position 6 Inspect the vehicle for proper operation WARNING Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position Make sure that the vehicle operates in the re...

Page 250: ...y bucket CAUTION Be careful not to break the two hooks 4 on the bottom of the cover Push the bottom of the cover up to release the hooks before pulling cover away from battery bucket ELECTRONICS MODULE COVER INSTALLATION 1 Install cover 5 by first hooking the four tabs 3 into the matching holes in the hood of the battery bucket Figure 13 8 Page 13 7 Then use the two hooks 4 to secure the cover to ...

Page 251: ...n switch 2 See Electronics Module Cover Removal on page 13 6 3 Remove Tow Run switch boot hex nut 1 Figure 13 9 Page 13 8 4 Remove Tow Run switch 2 from electronics module and disconnect the pink wire 3 and light green wire 4 TOW RUN SWITCH INSTALLATION 1 Installation is reverse of removal Make sure flat on switch is aligned with flat part of D shaped hole in electronics module Figure 13 9 Page 13...

Page 252: ... Remove the T25 torx screw securing the MCOR to the pedal group 5 Detach the two tabs from the accelerator pedal and remove the MCOR from vehicle MCOR INSTALLATION 1 Align the two tabs of the MCOR 2 with the slots in the accelerator pedal on the pedal group Insert the MCOR into the accelerator pedal until the tabs engage See following NOTE NOTE Rotate the pedal back and forth if necessary to align...

Page 253: ... from reverse buzzer 4 Remove the two screws from the reverse buzzer Remove the reverse buzzer from the dash panel REVERSE BUZZER INSTALLATION 1 Install the reverse buzzer in the reverse order of removal Pink wire must be connected to the positive terminal Tighten screws to 4 in lb 0 45 N m 2 Place the Tow Run switch in the TOW position and connect the batteries See Connect the Batteries Electric ...

Page 254: ...5 3 Remove the bolt 2 that secures the electronics module 3 to the battery bucket 4 Pull electronics module 3 forward and disconnect the heavy gauge wires from the controller 1 and solenoid 4 5 Disconnect the 16 pin connector 4 pin connector and spade connectors from the controller 1 6 Disconnect the spade connectors on the front of the solenoid 4 7 Disconnect the two wires from Tow Run switch 5 8...

Page 255: ...n electronics module 3 to its location in vehicle but leave it tilted forward 2 Complete connections to the controller 1 the Tow Run switch 5 and the solenoid 4 per the electrical schematics 3 Tighten bolts 6 on the controller to 108 in lb 12 2 N m 4 Tighten nuts 7 on the solenoid to 6 4 ft lb 8 7 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 13 11 ...

Page 256: ...A2 Motor Voltage on page 12 26 SPEED CONTROLLER REMOVAL 1 Disconnect the batteries and discharge the controller 1 See Disconnect the Batteries Electric Vehicles on page 1 4 2 Remove the electronics module cover 8 to access the controller 1 See Electronics Module Cover Removal on page 13 6 3 Disconnect the heavy gauge wires from the controller by removing the three screws 6 Figure 13 11 Page 13 11 ...

Page 257: ... and verify the value is 13 or higher If not contact a Club Car Technical Representative 7 8 Place the Tow Run switch in the TOW position for 30 seconds Then return it to RUN 8 Inspect the vehicle for proper operation WARNING Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position Make sure that the vehicle operates in the reverse dir...

Page 258: ... show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact TESTING THE CHARGER RECEPTACLE See Test Procedu...

Page 259: ...enoid Tighten nut 72 to 84 in lb 8 to 9 5 N m 5 Connect 10 gauge black wire to controller B terminal Tighten bolt to 108 in lb 12 2 N m 6 Connect light blue wire to main harness at bullet connector with light blue wire 7 Install kick plate See Kick Plate and Charger Receptacle Bezel Electric Vehicles on page 4 14 8 Place the Tow Run switch in the TOW position and connect the batteries See Connect ...

Page 260: ...Pagination Page 13 Charger Receptacle ELECTRIC VEHICLE ELECTRICAL COMPONENTS Page 13 16 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 261: ... a physician immediately WARNING Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery connections are clean and properly tightened Se...

Page 262: ...f batteries i e terminal posts Poor fair or proper cleanliness of batteries Added electric accessories Use of a single point watering system SPWS MEASURING VOLTAGE OF BATTERY SET Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 6 Record the reading BATTERY CELL NUMBERING 1 2 3 4 1 Cell 1 Cell with Pos...

Page 263: ...ecific to the battery installed Regrouping is now Club Car s standard battery replacement method Regrouping is the practice of placing batteries of similar condition together in one vehicle For example if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car after removing the failed batteries there will be six good batteries remaining ...

Page 264: ...14 Battery Regrouping ELECTRIC VEHICLE BATTERIES 3104 Figure 14 2 Battery Regrouping Process Flow Page 14 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 265: ...ull capabilities until they have been discharged and recharged 50 to 70 times To obtain the maximum service life from new batteries restrict vehicles with new batteries to one hour of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before use each day 3 If the ...

Page 266: ...es equipped with the Single Point Watering System SPWS and one for vehicles without SPWS used in combination with Battery Watering Nozzle Gun Alternate Methods Reverse Osmosis Reverse osmosis involves forcing water through a membrane that allows water to pass while trapping solids The choice of membrane used determines the amount of solids or impurities that get trapped and hence the purity qualit...

Page 267: ... supply hoses Be sure to replace the deionizer filter cartridge as indicated by the water quality light The Deionizer system has a battery powered water quality light Deionizer filters have a limited life cycle and are disposable Life cycle of the filter will vary based on incoming water quality and water usage If the deionizer system is equipped with a water quality light press the button to chec...

Page 268: ... terminals to proper torque See Connect the Batteries Electric Vehicles on page 1 5 See following WARNING WARNING If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in fire property damage or personal injury 3 After use charge the batteries The batteries should never be left discharged a...

Page 269: ...he plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life add only distilled water See following CAUTION and NOTE CAUTION Do not overfill the batteries NOTE A battery watering gun or bottle is available from your authorized Club Car dealer 3 The battery hold downs...

Page 270: ...ectrolyte may bubble out of the cap This reduces the battery s capacity and corrodes the metal parts around it The electrolyte level should be checked weekly to be sure electrolyte is at its proper level Figure 14 3 Page 14 10 Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive For best results ...

Page 271: ... one time inspection of all cells will identify any occurrence of a valve that fails to open If a valve fails to close it will become evident due to the cell overflowing during routine watering Either failure scenario is rare but should be monitored in the initial inspection and during routine watering sessions Replace malfunctioning valves to ensure maximum battery life After the initial six week...

Page 272: ...e sure the light is green in color indicating acceptable water quality If the light indicates unacceptable water quality the cartridge must be replaced 6 After ensuring adequate water flow rate and water quality press the grey button 7 on the end of the female coupler 8 to disconnect the purger from the pressure regulator Refilling the Batteries 1 Locate the battery fill coupling 9 on the driver s...

Page 273: ...eing rotated the CDT Controller Diagnostic Tool can be a very helpful service tool Monitoring the value of the Odometer or Amp Hours with the CDT simplifies vehicle usage scheduling See Monitor Menu Section 11 Page 11 9 DEEP DISCHARGE Never discharge batteries to the point the vehicle will no longer operate This will considerably shorten the cycle life of the batteries and may permanently damage t...

Page 274: ...Pagination Page 14 Early Excessive Discharging ELECTRIC VEHICLE BATTERIES Page 14 14 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 275: ... connection Fire or personal injury can result Have a qualified technician replace the damaged parts Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Jerking or pulling the...

Page 276: ...n includes information troubleshooting and service procedures pertaining to the external high frequency battery charger model number IC0650 048 CC and onboard high frequency battery charger model number IC0650 048 COMM Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor How To...

Page 277: ... battery chargers have been listed by UL and by the Canadian Underwriters and meet the criteria of the Canadian Standards Association CE COMPLIANCE This battery charger is compliant with the EU EMC Directive 2004 108 EC PLUG AND RECEPTACLE The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect for cracks loose connections frayed wiring or bent pins they ...

Page 278: ... operate THERMAL CUTBACK The charger operates at full power in ambient temperatures between 40 F 40 C and 104 F 40 C The charger also will function outside of that range although charging times will be longer CHARGE INDICATOR LIGHT Excel System vehicles with ERIC Charging system feature a dash mounted charge indicator light below the steering column that serves two functions 1 Battery low state of...

Page 279: ...g is in progress Battery pack has NOT reached a high state of charge Solid blue AC power to charger is present ONBOARD CHARGER STATUS INDICATORS The indicator lights on the onboard charger provides information concerning charger status _ LIGHT STATUS STATUS EXPLANATION Solid red Charger fault See the display panel for details Flashing orange External error condition caution See the display panel f...

Page 280: ...ive There is a potential risk of electric shock F code Internal fault condition has caused the charging to stop See the charger fault codes for more information E code External error condition has caused the charging to stop See the charger fault codes for more information P code The charger programming mode is active USB code The USB interface is active Do not remove the USB flash drive LONG TERM...

Page 281: ...ure 15 3 Position the charger so that is has adequate ventilation and the charger status indicator panel is visible The charger can be mounted in any orientation right side up upside down etc provided the cooling fins are unobstructed it has adequate ventilation Figure 15 4 To help ensure optimal charge times mount the charger in an area where ambient temperatures during charging remain below 104 ...

Page 282: ...plicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet within the voltage and frequency range shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock Place all cords so they will n...

Page 283: ...e plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances The use of an extension cord with the charger should be avoided If one must be used heed the following WARNING WARNING An extension cord or electrical outlet must accept a three prong plug The extension cord sho...

Page 284: ...e all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 15 8 Page 15 12 Do not pull on the DC cord Figure 15 9 Page 15 12 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by th...

Page 285: ...eplacement batteries Contact your authorized Club Car dealer distributor with any questions about battery and charger compatibility or algorithm updates NOTE Unlike the PowerDrive family of chargers battery pack voltage does not have to be above 32 volts for charging to begin When temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible...

Page 286: ...nted charge indicator light will flash three times and the reverse buzzer simultaneously will sound three times to indicate charging has begun The number of flashes and beeps can vary depending on the Beep Option setting See Beep Option Section 11 Page 11 8 4 The charger monitors battery voltage charge current and charge time to determine when the batteries are properly charged The charger will sh...

Page 287: ... all AC connections and the USB port clean and dry Keep all cooling fins clean If the detachable input power supply cord set is damaged replace with a cord that meets the following criteria _ For North America UL or CSA listed approved detachable cord 3 conductor 16AWG minimum and rated SJT terminating in a grounding type IEC 60320 C14 plug rated 250V 13A minimum For all other countries Safety app...

