Club Car EX40D Service, Repair, And Rebuild Manual Download

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Manual Number 105062943

Edition Code 0114A00000

EX40 EFI Engine

Service, Repair, and

Rebuild Manual

Summary of Contents for EX40D

Page 1: ...Manual Number 105062943 Edition Code 0114A00000 EX40 EFI Engine Service Repair and Rebuild Manual...

Page 2: ......

Page 3: ...PROCEDURE 19 4 ENGINE OIL 32 5 IGNITION SYSTEM 33 6 WIRING DIAGRAM 33 7 OIL SENSOR 34 8 TROUBLESHOOTING 35 9 ELECTRIC FUEL INJECTION SYSTEM 41 10 STANDARD REPAIR TABLES 49 10 1 STANDARD DIMENSIONS AN...

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Page 5: ...de Cooling System Forced air cooling system Lubrication System Splash lubrication system Lubricant Automobile engine oil Grade SE or higher SG SH or SJ in recomended SAE 10W 30 Under ordinary atmosphe...

Page 6: ...an be inspected with ease Pilots and bosses are machined into the cover to facilitate the direct coupling of the engine with machines such as generators and pumps Oil gauges fillers are on both sides...

Page 7: ...ain driven overhead cam and overhead valve construction with a single cam which has individual profile for intake and exhaust to perform high output Fig 2 6 Fig 2 5 TOP RING SECOND RING OIL RING 1 2 3...

Page 8: ...alves of the engine are lubricated with oil in the crankcase The oil is splashed onto the parts by the oil splasher on the connecting rod 2 9 COOLING SYSTEM The engine uses a forced air cooling system...

Page 9: ...vibration Fig 2 11 2 12 IGNITION SYSTEM The ignition system is a flywheel magneto digital C D I system The magneto consists of a flywheel and ignition coil The flywheel cooling fan is separete from th...

Page 10: ...make reassembly easier 3 To prevent parts from being mislaid keep each group provisionally assembled after removing the parts from the engine 4 Handle the disassembled parts with the utmost care Clea...

Page 11: ...in the engine oill Remove a drain plug M14 x 12mm located on both sides of the case Take care not to lose the gaskets To discharge oil quickly remove the oil guage M22 14 mm spanner 2 Remove oil fille...

Page 12: ...Step Parts to remove Remarks and procedures Fasteners 3 Blower housing 1 Remove the blower housing synthetic resin from the crankcase 10 mm box spanner M6 x 16 mm 5 pcs BLOWER HOUSING M6 x 16 BOLT 5...

Page 13: ...o remove Remarks and procedures Fasteners 4 Throttle body Insulator Remove the carburetor from the cylinder head Remove the insulator operation bracket GASKET GASKET ADAPTER AIR INTAKE THROTTLE BODY G...

Page 14: ...y knocking the wrench sharply with a hammer See Fig 3 6 NOTE 1 Do not insert a screwdriver or other object between the flywheel blades which is a synthetic resin otherwise the risk of damaging the bla...

Page 15: ...11 Step Parts to remove Remarks and procedures Fasteners 8 Baffle 1 Case Remove the Baffle 1 from the crankcase 12 mm box spanner M8 x 12 mm 1 pc Fig 3 8 M8 x 12 BOLT 1 pc BAFFLE 1 CASE STEP 8...

Page 16: ...ngine which has the oil sensor However please make sure do not damaged cut off the oil sensor wire after disassembly procedure 10 mm box spanner M6 x 10 mm 1 pc 10 Spark plug Remove the spark plug fro...

Page 17: ...emove the pin rocker arm and the rocker arm from the cylinder head at the compression top dead center See Fig 3 12 ROCKER ARM EXHAUST VALVE SIDE ROCKER ARM INTAKE VALVE SIDE PIN ROCKER ARM Punch marks...

Page 18: ...cover from the crankcase Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool See Fig 3 14 Be careful not to damage the oil gauge or oil seal or...

Page 19: ...not lose the pin tensioner 2 Remove the retaining bolt of pin camshaft from the cylinder head See Fig 3 17 3 Remove the pin camshaft taking care not to scratch the O ring 4 Remove the chain from the c...

Page 20: ...removed from the inner side of the crankcase it might be damaged 12 mm box spanner M10 75mm 4 pcs M8 35mm 2 pcs 16 Intake and exhaust valves 1 Remove the collet valve from the spring retainer See Fig...

Page 21: ...from the upper part of the cylinder 12 mm box spanner M8 x 40mm 2 pcs 18 Piston and piston rings 1 Remove the piston clips 2 pcs Take out the piston pin and then remove the piston from the connecting...

Page 22: ...nkshaft 1 Remove the woodruff key for the flywheel magneto 2 Remove the crankshaft from the crankcase by tapping its magneto side end with a plastic hammer taking care not to damage the oil seal See F...

