Club Car Precedent Villager 2 Manual
2019PrecedentVillager2
Maintenanceand
ServiceManual
ElectricVehiclewithERICChargingSystem
GasolineVehiclewithSubaruEX40Engine
ManualNumber105355116
EditionCodeB
FOREWORD
ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper
maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.
Thismanualprovidesdetailedinformationforthemaintenanceandrepairof2019PrecedentVillager2electricand
gasoline-poweredvehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovided
hereinmustbeproperlyimplemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.
Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland
mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe
vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed
byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.
ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand
facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,
vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications
alsorepresentClubCar’scontinuingcommitmenttocustomersupport.
ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout
ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sT echnicalServicesdepartmentfora
listofupcomingclasses.
Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga
vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized
ClubCardealerordistributorforassistance.
TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan
thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode
readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.
Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,
Augusta,Georgia30917-4658USA.
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Copyright©2019ClubCar,LLC
ClubCarisaregisteredtrademarkofClubCar,LLC
ThismanualeffectiveJuly,2019
2019PrecedentVillager2MaintenanceandServiceManualPagei
FOREWORD
TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY
Letyourvoicebeheard!
PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.
Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance
andidentifyareasforfutureimprovement.
Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.
Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.
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WARNING
•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking
tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.
Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar
dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe
obligationofmakingchangestounitspreviouslysold.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
Owner’sManual.
CONTENTS
SECTION1—Safety.........................................................................................................................................1-1
SafetyDetails................................................................................................................................................1-1
GeneralWarnings..........................................................................................................................................1-2
DisablingtheVehicle..................................................................................................................................1-3
DisconnectingtheBattery-GasolineVehicles..............................................................................................1-3
ConnectingtheBattery-GasolineVehicles..................................................................................................1-3
DisconnectingtheBatteries–ElectricVehicles............................................................................................1-4
ConnectingtheBatteries–ElectricVehicles................................................................................................1-4
RecyclingLead-AcidBatteries....................................................................................................................1-5
Internationalsafetysymbolsonbatteries.....................................................................................................1-5
SECTION2—VehicleSpecications..................................................................................................................2-1
VehicleSpecications–ElectricandSubaruEX40..........................................................................................2-1
E.R.I.C.BatteryChargerSpecications...........................................................................................................2-3
SECTION3—GeneralInformation.....................................................................................................................3-1
ModelIdentication........................................................................................................................................3-1
SafetyCommittee..........................................................................................................................................3-2
Storage–ElectricVehicle...............................................................................................................................3-3
PreparingtheElectricVehicleforExtendedStorage.....................................................................................3-3
ReturningtheStoredElectricVehicletoService..........................................................................................3-4
Storage–GasolineVehicle............................................................................................................................3-5
PreparingtheGasolineVehicleforExtendedStorage.................................................................................3-5
ReturningtheStoredGasolineVehicletoService........................................................................................3-6
SECTION4—BodyandTrim............................................................................................................................4-1
CleaningtheVehicle......................................................................................................................................4-1
Seat..........................................................................................................................................................4-1
FrontandRearBodyRepair...........................................................................................................................4-2
StressLinesorStreaks..............................................................................................................................4-2
MinorImpactDamage/Deformations...........................................................................................................4-2
MinorScratchesandSurfaceBlemishes.....................................................................................................4-3
Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3
FrontBody....................................................................................................................................................4-3
FrontBodyRemoval..................................................................................................................................4-3
FrontBodyInstallation...............................................................................................................................4-3
FrontBumper................................................................................................................................................4-5
HeadlightAdjustment.....................................................................................................................................4-6
AimingtheHeadlightBeam........................................................................................................................4-6
InstrumentPanel...........................................................................................................................................4-7
InstrumentPanelRemoval.........................................................................................................................4-7
InstrumentPanelInstallation......................................................................................................................4-7
FloorMatandRetainers.................................................................................................................................4-8
FloorMatRetainerRemoval.......................................................................................................................4-8
FloorMatRetainerInstallation....................................................................................................................4-8
KickPlateandChargerReceptacleBezel–ElectricVehicles...........................................................................4-9
KickPlateandChargerReceptacleBezelRemoval.....................................................................................4-9
KickPlateandChargerReceptacleBezelInstallation...................................................................................4-9