Page 288: ...argers and returning each vehicle to its designated charger each night can significantly reduce the amount of time spent troubleshooting a problem USB SERVICE PORT NOTE The triangular charge status light doubles as the USB light Flashing green means data transfer from the USB is occurring Solid green means data transfer is complete Use the USB service port for charging algorithm updates software u...

Page 289: ...ord to the vehicle 5 If the triangular status indicator light comes on contact your Club Car dealer If the light does not come back on attempt to charge the car as usual RESETTING POWER ONBOARD CHARGER The triangular status indicator light on the charger comes on in a solid red state to communicate a significant charger hardware or software failure See External Charger Status Indicators on page 15...

Page 290: ...ect and attempt to charge again 2 AC power supply was shut off Verify AC power is present and charge again See AC Power and Continuity Test of AC Circuit on page 15 21 3 AC circuit breaker is tripped Reset AC circuit breaker and charge again 4 Improper AC outlet voltage Test AC outlet voltage and correct if necessary See AC Power and Continuity Test of AC Circuit on page 15 21 OFF AC power to char...

Page 291: ...Continuity Test of AC Circuit on page 15 21 7 Ambient temperature too hot above 104 F 40 C Check for dirty obstructed or damaged cooling fins Clean if necessary and ensure sufficient cooling air flow Chargers stacked on top of or located too close to each other Move chargers farther apart If issue continues wait for ambient temperature to cool or relocate charger to a cooler environment 8 Ambient ...

Page 292: ... required voltage within safe time limit Possible causes Charger output reduced due to high temperatures poor battery health discharged battery and or the battery is not connected correctly Operate at lower ambient temperature Replace the battery pack Check the DC connections This error will automatically clear once the charger is reset by cycling DC E 0 0 4 Battery could not meet minimum voltage ...

Page 293: ...rger and the bat tery which passes through voltage but not current Make sure that the vehicle has original factory set up E 0 2 3 E 0 2 5 AC voltage out of range AC voltage is out of range Connect the charger to an AC source that pro vides stable AC between 85 270 VAC 45 65 Hz This error will automatically clear once the condi tion has been corrected E 0 2 4 Charger failed to initialize The charge...

Page 294: ...ttery Condition Using Charger 4 On Charge Battery Voltage Using Charger And Multimeter 5 AC Power and Continuity Test of AC Circuit 6 Charger DC Circuit Continuity Test 7 Charger Output Test TEST PROCEDURE 1 Battery Voltage Using Multimeter 1 Check battery pack voltage See Measuring Voltage of Battery Set Section 14 Page 14 2 2 Normal no load voltage should be between 50 and 52 volts for a fully c...

Page 295: ...atteries See External Charger Status Indicators on page 15 4 NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper and the upper half of the battery shaped status indicator will continue to flash Section 14 Electric Vehicle Batteries Continued poor performance may indicate a problem in the vehicle electrical system brakes or battery charger If the prob...

Page 296: ... attach DC cord white wire to positive terminal and black wire to negative terminal with torx screws See following NOTE Tighten torx screws to 39 8 in lb 4 5 N m NOTE The positive symbol and negative symbol are molded into the terminal block for easy identification 6 Install terminal block cover See Terminal Block Cover Installation on page 15 24 TEST PROCEDURE 7 Charger Output Test Without a Mete...

Page 297: ...cord from the AC outlet NOTE This charger has no internals to service or repair It only has a few external repairs that can be performed If an internal component needs repair the charger must be replaced 2 1 8 9 5 10 6 4 7 3 11 2790 Figure 15 10 External High Frequency Charger Components TERMINAL BLOCK COVER REMOVAL 1 Disconnect DC cord 1 from vehicle 2 Disconnect AC cord 2 from AC outlet 3 Push i...

Page 298: ...f 6 to charger 4 Remove terminal block cover 3 See Terminal Block Cover Removal on page 15 23 5 Remove torx screw 7 securing each DC cord wire to terminal block 4 DC CORD AND STRAIN RELIEF INSTALLATION 1 Attach DC cord white wire to positive terminal and black wire to negative terminal with torx screws 7 See following NOTE Tighten screws 7 to 39 8 in lb 4 5 N m NOTE The positive symbol and negativ...

Page 299: ...REMOVAL 1 Disconnect DC cord 1 from vehicle 2 Disconnect AC cord 2 from AC outlet 3 If mounted detach charger from shelf or wall 4 Squeeze barbs on back side of foot 10 and push foot out of charger mounting tab Repeat for other feet if necessary FOOT INSTALLATION 1 Push foot 10 into hole in charger mounting tab until the barbs come through and secure foot in place 2 If required mount charger to sh...

Page 300: ...of the rear facing seat This charger has no internals to service or repair It only has a few external repairs that can be performed If an internal component needs repair the charger must be replaced 6 10 7 5 8 9 12 11 13 4 2 1 3 2792 Figure 15 12 Onboard High Frequency Charger Mounting ONBOARD CHARGER REMOVAL 1 If connected disconnect AC cord 1 from AC outlet Figure 15 12 Page 15 26 2 Disconnect t...

Page 301: ... screws 9 Tighten screws 9 to 11 in lb 1 25 N m 4 Connect 14 pin plug 8 to onboard charger 4 5 Connect DC charging harness 6 to onboard charger DC cord 7 6 Ensure sleeve 5 is in place on charger s AC socket and connect lead 3 from AC cord reel to onboard charger 4 7 Lower rear facing seat bottom 2 8 Place the Tow Run switch in the TOW position and connect the batteries See Connect the Batteries El...

Page 302: ...ch DC cord red wire to positive terminal and black wire to negative terminal with torx screws 6 Figure 15 13 Page 15 28 See following NOTE Tighten screws 6 to 39 8 in lb 4 5 N m NOTE The positive symbol and negative symbol are molded into the terminal block for easy identification 2 With DC cord 1 seated properly in the terminal block 3 place strain relief 5 over cord and secure with two torx scre...

Page 303: ...uge red wire to solenoid Tighten nut 72 to 84 in lb 8 to 9 5 N m 2 Connect 10 gauge black wire to controller B terminal Tighten bolt to 108 in lb 12 2 N m 3 Connect blue wire to main wire harness at bullet connector with light blue wire 4 Install electronics module cover and access panel See Electronics Module Cover Installation Section 13 Page 13 6 See following NOTE NOTE Route DC charging harnes...

Page 304: ...Pagination Page 15 Onboard Charger Repairs ELECTRIC VEHICLE BATTERY CHARGER Page 15 30 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 305: ...s is only testing continuity Tag the motor wires for identification before disconnecting Remove motor wire from one of the A terminals and one of the F terminals if testing while motor is in vehicle When disconnecting wires from motor terminals use a second wrench on the lower nut of the terminal post to hold post steady Scrape a small amount of paint from motor housing ground and use this locatio...

Page 306: ... on page 16 4 4 1 An incorrect reading from the A1 or A2 terminal indicates three possible problems a grounded A1 or A2 terminal a grounded wire in the brush area or a grounded armature commutator An incorrect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 terminal or field coil 5 If readings are correct reconnect the motor wires See Motor Installation on page 16 15 6 Con...

Page 307: ... the red probe on the F1 terminal and the black probe on the F2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 16 4 3 If reading is correct reconnect the motor wires See Mo...

Page 308: ... hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 729 Figure 16 1 Lift Vehicle with Floor Ja...

Page 309: ... in step 9 Fingers may get pinched when motor disengages 10 Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle 748 Figure 16 4 Speed Sensor Magnet 749 Figure 16 5 End Cap MOTOR DISASSEMBLY 1 Before beginning disassembly place match marks on the motor end cap and motor frame 2 Remove speed sensor and magnet 2020 ...

Page 310: ... cap from the motor frame using the following procedure 5 1 With the end cap bolts loose about 1 4 inch 6 3 mm between the end cap and the head of the bolt place a socket on the head of the bolt See following CAUTION CAUTION Ensure that there is sufficient thread engagement of the end cap bolts before proceeding Performing the procedure without having adequate thread engagement could damage the mo...

Page 311: ...rmature for wear and damage See Armature Inspection and Testing on page 16 8 11 Inspect the motor frame and field windings See Motor Frame and Field Windings Inspection on page 16 10 12 Remove the brush rigging 12 1 Mark the brush terminal posts A1 and A2 12 2 Remove the two nuts securing the brush terminals A1 and A2 to the end cap Figure 16 9 Page 16 7 12 3 Remove the two screws and the brush ri...

Page 312: ...sual Inspection Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily commutators Raised commutator bars Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry Abnormalities identified during the inspection can help determine original c...

Page 313: ...ture Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clean with a clean cloth Remove any carbon dust and metal particles from between the commutator bars 1 With a multimeter set to 200 ohms place one probe on the commutator 1 and the other on the armature core 2 The multimeter should indicate no continuity Figure 16 12 Page 16 9 If the reading i...

Page 314: ...n do not over extend the spring Using excessive force will damage the spring 4 4 Replace springs which require a force of less than 35 ozf 0 99 kgf Figure 16 13 Page 16 11 See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging Refer to Motor Assembly on page 16 13 for brus...

Page 315: ...pe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 16 14 Page 16 11 4 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearing and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing A B 756 Figure 16 13 Brush Spring Tension Te...

Page 316: ...esting and Inspection ELECTRIC VEHICLE MOTOR 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 16 11 1 2 17 18 3 30 2613 Figure 16 15 Electric Motor EJ8 4001A Page 16 12 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 317: ... retaining ring to secure the bearing Figure 16 11 Page 16 8 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all four brushes Never replace only two Install the brushes in the same rigging 180 ap...

Page 318: ...o support the weight of the commutator The brushes can be easily damaged by this weight 4 Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown Figure 16 19 Page 16 14 5 Align the match marks on the end cap and the motor frame 1 and secure with two bolts 16 Figure 16 15 Page 16 12 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor mag...

Page 319: ...saxle away from the end of the shaft Figure 16 21 Page 16 15 2 4 The grease should be evenly distributed in the grooves to a width of approximately 3 8 inch 9 5 mm 2 5 Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft 1 2 1 2 mm inch 1 2 1 1 2 mm inch 1 8 INCH 3 1 MM 3 8 INCH 9 5 MM 741 Figure 16 20 Grease on ...

Page 320: ...nsaxle Figure 16 24 Page 16 17 Do not tighten 4 3 Begin finger tightening the bolts 1 2 and 3 in the sequence indicated Continue tightening by hand until the motor is seated in the transaxle housing See following CAUTION and NOTE CAUTION Make sure the motor is properly seated in the transaxle housing NOTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the pro...