Page 23: ...rankshaft connecting rod and bearings 2 Scrape off any carbon deposits on the cylinder head and the piston head Be particularly careful when removing carbon from the piston ring grooves 3 Inspect the...

Page 24: ...e careful not to twist the rings too much as they may be damaged Install the oil ring first followed by the top ring When installing the piston ring make sure that the R mark is face up See Fig 3 29 F...

Page 25: ...the MAG mark on the connecting rod 5 CONNECTING ROD a Install the piston and connecting rod assembly into the cylinder by holding the piston rings with the ring guide with the MAG mark on the connect...

Page 26: ...er to the STANDARD REPAIR TABLES on page 49 and 50 NOTE 2 Carefully scrape off any carbon deposits on the combustion chamber Apply oil to the valve stems before mounting the intake and exhaust valves...

Page 27: ...CHAIN GUIDE Fig 3 36 Models EX40 mounting positions 8 CYLINDER HEAD Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing Fig 3 38 M8 x 35 BOLT 2 pc...

Page 28: ...x 12 BOLT 1 pc Bolt used to prevent the pin camshaft from coming out Fig 3 39 9 SETTING THE TIMING CHAIN a Align the timing mark on the crankshaft sprocket with the mark plate of the timing chain b Al...

Page 29: ...LANCER GEAR BALANCER GEAR TIMING MARK for CHAIN 12 BALANCER SHAFT Mount the balancer shaft on the crankcase align the timing marks on the balancer gear and the crankshaft gear NOTE Incorrect alignment...

Page 30: ...Three Bond 1215 to the surface of the crankcase To avoid damaging the oil seal lip wrap the crankshaft key way portion with polyvinyl tape before mounting the main bearing cover Fig 3 44 MAIN BEARING...

Page 31: ...ROCKER ARM EXHAUST VALVE SIDE ROCKER ARM INTAKE VALVE SIDE 14 Pass the pin rocker arm through the rocker arm and mount them on the cylinder head NOTE 1 Conduct this job at the compression top dead cen...

Page 32: ...BR 6HS 21 mm plug wrench 16 ROCKER COVER Replace the gasket with a new one and mount the rocker cover M6 12 mm flange bolt 4 pcs Fig 3 49 M8 x 12 BOLT 1 pc PROJECTION BAFFLE 1 CASE Fig 3 48 SPARK PLU...

Page 33: ...ting pulley to the crankshaft c Tighten crankshaft nut with a strap wrench adopted as shown in the illustration COOLING BLOWER WASHER Fig 3 50 Fig 3 51 Fig 3 52 Fig 3 53 STRAP WRENCH IGNITION COIL THI...

Page 34: ...m screw and washer 2 pcs Tighten the wire 2 ground with the stop switch See Detail C 2 Mount the blower housing on the crankcase M6 16 mm bolt 5 pcs Tighten the wire 2 ground with the blower housing S...

Page 35: ...ut your hand with the muffler gasket to MUFFLER GASKET Attention to the direction of bulge forming Tightening torque Recommend 18 0 22 0 N m 180 220 kgf cm 13 0 16 2 ft lb 24 EXTERNAL INSPECTION Reass...

Page 36: ...falls below 20 or rises above 40 be sure to choose engine oil of appropriate viscosity and grade according to the prevailing conditions Care must be taken when using multi grade engine oil because th...

Page 37: ...y the digital CDI and the ignition timing is variable according to engine speed The flywheel cooling fan is separate from the flywheel is directly mounted on the crankshaft and the ignition coil is di...

Page 38: ...t moves up When the oil level is lower level the float moves down The permanent magnet is close to the lead switch and the lead switch is activated by the magnetic force NOTE With regards to the wirin...

Page 39: ...n the cylinder 3 Good spark properly timed to ignite the mixture The engine cannot be started unless these three conditions are met There are also other factors which make engine start difficult e g a...

Page 40: ...fuel lines Check and adjust connecting portion 5 Improper gasoline or water infiltration Replace 6 Throttle body Poor connection or discontinuity of throttle body ECU Clogged or damaged Improper oper...

Page 41: ...alfunction 1 Throttle body clogged Check and replace 2 Improper fuel pump operation Check and replace 3 Fuel strainer or fuel hose clogged Clean or replace 4 Air mixing into fuel lines Check and adjus...

Page 42: ...act 3 Excessive clearance between valve stem and guide Replace 5 Ignition system 1 Weak ignition spark Check and replace spark plug Phenomenon Possible causes Remedy 1 Oil leakage 1 Loosen drain plug...

Page 43: ...ilure diagnosis system and connect properly 2 Improper or damaged spark plug Clean or replace 2 Fuel system malfunction 1 Lean or rich air fuel mixture Check or replace throttle body 2 Throttle body d...