Page 321: ...all the shock absorbers Tighten nut until rubber bushing expands to the diameter of the cup washer 8 If removed install wheels and finger tighten the lug nuts 9 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 10 Connect the batteries See Connect the Batteries Electric Vehicles Section 1 Page 1 5 11 Place the Tow Ru...

Page 322: ...Pagination Page 16 Motor Installation ELECTRIC VEHICLE MOTOR Page 16 18 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 323: ...nt wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end in General Warnings on page 1 2 3 Remove the rear wheel and brake drum Section 6 Wheel Brake Assemblies Section 8 Wheels and Tires 4 Use 90 internal snap ring pliers to remove the internal retaining ri...

Page 324: ...seated against the shoulder on the axle shaft 8 Inspect bearing 5 Figure 17 5 Page 17 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced 1 2 762 Figure 17 1 Remove Internal Retaining Ring 763 Figure 17 2 Axle Seal and Adapter Ring Removal 15 39 A A Adapter Ring Lip 764 Figure 17 3 Axle Seal and Adapter Ring 765 Figure 17 4 Axle Seal and...

Page 325: ...Shaft 17 1 3 14 15 39 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 3 8 36 27 30 28 37 38 5 6 4 15 39 766 Figure 17 5 Transaxle Type G 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 17 3 ...

Page 326: ...gh to the bearing on the shaft then rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 17 5 Page 17 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 2 2 Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube hub so that it seats against the axle bearing assembly and i...

Page 327: ...e 17 6 Vehicle Supported on Jack Stands 651 Figure 17 7 Brake Cable 6 Disconnect the shock absorbers from their lower mounts Figure 17 8 Page 17 6 7 Disconnect the four motor wires Use two wrenches to prevent the post from turning 8 With a floor jack supporting the transaxle remove lower spring shackle nuts and bolts Position shackles so they are clear of springs Figure 17 9 Page 17 6 9 If a chain...

Page 328: ... on the leaf spring and slide the transaxle to the rear and out of the vehicle 15 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on page 17 1 See following NOTE NOTE Recycle or dispose of used oil or lubricant in accordance with local state and federal regulations 16 Remove the brake assemblies if required See Brake Cluster Removal on page 6 1...

Page 329: ...embly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 17 5 Page 17 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil seal 10 is damaged replace it Figure 17 5 Page 17 3 See also Figure 17 12 Page 17 7 See following CAUT...

Page 330: ...l pin 31 by pushing pin through differential gear case from one side Figure 17 5 Page 17 3 See also Figure 17 14 Page 17 8 8 5 Remove the idler gears 1 and 2 and thrust plates 3 and 4 Figure 17 15 Page 17 8 1 5 6 26 2 8 7 3 4 773 Figure 17 14 Differential Pin 774 Figure 17 15 Left Differential 8 6 Remove the differential gears 5 and 6 and thrust plates 7 and 8 8 7 Inspect the bearings 13 of the di...

Page 331: ...et on mating surface of housing 8 2 Install left half of transaxle housing 20 Figure 17 5 Page 17 3 8 3 Install bolts 24 in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 4 Install axle tube 14 and 35 with bolts 8 Figure 17 5 Page 17 3 Tighten the bolts to 37 ft lb 50 2 N m 9 Install the brake assemblies as instructed See Brake Cluster Installation on...

Page 332: ...se the differential while guiding the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Connect the motor wires making sure they are connected to the correct motor terminals and that the terminal orientation is correct Hold the bottom nut of stud with wrench and tighten the terminal retaining nuts For 5 16 inch 8mm diameter studs tighten the nuts to 1...

Page 333: ...when the Forward Reverse switch is in the REVERSE position The reverse buzzer will sound as a warning when the Forward Reverse switch is in REVERSE Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 17 11 ...

Page 334: ...Pagination Page 17 Transaxle Installation ELECTRIC VEHICLE TRANSAXLE Page 17 12 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 335: ...the instrument panel FEATURES OF THE ELECTRONIC FUEL INJECTION EFI SYSTEM Closed loop system oxygen O2 sensor included Controls fuel pump fuel injector malfunction indicator light MIL Inputs Temperature Manifold Absolute Pressure TMAP Throttle Position Sensor TPS oxygen O2 sensor crank sensor ignition timing cylinder head temp Separate EFI wire harness GROUND LOCATIONS Electrical grounds are locat...

Page 336: ...ys on have a trained technician examine the vehicle MALFUNCTION INDICATOR LIGHT _ The malfunction indicator light MIL gives a visual indication of an engine fault When the key switch is set to ON the MIL will turn on for 3 seconds If an engine fault is sensed the MIL will stay on See the Kohler Engine Service Manual for more information TROUBLESHOOTING GUIDE The following troubleshooting guides wi...

Page 337: ...perate Cylinder and or crankcase flooded with fuel See the Fuel System Section Loose or broken wire in the starter generator circuit See the Starter Generator Generator Function Test Procedure Generator field coil is shorted See the Starter Generator Generator Function Test Procedure Brushes are worn or commutator is dirty See Starter Generator in the Electrical Components Section Starter generato...

Page 338: ...ical Components Section Excessive vehicle vibration RPM setting is incorrect See Engine RPM Adjustment in the Fuel System Section Drive belt is worn cracked glazed or frayed See the Clutches Gasoline Vehicles Section Drive clutch malfunction See the Clutches Gasoline Vehicles Section Clutches do not shift smoothly Governor is sticking See the Transaxle ED65 Section Accelerator pedal linkage out of...

Page 339: ... VEHICLE TROUBLESHOOTING AND ELECTRICAL SYSTEM Fuse And Relay Locations 18 FUSE AND RELAY LOCATIONS Figure 18 2 Fuse and Relay Locations 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 18 5 ...

Page 340: ...me and consists of the following circuits that are easily identified Starter Circuit Generator Circuit Electronic Fuel Injection Circuit Engine Ignition Circuit Engine Kill Circuit Multi purpose Buzzer Circuit Low Oil Warning Light Circuit Neutral Lockout Circuit Fuel Pump Circuit Fuel Gauge and Sending Unit Circuit Hour Meter Circuit Lighting Circuit Recognizing and understanding the function of ...

Page 341: ...ocedures Battery voltage is accessed in the Battery test procedure The Maintenace Operate switch in the MAINTENANCE position grounds and kills the ignition if the Forward Neutral Reverse control FNR is placed in F or R The key switch powers the ECU fuel pump solenoid lights and the connected car device The 2 amp fuse is powered by the key switch via the 10 amp ATM fuse and carries battery voltage ...

Page 342: ...witch 9 Transaxle Limit Switch 10 Starter Generator Generator Function 11 Starter Generator Starter Function 12 Voltage Regulator 13 Ignition Spark 14 Multi Purpose Buzzer and Multi Purpose Buzzer Limit Switch 15 Malfunction Indicator Light MIL 16 Low Oil Warning Light LED 17 Battery Test Under Load 18 Fuel Pump 19 Fuel Level Sending Unit 20 Fuel Gauge 21 Hour Meter 22 4 Pin Connector to Visage Pa...

Page 343: ...est procedures Battery maintenance procedures can be found in the Electrical Components Pedal Start Gas Vehicle section 1 Disable the vehicle 2 Set the Maintenance Operate switch to MAINTENANCE 3 Check for loose or corroded battery terminal connections 4 Disconnect the battery 5 Clean the battery terminals and connections Replace the connections and wires as necessary 6 Connect the battery Voltage...

Page 344: ...ing voltage replace the battery 5 1 If the electrical problem continues test the electrical circuits 6 If the battery voltage is the minimum cranking voltage or higher test the electrical circuits TEST PROCEDURE 2 Fuse Inspection See General Warnings on page 1 2 WARNING Failure to use properly rated fuse can result in a fire hazard 1 Disable the vehicle 2 Remove the fuse 3 Examine the fuse Replace...

Page 345: ... incorrect clean and tighten cable connections If the connections are good and the reading is incorrect repair or replace the wire or cable TEST PROCEDURE 4 Key Switch Start Circuit See General Warnings on page 1 2 NOTE This is a voltage test The key switch provides power and KEY INPUT to the ECU 1 If necessary see Testing Basics 2 Remove the instrument panel Do not disconnect the wires 3 With the...

Page 346: ...witch This sensor is sealed and is not to be repaired or replaced If sensor is determined to need replacing through test procedures found in this manual the accelerator pedal assembly must be replaced See Accelerator Pedal Removal The sensor is joined to the main wire harness through a six pin connector Tests for the sensor are found in the following two procedures Accelerator Pedal Limit Switch F...

Page 347: ... when the pedal is released NOTE Keep the battery connected while performing this test procedure 1 Set the Maintenance Operate switch to MAINTENANCE 2 Disconnect the spark plug wire 3 Disconnect gray 18 pin connector from ECU 4 Set the multimeter to the diode test function 5 Attach the red lead to the negative battery terminal 6 Attach the black lead to the white black wire at the limit switch loc...

Page 348: ... post of the solenoid Figure 18 4 Page 18 14 Do not let the wires to touch the frame or other components of the vehicle Cover the other large post 2424 Figure 18 4 Solenoid Wire Removal 4 1 Set the Forward Neutral Reverse control FNR to N 4 2 Set the Maintenance Operate switch to MAINTENANCE 4 3 Set the key switch to ON 4 4 Check voltage between the empty large post and ground Figure 18 5 Page 18 ...

Page 349: ... T3 Black Yellow Stripe 478 Figure 18 6 Maintenance Operate Switch Test 3 Set the switch to MAINTENANCE 1 Figure 18 6 3 1 Check for no continuity between terminals T1 and T2 If there is continuity replace the switch 3 2 Check for continuity between terminals T2 and T3 If there is no continuity replace the switch 4 Set the switch to OPERATE 2 4 1 Check for no continuity between terminals T2 and T3 ...

Page 350: ...is being shifted 4 1 If the transaxle limit switch does not make an audible click as it is pressed check for wear on the cam lobe and replace shift lever if necessary 5 Check the following terminals for no continuity with the lever released and continuity with the lever engaged Figure 18 7 Page 18 16 PROBE BETWEEN LOCATIONS TEST RESULT With lever released No continuity Between terminal 1 COM black...

Page 351: ...round DF to A1 6 Cover terminal on yellow wire to make sure it will not short to ground 7 Use a jumper wire 3 to ground DF terminal to A1 terminal 4 8 Set the multimeter 20 VDC 9 Put the red probe on the positive post of the battery 10 Put the black probe on the negative post 11 Start the engine and run it at full governed speed The reading should show the voltage rising on the meter 11 1 If the v...

Page 352: ...post to hold post steady Scrape a small amount of paint from starter generator housing ground and use this location when testing motor terminals to electrical ground _ MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 F1 to F2 Continuity A1 to F1 A1 to F2 No Continuity A2 to F1 A2 to F2 No Continuity A1 to Ground A2 to Ground No Continuity F1 to Ground F2 to Ground No Continuity 1 If necessary see T...

Page 353: ...auses A grounded wire in the brush area A grounded armature commutator A grounded A1 or A2 terminal 8 Put the red probe on the F1 terminal and the black probe on the F2 terminal The reading should be between approximately 0 1 and 0 3 ohms 8 1 If the reading is incorrect the starter generator will need to be removed from the vehicle and disassembled by a qualified technician Possible causes A groun...

Page 354: ...lator 1 is connected to the solenoid 2 R ED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 463B Figure 18 10 Voltage Regulator Test 11 Set the multimeter to 20 VDC 12 Put the red probe on the large post of the solenoid 13 Put the black probe on the negative battery post 14 Turn the key switch to the ON position 15 Pres...

Page 355: ... Test 5 Adjust the spark gap test tool 3 probes to approximately 18 000 volts 18 kV setting SE Small Engine Setting on the Thexton 404 tool 6 Connect the ignition spark gap test tool to the spark plug wire 7 Connect the alligator clip 4 to a solid engine ground 5 8 Start the engine 8 1 If the spark gap test tool has no spark test the ignition circuit 8 2 If the spark gap test tool has a faint yell...

Page 356: ...heck the 10 amp ATM fuse 6 Set the Forward Neutral Reverse control FNR to R 6 1 If the multi purpose buzzer does not sound check the multi purpose buzzer limit switch 7 Turn the key switch to OFF NOTE Multi purpose Buzzer Limit Switch This is a continuity test The multi purpose buzzer limit switch is located on the FNR Red white and orange wires are connected to it 1 Disconnect the black wire from...

Page 357: ...minates the MIL is good 5 2 2 If the light does not illuminate replace the MIL TEST PROCEDURE 16 Low Oil Warning Light LED NOTE This is a voltage test 1 If necessary see Testing Basics 2 Remove the instrument panel 3 Make sure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Turn the key switch to ON 5 Check for battery voltage at yellow white w...

Page 358: ...ry post 8 Turn the key switch to ON 9 Make sure that the FNR is in N and push the accelerator pedal NOTE With the accelerator pedal pushed the battery is under load 9 1 If the voltage reading is over 9 6 volts with an electrolyte temperature of 70 F 21 C check the starter generator 9 2 If the reading is below 9 6 volts with an electrolyte temperature of 70 F 21 C check the battery 9 3 If the readi...

Page 359: ... engine is running check for battery voltage between ground and the pin 5 of the fuel pump connector Pin Wire Color Description 1 Open Open 2 Orange Sending Unit Positive 3 Black Sending Unit Negative 4 Black White Fuel Pump Negative 5 Red White Fuel Pump Positive Figure 18 13 Fuel Pump Connector 6 1 If there is no voltage check for battery voltage at the red wire of the fuel pump relay while the ...

Page 360: ... for approximately 2 to 5 ohms between pin 1 and pin 2 terminals in fuel pump module 2 4 3 1 Description WIRE COLOR 1 Fuel Pump Positive Red White 2 Fuel Pump Negative Black White 3 Sending Unit Positive Orange 4 Sending Unit Negative Black Wire Black 3031 Figure 18 14 Fuel Pump Module Terminals 5 1 If the reading indicates no resistance the fuel pump has failed and the fuel pump module must be re...

Page 361: ...nstant 12V Power C Open NA D Tan Malfunction Indicator Light MIL E White Ground Kill Wire F Green Low Oil Light G Black White Fuel Pump H Open NA Figure 18 15 ECU Connector TEST PROCEDURE 19 Fuel Level Sending Unit WARNING To avoid the possibility of fire or explosion make sure the fuel tank cap is securely in place while performing this test procedure NOTE This is a resistance test 1 If necessary...

Page 362: ...Half full Upper position tank full 33 3 ohms 6 Full 5 1 If the readings are within the specifications listed above the fuel level sending unit is working properly 5 2 If the readings are incorrect the fuel level sending unit has failed and the fuel pump module must be replaced 5 3 If the readings are correct and the fuel gauge does not function correctly go to step 5 3 1 Leave the battery disconne...

Page 363: ...icle 2 Remove the instrument panel to gain access to the back of the fuel gauge hour meter 3 Place a sheet of insulating material between the front frame and the electrical connections on the rear of the instrument panel to prevent contact between the two 4 Disconnect the orange wire 1 from the fuel gauge hour meter Figure 18 18 Page 18 29 481B Figure 18 18 Fuel Gauge Voltage Test Terminal 2 5 Set...

Page 364: ...ding should be approximately 4 94 volts 13 1 If the reading is incorrect replace the fuel gauge hour meter TEST PROCEDURE 21 Hour Meter DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison NOTE Keep the battery connected while performing this test procedure 1 Disable the vehicle 2 Make sure that the key ...

Page 365: ...elds no 4 10 and 14 3 Probe pin 2 red wire It should show battery voltage with the key switch in the ON position If not check 2 amp fuse near ATM fuse holder See following NOTE NOTE The red wire only has battery voltage with the key switch in the ON position 4 Probe pin 4 brown wire It should show approximately 11 8 volts supplied by pin B red wire of the engine harness If not check wiring and the...

Page 366: ...Pagination Page 18 Test Procedures GASOLINE VEHICLE TROUBLESHOOTING AND ELECTRICAL SYSTEM Page 18 32 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 367: ...g Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables GENERAL INFORMATION See preceding DANGER and WARNING stateme...

Page 368: ...he vent cap holes See Self Discharge on page 19 2 3 Check battery periodically to see that it is in a full state of charge See Charging the Battery on page 19 3 4 Keep battery hold down clamp tight See Vibration Damage on page 19 2 SELF DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To prevent self discharge the battery should always ...

Page 369: ... negative battery post 4 The battery may be charged with a slow charge 3 to 10 amps or a fast charge 20 to 30 amps Charge until the battery voltage is greater than 12 4 volts See following WARNING WARNING If the battery case feels hot approximately 125 F 52 C or more emits gases or fluid boils from vents stop charging immediately Failure to stop charging battery when any of these conditions are pr...

Page 370: ...e of the storage area but it is recommended that the battery be monitored for state of charge every month Also if the storage area is unheated in a cold climate and recharging is required it is recommended that the area be heated to at least 60 F 16 C prior to charging The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold te...

Page 371: ...oved or installed could damage the brushes Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 19 5 Page 19 7 2 Remove brush covers 29 and 30 terminal hardware 25 brush springs 28 and brushes 27 Figure...

Page 372: ...spring has a tension less than 24 ozf 0 68 kgf replace all four springs Figure 19 4 Page 19 6 See following CAUTION CAUTION When checking brush spring tension do not push springs beyond the point they would normally be if there were new brushes installed Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs 0 5 10 15 20 25 30 35 40 45 50 ...

Page 373: ...tall the remaining three brush covers 29 in the openings in the commutator end cover 23 Figure 19 2 Page 19 5 Figure 19 5 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER GENERATOR TO SERVICE THE ARMATURE COMMUTATOR 1 Remove the commutator end cover to prevent damage to the brushes and armature See Commutator End Cover on page 19 5 2 To separate armature and out...

Page 374: ...nd radial B play Figure 19 7 Page 19 8 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to be re...

Page 375: ...st armature shaft 7 Use bearing puller if a press is not available 494 Figure 19 8 Bearing Removal FIELD COIL ASSEMBLY Replace entire field coil housing assembly if coils pole shoes or terminals are damaged Figure 19 9 Page 19 10 VISUAL INSPECTION OF ARMATURE Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or thrown solder it is ob...

Page 376: ...or can be polished away with 400 grit or finer sandpaper See following CAUTION CAUTION Do not use emery cloth on the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes 2 Using a micrometer measure the outside diameter at two points along the commutator If the commutator outside diameter is less than 1 535...

Page 377: ...re testing wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars Using a multimeter set on 200 ohms place the positive probe on the commutator bars and the negative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 19 11 Page 19 12 2020 Precedent Villager...

Page 378: ...ER GENERATOR REWORK Any rework must be performed by a qualified technician Starter generator service specifications are listed in the following table _ ITEM SERVICE LIMIT Commutator diameter minimum 1 60 in 41 mm Concentric with armature shaft within 0 002 in 0 051 mm Minimum commutator diameter for reslotting 1 65 in 42 mm Undercut Commutator must have a minimum diameter of 1 65 in 42 mm for resl...

Page 379: ...ds the center of the cover Figure 19 5 Page 19 7 6 Install the commutator end cover 23 onto the armature shaft Use the tapped mounting holes to align housing to the cover rotate and orient as shown Install the two M6 x 180 mm bolts 20 and tighten to 60 lb in 6 8 N m Figure 19 1 Page 19 5 7 Push the brushes down into the holders Place springs into the notches in the brushes Install the brush cover ...

Page 380: ...CAL COMPONENTS 1 2 F1 DF 3 90 F2 1 Jumper Wire 2 1 inch 25 4 mm Minimum Radius 3 Jumper Wire Not Allowed in this Area 2687 Figure 19 12 A1 to F1 Terminal Jumper Wire Routing Page 19 14 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 381: ...ket 3 and then through the starter generator Install a lock washer 6 and nut 4 onto adjustment bolt 1 finger tight Figure 19 13 Page 19 15 4 Install starter generator belt 2 and adjust belt tension as instructed 5 Connect the yellow wire 2 from the voltage regulator to the DF terminal on the starter generator Figure 19 14 Page 19 16 Install a flat washer lock washer and nut onto the terminal Tight...

Page 382: ... belt is tensioned varies between a used and new belt EFI engines have higher starting torque demands that require consistent belt tension to prevent slipping Belt tension should be checked periodically Locate gauge midway between pulleys 2724 Figure 19 15 Belt Tension Gauge 2725 Figure 19 16 Belt Tensioning Tool Installation 1 Disconnect battery and spark plug wire See Disconnect the Battery Gaso...

Page 383: ...re 19 13 Page 19 15 6 Install belt tension tool 6 1 Carefully insert pry bar between starter generator and bracket 6 2 Carefully lift starter up until tension tool can be installed as shown over the slotted adjustment bracket Figure 19 16 Page 19 16 Note orientation of tension tool on the slotted adjustment bracket and how the threaded J bolt is inserted into the slot under the starter generator m...

Page 384: ... PLUG WIRE See Connect the Battery Gasoline Vehicles on page 1 4 See following WARNING WARNING Remove pry bar before starting engine Ensure clearance between F2 terminal and starter generator bracket before starting engine 8 4 Engage starter and crank engine a minimum of 5 seconds and a maximum of 15 seconds to fully seat the belt into pulleys and help eliminate any slack 9 Repeat step 7 10 Mainta...