Page 44: ...em wirings Check with failure diagnosis system and connect properly 2 Fuel system 1 Lean or rich air fuel mixture Check and replace throttle body 2 Clogged throttle body Check and replace 3 Throttle b...

Page 45: ...luding starting acceleration fuel consumption output power characteristics The throttle body monitors air and engine temperature at start up and performs the choke function automatically While the eng...

Page 46: ...o controls the low oil sensor system and monitors voltage of DC battery and each wiring whether disconnecting or electrical short circuit 9 1 3 CHOKE SYSTEM The throttle body monitors air pressure and...

Page 47: ...16 117 118 10 11 12 13 14 15 16 17 18 101 102 103 104 105 106 107 108 109 1 2 3 4 5 6 7 8 9 JAPAN AVIATION ELECTRONIC INDUSTRY PARTS No MX23A18NFG COLOR GRAY JAPAN AVIATION ELECTRONIC INDUSTRY PARTS N...

Page 48: ...to the ON position 4 Measure the voltage between the terminals of the connector with voltage range of circuit tester 5 When the measurements are the table value below the ECU is normal The engine case...

Page 49: ...the resistance between the terminal 1 of injector connector and ECU terminal 101 with resistance range of circuit tester harness side 8 When the measurements are the table value below the ECU is norma...

Page 50: ...rminal 113 with resistance range of circuit tester harness side 11 Measure the resistance between the terminal 3 and ECU terminal 116 earth with resistance range of circuit tester harness side 12 When...

Page 51: ...e not within factory specification replace the ignition coil 4 Check the state of the harness and if it is abnormal replace it Terminal C Circuit tester Terminal B Terminal A Ignition coil Fig 9 8 Ign...

Page 52: ...E IF MORE THAN ONE FAILURE OCCURED BLINK CODE WILL BE DISPLAYED IN ORDER FROM 21 TO 51 FOLLOWED BY A PAUSE DISPLAY MODE CONDITION LAMP CONTROL BLINK CODE NO FAILURE STEP1 LAMP OFF DETECT FAILURE STEP1...

Page 53: ...epaired 10 1 STANDARD DIMENSIONS AND LIMITS OF USE ITEM STD Limit CYLINDER HEAD Flatness 0 05 0 002 0 1 0 004 Intake exhaust valve seat contact width Intake Exhaust 0 7 1 0 0 0276 0 0394 Intake exhaus...

Page 54: ...meter reached to 0 1 0 004 First reboring 89 250 89 272 3 5138 3 5147 Ditto Second reboring 89 500 89 522 3 5236 3 5245 Ditto Less than 0 01 0 0004 Less than 0 015 0 0006 PISTON Outer diameter at skir...

Page 55: ...9 Piston pin hole 20 989 21 022 0 8263 0 8276 21 045 0 82854 Piston pin outer diameter 20 992 21 000 0 8265 0 8268 20 960 0 8252 Clearance between piston and cylinder at skirt 0 065 0 107 0 0026 0 004...

Page 56: ...end inner diameter 21 010 21 023 0 8272 0 8277 21 08 0 8299 Clearance between small end and piston pin 0 010 0 032 0 0004 0 0013 0 12 0 0047 Large end side clearance 0 100 0 780 0 0039 0 0307 1 0 0 0...

Page 57: ...eter Pin outer diameter D3 D4 9 953 9 975 0 3919 0 3927 9 95 0 3917 INTAKE EXHAUST VALVES Valve stem outer diameter Intake 5 970 5 985 0 2350 0 2356 5 85 0 2303 Exhaust 5 970 5 985 0 2350 0 2356 5 85...

Page 58: ...a 90 b 0 7 1 0 0 0276 0 0394 2 0 0 0787 CHAIN LENGTH 346 20 13 6299 349 0 13 7402 160N 16kgf F L L EX40 Compression pressure Mpa 500 rpm 1 15 Mpa Lubricant Capacity L 1 2 Effective Capacity mL 600 Co...

Page 59: ...275 16 3 19 9 Flywheel nut 100 0 120 0 1000 1200 72 3 86 8 Main bearing cover bolts 22 0 24 0 220 240 16 2 17 7 Spark plug New 12 0 15 0 120 150 8 7 10 8 Re tightening 23 0 27 0 230 270 16 6 19 5 Muff...

Page 60: ...detailed instructions on proper disposal Note 2 As to the procedures please refer to the Service Manual or consult your nearest service dealer Note 3 More frequent oil changing oil filter replacement...

Page 61: ...bove 2 To prevent rust in the cylinder bore inject 5cc oil through the spark plug hole run motor 1 2 seconds and then put back the spark plug 3 Clean the exterior of the engine with an oiled cloth Pla...

Page 62: ...NOTES...

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Page 64: ...Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808...

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