Page 385: ...ve the solenoid SOLENOID INSTALLATION 1 Install the solenoid 1 in the vehicle Figure 19 19 Page 19 19 Figure 19 19 Solenoid Installation 2 Install the two screws 2 Tighten the screws to 31 lb in 3 5 N m 3 Connect the white wire to the large post 3 on the solenoid Figure 19 20 Page 19 20 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 19 19 ...

Page 386: ...d Figure 19 21 Page 19 20 Figure 19 21 Solenoid Small Posts 7 Connect the orange wire to the small post 7 on the solenoid 8 Install the nuts 8 Tighten the nuts to 22 lb in 2 5 N m 9 Connect the battery and spark plug wire VOLTAGE REGULATOR See General Warnings on page 1 2 VOLTAGE REGULATOR REMOVAL 1 Disconnect battery and spark plug wire See Disconnect the Battery Gasoline Vehicles on page 1 3 Pag...

Page 387: ...three pin connector 3 to the wire harness 3 Connect battery and spark plug wire See Connect the Battery Gasoline Vehicles on page 1 4 4 Set the Forward Neutral Reverse control FNR to N 5 Set the maintenance operate switch to MAINTENANCE 6 Start the engine and check regulator for proper functioning as described in the voltage regulator test procedure See Test Procedure 12 Voltage Regulator on page ...

Page 388: ...RNING 3 Install black connector to the black port on the ECU 4 Connect the battery FUEL LEVEL SENDING UNIT See General Warnings on page 1 2 The fuel level sending unit is an integral part of the fuel pump module and is not replaceable Thoroughly test the fuel level sending unit before replacing the fuel pump module MAINTENANCE OPERATE SWITCH MAINTENANCE OPERATE SWITCH REMOVAL 1 Disconnect the batt...

Page 389: ...te switch 2 Figure 19 24 Page 19 23 000755 004 Figure 19 24 Maintenance Operate Switch 3 Install the boot hex nut 1 Tighten the boot hex nut to 16 in lb 1 8 N m 4 Connect the battery ACCELERATOR PEDAL LIMIT SWITCH See General Warnings on page 1 2 The accelerator pedal limit switch is housed inside the throttle position sensor The throttle position sensor itself is not intended to be replaced If se...

Page 390: ... LIMIT SWITCH See General Warnings on page 1 2 The multi purpose buzzer limit switch is located on the back of the Forward Neutral Reverse control FNR Figure 19 25 Multi purpose Buzzer Limit Switch MULTI PURPOSE BUZZER LIMIT SWITCH REMOVAL 1 Disconnect the battery and spark plug wire 2 Disconnect the multi purpose buzzer limit switch wires from the main harness 3 Remove the nuts 1 and washers 2 Fi...

Page 391: ...r limit switch wire to the main harness red wire 7 Connect the black multi purpose buzzer limit switch wire to the main harness orange wire NOTE The red multi purpose buzzer limit switch wire is not connected 8 Connect the battery and spark plug wire 9 Set the FNR to R Make sure that the multi purpose buzzer operates NEUTRAL LOCKOUT LIMIT SWITCH See General Warnings on page 1 2 The neutral lockout...

Page 392: ...en the nuts If the nuts are over tightened the limit switches could be damaged 2 Install the washers 2 and nuts 3 Tighten the nuts to 4 in lb 0 45 N m 3 Set the Forward Neutral Reverse control FNR to R 4 Make sure that both limit switches actuate 5 Connect the black yellow wire to the COM1 terminal 4 Figure 19 28 Page 19 26 Figure 19 28 Neutral Lockout Limit Switch Terminals 6 Connect the green wi...

Page 393: ...onnect the 3 wire connector from the transaxle limit switch 1 Figure 19 29 000999 003 Figure 19 29 Transaxle Limit Switch 4 Remove the nuts 2 washers 3 and bolts 4 5 Remove the transaxle limit switch TRANSAXLE LIMIT SWITCH INSTALLATION CAUTION Do not overtighten the retaining nuts If the nuts are overtightened limit switches could be damaged 1 Install the limit switch 1 with the bolts 4 washers 3 ...

Page 394: ...ransaxle limit switch lead 4 Connect the battery and spark plug wire 5 Test drive the vehicle in both forward and reverse for proper operation BRAKE LIGHT RELAY Figure 19 31 Brake Light Relay BRAKE LIGHT RELAY REMOVAL 1 Disconnect the battery and spark plug 2 Remove the instrument panel 3 Disconnect the wires from brake light relay 1 Figure 19 31 Page 19 28 Page 19 28 2020 Precedent Villager 2 and...

Page 395: ...l 5 Connect the battery and spark plug wire FUEL GAUGE HOUR METER GENERAL INFORMATION With the key switch in the OFF position the fuel gauge field is blank however the hour meter field is always ON When the key switch is turned to ON the fuel gauge field activates The fuel gauge initially registers full before indicating the actual fuel level The hour meter displays the number of hours of use in i...

Page 396: ...the lower and upper tabs away from the gauge housing 2 to remove clip 5 Remove the fuel gauge hour meter from the instrument panel FUEL GAUGE HOUR METER INSTALLATION 1 Install the fuel gauge hour meter 1 into the hole in the instrument panel until the flange seats against the instrument panel Figure 19 33 Page 19 30 2 Install the gauge housing 2 3 Connect the wires to the fuel gauge hour meter Fig...

Page 397: ...instrument panel 3 Disconnect the wires from the headlight switch 1 Figure 19 35 Page 19 31 4 Loosen the set screw 2 5 Remove the threaded knob 3 6 Remove the nut 4 7 Remove the headlight switch and nut 5 HEADLIGHT SWITCH INSTALLATION 1 Install the nut 5 onto the headlight switch 1 Figure 19 35 Page 19 31 2 Install the headlight switch into the instrument panel 3 Install the nut 4 Tighten the nut ...

Page 398: ...e instrument panel push down on the retaining tabs and remove the key switch cap 2 5 Hold the key switch and remove the switch retaining nut 3 from the outside of the instrument panel 6 Remove the washer 4 and the key switch KEY SWITCH INSTALLATION 1 Install the key switch 1 and washer 4 into the instrument panel Figure 19 36 Page 19 32 2 Install the key switch nut 3 Tighten the nut to 35 to 45 lb...

Page 399: ... wire 2 Remove the instrument panel 3 Disconnect the wires 1 Figure 19 37 Page 19 33 4 Push the retaining tabs 2 and remove the low oil warning light 3 LOW OIL WARNING LIGHT INSTALLATION 1 Push the low oil warning light 1 into the hole in instrument panel until retaining tabs engage Figure 19 37 Page 19 33 2 Connect the wires from the wire harness to the low oil warning light 3 Install the instrum...

Page 400: ...gure 19 38 Page 19 34 Do not allow wires to touch 4 Push the retaining tabs 2 and remove the malfunction indicator light 3 from the instrument panel MALFUNCTION INDICATOR LIGHT INSTALLATION 1 Push the malfunction indicator light MIL 1 into the hole in instrument panel until retaining tabs engage Figure 19 38 Page 19 34 2 Connect the MIL wires 3 Install the instrument panel 4 Connect the battery an...

Page 401: ...mounting screws 2 MULTI PURPOSE BUZZER INSTALLATION 1 Install the multi purpose buzzer 1 onto the instrument panel Figure 19 39 Page 19 35 2 Install the screws 2 Tighten the screws to 3 5 lb in 0 40 N m 3 Connect the black wire to the negative terminal 4 Connect the red white wire to the positive terminal 5 Install the instrument panel 6 Connect battery and spark plug wire 7 Set the Forward Neutra...

Page 402: ...36 Figure 19 40 USB Receptacle 4 Disconnect the USB receptacle wires 3 and 4 from the key switch 5 Push the lock tabs 5 on both sides and remove the USB receptacle 6 USB RECEPTACLE INSTALLATION 1 Put the USB receptacle wires into the dash 2 Push the USB receptacle 6 into the dash Figure 19 40 Page 19 36 3 Make sure that the locking tabs 5 engage 4 Connect the red instrument panel wire to the red U...

Page 403: ...igure 19 41 Page 19 37 Figure 19 41 Oxygen Sensor 3 Remove the oxygen sensor 2 OXYGEN SENSOR INSTALLATION 1 Install the oxygen sensor 2 into the muffler tube Figure 19 41 Page 19 37 Tighten the oxygen sensor to 13 25 ft lb 18 N m 2 Connect the oxygen sensor connector to the engine wire harness 1 3 Connect the battery 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 19 37 ...

Page 404: ...Pagination Page 19 Oxygen Sensor GASOLINE VEHICLE ELECTRICAL COMPONENTS Page 19 38 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 405: ...ine This section contains information for removing and replacing the engine and snubber For complete disassembly rebuild maintenance and repair information BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting en...

Page 406: ...e fuel line See Fuel Line Removal 6 Remove the screw 1 Figure 20 1 Page 20 2 Figure 20 1 Governor Cover and Ground Cable Removal 7 Remove the governor cover 2 8 Loosen the clamp and disconnect the vent line 3 9 Disconnect the engine wire harness from the main harness 10 Remove the governor cable See Governor Cable Removal 11 Remove the accelerator cable See Accelerator Cable Removal 12 Disconnect ...

Page 407: ... Figure 20 2 Page 20 3 Figure 20 2 Clutch Plate Removal 17 Remove the clutch plate 7 18 Remove the bolts 8 Figure 20 3 Page 20 3 Figure 20 3 Exhaust Weldment Removal 19 Remove the exhaust weldment 9 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 20 3 ...

Page 408: ...n 13 See following NOTE NOTE The engine weighs approximately 54 lb 24 5 kg 22 Remove the oil drain plug and drain all oil from crankcase Dispose of engine oil properly 23 If replacing the engine remove the starter generator mounting weldment and retain for installation on new engine See following NOTE Page 20 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 409: ...ten to 13 ft lb 18 N m 3 Place the engine onto the engine pan 13 and secure with mounting hardware 10 11 and 12 Figure 20 5 Page 20 5 Tighten the nuts to 33 ft lb 40 6 N m Figure 20 5 Engine Pan Installation 4 Install the muffler weldment 9 with the bolts 8 Figure 20 6 Page 20 5 Tighten the bolts to 18 ft lb 24 N m Figure 20 6 Exhaust Weldment Installation 2020 Precedent Villager 2 and 4 Maintenan...

Page 410: ...r Installation 9 If necessary install the powertrain See Transaxle Installation 10 Install the governor cable See Governor Cable Installation and Adjustment 11 Install the accelerator cable See Accelerator Cable Installation and Adjustment 12 Secure the accelerator cable and governor cable P clamps to engine Tighten the P clamp bolts to 36 in lb 4 0 N m 13 Connect the air intake hose See Air Clean...

Page 411: ... 75 to 85 in lb 8 48 to 9 6 N m 20 Check all hardware for proper torque tightness 21 Fill engine to proper level with correct type of oil See Vehicle Specifications CAUTION Do not overfill with oil 22 Connect the battery and spark plug wire 23 Adjust the idle See ECU Reset Procedure and TPS Learn Procedure for Pedal Start Applications in the Kohler Service Manual 24 Adjust the engine RPM setting S...

Page 412: ... two lock nuts 4 securing the snubber bracket 5 to the engine pan 3 Slide the snubber and snubber bracket assembly toward the battery to remove it from vehicle 4 Slide the snubber off the snubber bracket SNUBBER INSTALLATION 1 Slide the snubber 2 onto the snubber bracket 5 Figure 20 9 Page 20 8 2 Install the snubber bracket and snubber assembly onto engine pan 1 3 Install the bolts 3 and lock nuts...

Page 413: ...re MAP sensor engine block temperature sensor and ignition timing EFI SYSTEM FEATURES SPECIFICATIONS The fuel pump operating pressure is 50 psi 3 The Kohler fuel pressure gauge has a psi variance of 3 Fuel pump operates for a few seconds when key switch is turned to the ON position it stops if no engine RPM is detected by the ECU The ECU indicates a fault code through the malfunction indicator lig...

Page 414: ...al governor linkage and throttle adjustments are done correctly and in the proper sequence See following CAUTION CAUTION Improper adjustment can result in poor vehicle performance and or damage to the engine components GROUND SPEED NOTE If possible the manufacturer recommends measuring ground speed when setting engine RPM This vehicle should reach the forward ground speed specified in the Vehicle ...

Page 415: ...nor cable from throttle body bracket 4 4 At transaxle 4 1 Disconnect Z fitting of governor cable 1 from governor arm 2 Figure 21 2 Page 21 3 Figure 21 2 Governor Cable Removal Governor Arm 4 2 Loosen jam nuts at governor bracket 3 and remove the governor cable from vehicle Governor Cable Installation and Adjustment 1 At engine 1 1 Snap governor cable into throttle body bracket 4 Figure 21 3 Page 2...

Page 416: ...ner 3 2 At transaxle 2 1 Slide bellows off threaded end of cable housing separate jam nuts and place threaded end into governor bracket 4 Figure 21 4 Page 21 4 Figure 21 4 Governor Cable Installation Governor Arm 2 2 Finger tighten the jam nuts 2 3 Push bellows back onto threaded end of cable housing 2 4 Connect Z fitting of governor cable 5 to governor arm 6 Page 21 4 2020 Precedent Villager 2 an...

Page 417: ...to idle position 3 6 Adjust the gap A between governor arm and stop screw 8 to 0 055 in 0 039 1 4 mm 1 Tighten the jam nut 7 to 36 in lb 4 0 N m 3 7 Rotate the governor arm counterclockwise 3 8 Adjust the stop screw 12 until the throttle position sensor is between 75 80 Tighten the jam nut 11 to 36 in lb 4 0 N m 3 9 Check engine RPM adjustment See Engine RPM Adjustment ACCELERATOR CABLE Accelerato...

Page 418: ...he end of the cable housing 4 3 Unsnap the accelerator cable from FNR accelerator cable bracket 5 5 At pedal group 5 1 Remove the floor mat 5 2 Remove the push rivet 6 Figure 21 7 Page 21 6 Figure 21 7 Accelerator Cable At Pedal Group 5 3 Remove the floor cover plate 7 Page 21 6 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 419: ... accelerator cable 2 to governor arm 3 Figure 21 8 Page 21 7 3130B Figure 21 8 Accelerator Cable At Transaxle 1 2 Snap the accelerator cable into FNR accelerator cable bracket 5 1 3 Push the dust shield 4 onto end of cable housing 2 At pedal group 2 1 Insert the accelerator cable through the hole in the frame and feed it towards the pedal group 2 2 Connect the accelerator cable clip 9 to the accel...

Page 420: ...LE ADJUSTMENT To adjust the idle see ECU Reset Procedure and TPS Learn Procedure for Pedal Start Applications in the Kohler Service Manual HOW TO MEASURE GROUND SPEED Best Method An easy way to check ground speed is by using a GPS device or smartphone application app If these are not available use the alternate method below Alternate Method Calculated Ground speed is easily determined by a known d...

Page 421: ...nect the battery and spark plug wire 3 Measure vehicle ground speed See How to Measure Ground Speed 4 Compare measured ground speed with forward ground speed specified in Vehicle Specifications 5 If adjustment is necessary use the following procedures 5 1 To reduce RPM loosen the accelerator cable jam nut on the outside of the electrical component box and tighten the jam nut on the inside of the b...

Page 422: ...hrottle body Figure 21 10 Page 21 10 4 Remove the screws 2 5 Remove the air intake system 3 AIR CLEANER INSTALLATION 1 Install the air intake system 3 into the vehicle Figure 21 10 Page 21 10 2 Install the screws 2 Tighten the screws to 85 in lb 9 5 N m 3 Connect the air intake hose to the throttle body 4 Install the clamp 1 5 Connect the battery and spark plug wire Page 21 10 2020 Precedent Villa...

Page 423: ...ese suggested procedures MUST be followed before attempting ANY service work on the EFI fuel system Following these will relieve any pressure in the fuel hose prior to opening the fuel system TO RELIEVE FUEL PRESSURE Option 1 1 Turn the key switch to OFF 2 Disconnect the battery 3 Wait 15 minutes or more to let the fuel pressure dissipate Option 2 1 Turn the key switch to OFF 2 Disconnect the fuel...

Page 424: ... 4 6 Disconnect the vent line and purge line 7 Remove the carbon canister from the bucket brace 7 1 Lift the tab 5 7 2 Slide the carbon canister towards the fuel tank and remove from the bucket brace CARBON CANISTER INSTALLATION 1 Install the carbon canister 3 on the bucket brace Make sure that the tab 5 is secured Figure 21 11 2 Connect the vent line 1 3 Connect the purge line 2 4 Install the cla...

Page 425: ...The fuel line must be properly routed from the fuel tank to the throttle body The fuel line has dual locking connectors at both ends FUEL LINE REMOVAL WARNING Fuel may be under pressure Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine See Relieving Fuel Pressure Carefully drain any fuel into an approved container Add drained fuel back into fuel tank or ...

Page 426: ...e locking clip 4 Figure 21 13 Page 21 14 Figure 21 13 5 3 Push in and hold the release tab 5 5 4 Remove the fuel line from the throttle body 5 5 Drain the fuel line into an appropriate container 6 At fuel tank 6 1 Pull out the locking clip 6 2 Push in and hold the release tab 6 3 Remove the fuel line from fuel tank Page 21 14 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 427: ... to avoid a leak that can cause a fire 2 Push the fuel line 1 onto the nipple until it locks into place Figure 21 14 Figure 21 14 3 Push in the locking clip 2 until it is fully seated 4 Make sure that the fuel line is 8 5 toward the fuel tank from the bucket brace Figure 21 15 Figure 21 15 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 21 15 ...

Page 428: ... 180 degrees and connect it to the nipple Figure 21 17 Page 21 16 Figure 21 17 8 Push the fuel line until it locks into place 9 Push in the locking clip until it is fully seated DANGER Make sure that the fuel line is connected properly to avoid a leak that can cause a fire Make sure fuel line is the correct length and properly routed Failure to heed this warning could result in damage to fuel line...

Page 429: ...eturning the vehicle to service 16 If no leaks are found set the Maintenance Operate switch in the OPERATE FUEL PUMP MODULE GENERAL INFORMATION NOTE The fuel pump and fuel level sending unit themselves are not replaceable If necessary the fuel pump module must be replaced as an assembly The fuel pump module can be disassembled to replace the fuel filter NOTE Fuel pump replacement kits will include...

Page 430: ... fuel line to prevent the spray of fuel onto hot engine See Relieving Fuel Pressure Carefully drain any fuel remaining in the hose or pump module into an approved container Add drained fuel back into fuel tank or dispose of properly 8 Disconnect the fuel line 4 and drain into an appropriate container See Fuel Line Removal 9 Remove the screws 5 10 Remove the ground wire 6 and hold down ring 7 11 Li...

Page 431: ... NOTE If equipped with a fuel level sending unit carefully maneuver module so as to avoid damaging the float arm mechanism CAUTION Ensure o ring stays seated in place during fuel pump module installation 4 Install the hold down ring 7 5 Install the ground wire 6 and screws 5 See following WARNING Tighten the screws in a crisscross pattern to 66 in lb 7 5 N m WARNING Always install ground wires dur...

Page 432: ...RATE FUEL TANK GENERAL INFORMATION The vehicle is equipped with a high impact plastic fuel tank WARNING If the fuel tank is damaged replace it Do not attempt to repair it See the following tank removal and disposal procedure CAUTION Add only unleaded fuel to the tank Do not put oil in the fuel tank NOTE This gasoline vehicle complies with the California Air Resources Board CARB and EPA evaporative...

Page 433: ...o not attempt to siphon fuel using a hose that does not have a built in suction device Do not attempt to siphon fuel using your mouth 6 Disconnect the wire harness 1 from the fuel pump module Figure 21 21 Page 21 21 Figure 21 21 Fuel Tank Removal 7 Disconnect the vent hose 2 from fuel tank vent 3 8 Disconnect the fuel line 4 from the fuel pump module and drain into an appropriate container See Fue...

Page 434: ...th local state and federal laws and ordinances FUEL TANK STORAGE 1 Remove gas cap and fuel pump module from tank See Fuel Pump Module Removal 2 In a well ventilated area flush the fuel tank with water to remove any remaining fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours ...

Page 435: ...to main wire harness See following WARNING WARNING Always install ground wires during reassembly 4 Connect the fuel line 4 to the fuel pump module See following DANGER DANGER Ensure line is connected properly to avoid a leak that can cause a fire 5 Install the vent line 2 onto the fuel tank vent 3 6 Connect the wire harness 1 to fuel pump module 7 Clean spilled fuel and remove any drained fuel fro...

Page 436: ...it is replaceable if the need should arise In addition the module assembly features a fuel pickup screen to catch larger particles before entering the fuel filter FUEL FILTER REMOVAL 3052E Figure 21 23 Fuel Filter Removal 1 Disable the vehicle 2 Disconnect the battery 3 Remove fuel pump module 1 Figure 21 23 Page 21 24 See Fuel Pump Module Removal 4 Disconnect the flex hoses 2 and 3 from filter 4 ...

Page 437: ...ses 2 and 3 to the fuel filter 2 1 Orient flex hoses with matching port in filter and push each hose end straight into filter until fully seated 2 2 Push hose retainer clip straight into filter until fully seated 3 Install fuel pump module See Fuel Pump Module Installation 4 Connect the battery and spark plug wire 5 Set the Forward Neutral Reverse control FNR to N 6 Chock the wheels 7 Set the Main...

Page 438: ...Pagination Page 21 Fuel Filter GASOLINE VEHICLE FUEL SYSTEM Page 21 26 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 439: ...AL 1 Disconnect the battery and spark plug wire 2 If necessary remove the oxygen sensor 1 from the muffler 2 Figure 22 1 Page 22 1 See Oxygen Sensor Removal Figure 22 1 Muffler Removal 3 Remove the nuts 3 4 Remove the bolt 4 and washer 5 5 Remove the bolts 6 6 Remove the muffler 7 Remove the exhaust gasket 7 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 22 1 ...

Page 440: ... Tighten the bolts 6 to 17 ft lb 23 N m 5 If the oxygen sensor 1 was removed install the oxygen sensor See Oxygen Sensor Installation 6 Connect the battery and spark plug wire 7 Set the Forward Neutral Reverse control FNR to N 8 Set the Maintenance Operate switch to MAINTENANCE 9 Put the chocks against the wheels DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation...

Page 441: ... decreases On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in engine RPM The engine and torque converter rotate counter clockwise as...

Page 442: ...or dirt and dust buildup on its component parts Clean the driven clutch with water to remove any dust or dirt then drive the vehicle and check for proper operation 3 If cleaning the driven clutch does not solve the problem disassemble and thoroughly clean all parts of the drive clutch Be sure to clean the plastic drive buttons 7 Figure 23 2 Page 23 4 Page 23 2 2020 Precedent Villager 2 and 4 Maint...

Page 443: ... driven clutch 1 apart then roll the belt off the driven clutch by rotating the clutch counterclockwise Figure 23 1 Page 23 3 See following CAUTION CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch NOTE Roll away from compression to make removal easier 3 Remove the belt from the drive clutch 2 1 2 594 Figure 23 1 Drive Belt Removal DRIVE BELT INSTALL...

Page 444: ...Split Drive Clutch 4 Cap Plug 13 Sheave Moveable Drive 5 Drive Hub Assy Drive Clutch 14 Spacer Fixed Face Shaft 6 Ring 0 810 in 20 5 mm Internal Retaining 15 Spring Drive Clutch 7 Drive Clutch Button 16 No Item to Show 8 Drive Clutch Weight 17 Spacer Idler Drive 9 Thrust Washer 18 Sheave Fixed Drive 2960 Figure 23 2 Drive Clutch Exploded View Page 23 4 2020 Precedent Villager 2 and 4 Maintenance a...

Page 445: ...ure 23 4 Drive Clutch Removal 3 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the chassis to support the vehicle The weight of the powertrain will allow the centerline of the drive clutch to drop below the frame I beam for access to the bolt securing the drive clutch See following WARNING WARNING Lift only one end of the ...

Page 446: ...f the crankshaft 7 Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft CAUTION Do not hit or tap the clutch with a hammer Do not pry the clutch These actions will damage the clutch DRIVE CLUTCH CLEANING AND INSPECTION 1 Use a dry lint free cloth to clean clutch parts CAUTION Do not lubricate the drive clutch Lubricants attract dirt and dust which in...

Page 447: ...onding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 23 6 Page 23 7 2 4 Unscrew the puller center bolt out of the clutch to pull drive clutch hub off 598 Figure 23 5 Mark Drive Clutch Hub 599 Figure 23 6 Remove Drive Clutch Hub 3 Remove the thrust washer 9 from the moveable sheave 13 Figure 23 2 Page 23 4 4 Remove the...

Page 448: ...3 as shown Figure 23 8 Page 23 8 5 2 Pull the weight assemblies 3 with pins from slots 4 in the clutch See following NOTE NOTE Before removing note the orientation of the wave washer 1 and secondary weight 2 on the primary weight 3 Figure 23 9 Page 23 9 5 3 Remove the plastic washers weights 2 and 3 and wave washer 1 from the pin 4 Retain all parts Page 23 8 2020 Precedent Villager 2 and 4 Mainten...

Page 449: ...re in the fixed sheave Figure 23 2 Page 23 4 See also Figure 23 10 Page 23 9 Discard the rings 605 Figure 23 10 Spiral Back up Rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler spacer 17 for smoothness Figure 23 2 Page 23 4 2 Inspect the bore of the moveable sheave 13 for scarring or wear The moveable sheave must be replaced if the bore is worn to a diameter of 0 883 in 22 4 mm or larger ...

Page 450: ...e retaining ring 6 Figure 23 2 Page 23 4 5 Install the primary weights 3 on the mounting pins 4 Figure 23 9 Page 23 9 6 Install a wave washer 1 on each mounting pin 4 Make sure that the concave side of the washer faces the side of the primary weight 3 with the small guide pin protruding from it Figure 23 9 Page 23 9 7 Install the secondary weights 2 onto the mounting pins 4 with the weight pins on...

Page 451: ... on by hand 16 Replace the three plastic plugs 4 into the holes Figure 23 2 Page 23 4 3054 Figure 23 12 Correct Orientation of Drive Button Take up Springs DRIVE CLUTCH INSTALLATION 1 Place the drive clutch assembly on the crankshaft taper Position the mounting washers 2 and 3 on the bolt 1 and start the bolt into the crankshaft Figure 23 2 Page 23 4 See following NOTE NOTE The drive clutch retain...

Page 452: ...tch 8 Button Drive 3 Ring Retaining 9 Sheave Movable Driven 4 Key Driven Clutch 10 Washer Acetal Driven Clutch 5 Cam Driven Clutch 11 Sheave Fixed Driven 6 Spring Driven Clutch CCW Red 12 Key 3 16 in 4 7 mm Square X 1 50 in 38 mm Long 2961 Figure 23 13 Driven Clutch Exploded View Page 23 12 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 453: ...lutch fixed sheave and on the moveable sheave to maintain balance upon reassembly 2 Set the edge of the clutch body 1 on a clean flat surface Figure 23 14 Page 23 13 Figure 23 14 Driven Clutch Tool Disassembly 3 Assemble the threaded bolt 2 through the washer 3 and thrust collar 4 NOTE It is very important that the bolt washers and thrust bearing assembly be assembled in the order described and sh...

Page 454: ...resulting in severe personal injury 8 Remove the retaining ring 10 Figure 23 15 Page 23 14 608B Figure 23 15 Remove Retaining Ring 9 Insert a puller plug 11 into the shaft bore Figure 23 16 Page 23 14 609B Figure 23 16 Cam Removal 10 Use a driven clutch cam puller 12 to remove the cam 13 from the fixed sheave Page 23 14 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 455: ...3 Slide the moveable sheave 16 off the fixed sheave 17 DRIVEN CLUTCH INSPECTION 1 Inspect the cam for excessive wear Replace it if necessary 2 Inspect the drive buttons 2 for excessive wear Figure 23 18 Page 23 16 Replace if necessary To remove the drive buttons remove the socket head cap screws 1 and then the buttons 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 23 15 ...

Page 456: ...ld be no noticeable wear Replace the fixed sheave if it is worn scratched or damaged 6 Inspect the retaining ring If the outside diameter is more than 1 607 in 40 82 mm replace the retaining ring DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 2 in position Apply one drop of Loctite 222 to each of the socket head cap screws 1 and then install and tighten them to 8 in lb 0 9 N m Figure 23 19...

Page 457: ...ntil the keyway is aligned with the key on the fixed sheave and then start the cam onto the shaft approximately 1 4 to 3 8 in 6 3 to 9 5 mm 6 With the clutch loosely assembled set the edge of the clutch body 9 on a clean flat surface Figure 23 21 Page 23 17 Figure 23 21 Driven Clutch Tool Assembly 7 Assemble the threaded bolt 10 through the washer 11 and thrust collar 12 NOTE It is very important ...

Page 458: ...press plate to press the cam onto the keyed shaft Advance the cam press plate until it is firm against the shaft end WARNING Do not place fingers under the cam when removing the cam The moveable face may spin when the cam buttons release from the cam ramps resulting in severe personal injury 14 Install the retaining ring 18 Figure 23 22 Page 23 18 608C Figure 23 22 Install Retaining Ring 15 Remove...

Page 459: ... through the transaxle to the wheels SHIFTER LEVER A shifter lever connected to a shifter arm is used to change the gears to one of three shift positions forward F neutral N or reverse R Bring the vehicle to a complete stop before changing F or R direction MAINTENANCE OPERATE SWITCH WARNING With the switch in the MAINTENANCE position and the engine running the vehicle may move suddenly if the Forw...

Page 460: ...er normal operating conditions adjustment to the system should not be required LUBRICATION There are two oil port plugs located on the right driven clutch side of the transaxle Figure 24 2 Page 24 3 When the vehicle is on a level surface use the upper plug as a lubricant level indicator Lubricant level should be even with the bottom of level indicator hole Use the lower plug for draining Oil Chang...

Page 461: ...joint pliers 7 16 in socket 3 8 in drive Small flat blade screwdriver External snap ring pliers 0 047 in tip 1 2 in socket 3 8 in drive Medium flat blade screwdrivers 2 90 Internal snap ring pliers 0 090 in tip 9 16 in socket 3 8 in drive No 2 phillips head screwdriver 16 in rolling head prybar 5 8 in socket 3 8 in drive 1 4 in nut driver Plastic or rubber mallet Axle seal tool 5 16 in nut driver ...

Page 462: ...e rear of vehicle 8 Remove the lug nuts and wheel 9 Slide brake drum off hub 10 Remove hub nut 4 and large flat washer 5 and pull hub 6 off axle shaft See following NOTE NOTE If the hub 6 does not slide easily off the axle shaft use a two or four jaw wheel puller to remove the hub 6 1 3 4 5 2 3056 Figure 24 3 Rear Hub Exploded View REAR HUB INSTALLATION 1 Inspect brake shoes for wear and replace i...

Page 463: ... 3 on hub nut 4 and install new cotter pin 2 If necessary tighten hub nut 4 further 177 lb ft 240 N m max until the locking cap 3 and new cotter pin 2 can be installed 11 Deform cotter pin 2 as shown Figure 24 4 Page 24 5 Either way is acceptable No part of the cotter pin 2 should protrude beyond the perimeter of the locking cap 3 12 Install rubber dust cap 1 13 Tighten lug nuts to 65 lb ft 88 N m...

Page 464: ...n be done one side at a time without removing the transaxle 1 Clean debris from drain plug and area around it at the bottom of the transaxle Drain oil Install plug after draining 2 If removing entire transaxle from vehicle remove the transaxle and clean it in preparation for disassembly See Transaxle Removal on page 24 9 See following NOTE NOTE After cleaning move transaxle to a clean location bef...

Page 465: ...2 REAR WHEEL BEARING REMOVAL 1 Remove hub See Rear Hub Removal on page 24 4 2 Remove axle tube 2 from transaxle See Axle Tube and Axle Shaft Removal on page 24 6 3 Remove the snap ring 5 that is in front of the bearing 6 and discard Figure 24 5 Page 24 6 4 Drive axle shaft 3 and bearing 6 from outer end of axle tube 2 as an assembly 5 Use a puller to remove bearing 6 from axle shaft 3 See followin...

Page 466: ...7 will sit Figure 24 5 Page 24 6 2 Using an appropriate sized seal driver drive in new oil seal 7 until 0 0393 in 1 mm below surface not fully seated 3 Clean end of axle shaft 3 and carefully install axle tube 2 to avoid damaging new oil seal 7 with splines of axle shaft See Axle Tube and Axle Shaft Installation on page 24 7 4 Refill transaxle with appropriate type and volume of oil See Oil Change...

Page 467: ...three wires of main wire harness from starter generator Figure 19 14 Page 19 16 9 Loosen jam nuts 1 securing shifter cable 2 to FNR accelerator cable mounting bracket Then remove bowtie clip 3 to disconnect shifter cable end 4 from transaxle shift lever 5 and set shifter cable 2 aside Figure 24 16 Page 24 14 10 Remove bolts 1 securing governor cable bracket 2 and FNR accelerator cable bracket 3 to...

Page 468: ...Both Sides of Frame 18 Continue raising vehicle until chassis is higher than the top of the transaxle i e enough to allow powertrain to be rolled out from under vehicle Figure 24 10 Page 24 10 Position jack stands adjusted to support the vehicle at this height under the frame crossmember between the leaf spring mounts and side stringers just forward of each rear wheel Figure 24 11 Page 24 10 Lower...

Page 469: ...ansaxle Dispose of gear oil properly 24 Remove driven clutch See Driven Clutch Removal Section 23 Page 23 13 25 Remove eight bolts 1 total that secure transaxle to powertrain Figure 24 13 Page 24 12 at the following locations Four bolts 1 at engine pan 2 Two bolts 1 at clutch plate 3 Two bolts 1 at muffler bracket 26 Roll transaxle from engine pan 2 See following NOTE NOTE The transaxle weighs app...

Page 470: ...ection 1 6 Tighten lower nuts of shock absorbers until cushions expand to be the same diameter as the mounting washers 1 7 Tighten transaxle drain plug to 17 lb ft 23 5 N m 2 Fill transaxle with appropriate type and volume of oil See Oil Change Transaxle on page 24 2 3 Ensure that all wires and cables are secured properly with wire ties See following WARNING WARNING If wires and cables are removed...

Page 471: ... 5 N m Figure 24 14 Forward Neutral Reverse Handle SHIFTER CABLE See General Warnings on page 1 2 If the Forward Neutral Reverse shifter cable is damaged in any way it must be replaced SHIFTER CABLE REMOVAL NOTE Before removing cable note cable routing and positions of wire ties or other devices securing the cable to the vehicle When installed cable must be routed and secured as it was originally ...

Page 472: ... was originally from Forward Neutral Reverse shifter handle to transaxle 2 Place rear of cable 2 in FNR accelerator cable bracket with a jam nut 1 on each side of bracket Figure 24 16 Page 24 14 Tighten jam nuts 1 to 22 lb ft 29 8 N m 3 Hook shifter cable end 4 into transaxle shift lever 5 and secure with bowtie clip 3 4 Feed front of cable 2 through its mounting hole and push the plastic anchor i...

Page 473: ...ust the jam nuts 6 at the FNR accelerator cable bracket must be loosened and moved forward or backward as required Figure 24 16 Page 24 14 Tighten jam nuts 6 to 22 lb ft 29 8 N m 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 24 15 ...

Page 474: ...Pagination Page 24 Shifter Cable GASOLINE VEHICLE TRANSAXLE Page 24 16 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 475: ...SECTION 25 KOHLER ENGINE SERVICE MANUAL 25 Kohler Engine Service Manual 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 25 1 ...

Page 476: ...Pagination Page 25 Shifter Cable KOHLER ENGINE SERVICE MANUAL Page 25 2 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 477: ...re Color BLK Black BLU Blue LT BLU Light Blue BRN Brown GRAY Gray GRN Green ORG Orange PINK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow BLK_LT_BLUE Black with Light Blue Stripe BLK_ORG Black with Orange Stripe BLK_PINK Black with Pink Stripe BLK_WHT Black with White Stripe BLK_YEL Black with Yellow Stripe BLU_WHT Blue with White Stripe BRN_WHT Brown with White Stripe GRN_RED Green with Re...

Page 478: ...NESS WIRING DIAGRAM TABLE _ Callout Description 1 Red 2 Red Black 3 Red White 4 Yellow 5 Light Green 6 Dark Green 7 Dark Blue 8 Purple 9 Pink 10 Tan 11 White 12 Grey 13 Black 14 To Main Harness 15 Oil Level Switch 16 10 amp Fuse Ignition Switch 17 10 amp Fuse Battery Power 18 Black Connector 19 Grey Connector 20 Fuel Injector 21 Ignition Coil 22 Crankshaft Position Sensor 23 Oxygen Sensor 24 Throt...

Page 479: ...WIRING DIAGRAMS Engine Harness Wiring Diagram Table 26 25 TMAP Sensor 26 Engine Temperature Sensor 27 Diagnostic Connector 2020 Precedent Villager 2 and 4 Maintenance and Service Manual Page 26 3 ...

Page 480: ...Pagination Page 26 Engine Harness Wiring Diagram Table WIRING DIAGRAMS Page 26 4 2020 Precedent Villager 2 and 4 Maintenance and Service Manual ...

Page 481: ...GASOLINE ENGINE HARNESS Wiring Diagrams Gasoline Engine Harness 26 ...

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Page 483: ...GASOLINE MAIN HARNESS Wiring Diagrams Gasoline Main Harness 26 ...

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Page 485: ...GASOLINE INSTRUMENT PANEL HARNESS Wiring Diagrams Gasoline Instrument Panel Harness 26 ...

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Page 487: ...GASOLINE INSTRUMENT PANEL LIGHT HARNESS Wiring Diagrams Gasoline Instrument Panel Light Harness 26 ...

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Page 489: ...ELECTRIC MAIN HARNESS Wiring Diagrams Electric Main Harness 26 ...

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Page 491: ...ELECTRIC INSTRUMENT PANEL DASH HARNESS Wiring Diagrams Electric Instrument Panel Dash Harness 26 ...

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Page 493: ...ELECTRIC INSTRUMENT PANEL LIGHT HARNESS Wiring Diagrams Electric Instrument Panel Light Harness 26 ...

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Page 495: ...ELECTRIC LIGHT HARNESS Wiring Diagrams Electric Light Harness 26 ...

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Page 497: ...ELECTRIC DC TO DC CONVERTER HARNESS Wiring Diagrams Electric DC to DC Converter Harness 26 ...

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Page 499: ... 15 14 numbering vehicles and chargers 15 14 resetting power external 15 15 resetting power onboard 15 15 terminal block cover 15 15 USB service port 15 14 battery wiring diagram 12 4 bearing axle see transaxle type g axle bearing 17 4 bearing motor see motor bearing 16 11 belt drive see drive belt 23 3 body repair 4 2 gouges punctures tears 4 3 minor impact damage deformations 4 2 minor scratches...

Page 500: ... 11 9 walkaway deterrent 11 8 charge indicator light installation 13 2 removal 13 2 testing 12 31 charger battery ERIC 15 1 charger receptacle inspection 13 14 installation 13 15 removal 13 14 testing 12 27 charger receptacle bezel 4 14 installation 4 15 removal 4 14 charging system test procedures 15 20 choke button bezel installation 4 16 removal 4 16 cleaning brake assembly 6 5 seats 4 2 vehicl...

Page 501: ...nt suspension front wheel hub 7 22 free play inspection 7 22 installation 7 23 removal 7 22 fuel relieving pressure 21 11 fuel filter installation 21 25 removal 21 24 fuel gauge hour meter 19 29 fuel gauge circuit testing 18 29 fuel level sending unit 19 22 fuel level sending unit testing 18 27 hour meter circuit testing 18 30 installation 19 30 removal 19 30 fuel gauge hour meter gasoline vehicle...

Page 502: ... 4 15 removal 4 14 kick plate gasoline 4 16 installation 4 16 removal 4 16 kill limit switch function engine testing 18 13 L low oil warning light installation 19 33 removal 19 33 testing 18 23 lubrication front suspension 7 9 transaxle type g 17 1 M magnet motor speed sensor see motor speed sensor magnet 16 11 maintenance operate switch 24 1 maintenance operate switch pedal start testing 18 15 ma...

Page 503: ...49 seat assembly removal 4 49 seat bottom installation 4 48 seat bottom removal 4 48 side frame installation 4 51 side frame removal 4 51 foot deck 4 53 assembly 4 55 disassembly 4 54 installation 4 56 removal 4 53 rear underbody 4 57 4 58 installation 4 58 nstallation 4 57 removal 4 57 4 58 seat back 2 2 4 43 installation 4 44 removal 4 43 seat support 4 52 installation 4 52 removal 4 52 rear bod...

Page 504: ...on 19 5 replacement 19 5 commutator 19 7 armature replacement 19 10 cleaning 19 10 inspection 19 10 disassembly 19 5 19 7 field coil inspection 19 12 removal 19 9 installation 19 15 removal 19 4 rework 19 12 testing 18 17 18 18 steering column 7 4 installation 7 5 removal 7 4 steering wheel 7 1 installation 7 2 removal 7 1 suspension front lubrication 7 9 suspension front non lifted camber adjustm...

Page 505: ...er generator 18 17 18 18 transacle limit switch 18 16 voltage regulator 18 20 test procedures index of gasoline vehicle 18 7 test procedures motor 1 internal short circuits 16 2 2 armature circuit open 16 2 3 field circuit open 16 3 armature ground test 16 9 testing armature ground test starter generator 19 11 throttle body 21 1 throttle position sensor 5 3 5 5 tie rod and drag link removal 7 9 ti...

Page 506: ...res 12 32 18 31 voltage regulator installation 19 20 removal 19 20 testing 18 20 W walk away braking 12 3 water level see batteries electrolyte level 14 10 wheel installation 8 1 removal 8 1 see also tire 8 1 wheel bearing installation 24 7 removal 24 7 wiring diagrams engine wire harness 26 2 ...

Page 507: ...NOTES ...

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Club Car DS Villager 4, Maintenance And Service Manual

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