KickPlate–EFIGasolineVehicles...............................................................................................................4-10
KickPlateRemoval..................................................................................................................................4-10
KickPlateInstallation...............................................................................................................................4-10
SeatBottom.................................................................................................................................................4-11
RearBody....................................................................................................................................................4-11
UniversalAccessoryMounting...................................................................................................................4-11
SeatBackandStructuralAccessoryModule(SAM)...................................................................................4-12
RearBodyComponents...........................................................................................................................4-13
2019PrecedentVillager2MaintenanceandServiceManualPageiii
SECTION5—AcceleratorandBrakePedalGroup.............................................................................................5-1
PedalGroup–ElectricVehicle.......................................................................................................................5-1
PedalGroupRemoval................................................................................................................................5-1
MCOR......................................................................................................................................................5-3
PedalGroupInstallation.............................................................................................................................5-3
PedalGroup–GasolineVehicle.....................................................................................................................5-4
PedalGroupRemoval................................................................................................................................5-4
ThrottlePositionSensor.............................................................................................................................5-5
PedalGroupInstallation.............................................................................................................................5-6
DebrisShields...............................................................................................................................................5-6
AcceleratorPedalRemoval............................................................................................................................5-6
AcceleratorPedalInstallation.........................................................................................................................5-6
BrakePedalRemoval....................................................................................................................................5-7
BrakePedalInstallation.................................................................................................................................5-7
SECTION6—WheelBrakeAssemblies.............................................................................................................6-1
GeneralInformation.......................................................................................................................................6-1
BrakeShoeRemoval.....................................................................................................................................6-1
BrakeAssemblyCleaning..............................................................................................................................6-4
BrakeShoeInstallation..................................................................................................................................6-6
BrakeCableEqualizerAdjustment..................................................................................................................6-8
BrakeClusterRemovalandInstallation...........................................................................................................6-9
BrakeClusterRemoval..............................................................................................................................6-9
BrakeClusterInstallation.........................................................................................................................6-10
BrakeCableRemovalandInstallation...........................................................................................................6-12
BrakeCableRemoval..............................................................................................................................6-12
BrakeCableInstallation...........................................................................................................................6-13
SECTION7—SteeringandFrontSuspension....................................................................................................7-1
GeneralInformation.......................................................................................................................................7-1
SteeringWheel..............................................................................................................................................7-1
SteeringWheelRemoval............................................................................................................................7-1
SteeringWheelInstallation.........................................................................................................................7-2
SteeringColumn............................................................................................................................................7-2
SteeringColumnRemoval..........................................................................................................................7-2
SteeringColumnInstallation.......................................................................................................................7-3
RackandPinion............................................................................................................................................7-4
RackandPinionInspection........................................................................................................................7-4
RackandPinionRemoval..........................................................................................................................7-5
RackandPinionInstallation.......................................................................................................................7-5
FrontSuspension..........................................................................................................................................7-6
Lubrication................................................................................................................................................7-6
WheelAlignment.......................................................................................................................................7-6
FrontSuspensionComponents.......................................................................................................................7-8
TieRodEndRemoval................................................................................................................................7-8
TieRodInstallation....................................................................................................................................7-8
LeafSpringRemoval.................................................................................................................................7-9
LeafSpringInstallation...............................................................................................................................7-9
KingpinandSteeringSpindleRemoval.......................................................................................................7-9
KingpinandSteeringSpindleInstallation...................................................................................................7-10
ControlArmRemoval...............................................................................................................................7-10
ControlArmInstallation............................................................................................................................7-10
ShockAbsorberRemoval..........................................................................................................................7-11
ShockAbsorberInstallation.......................................................................................................................7-11
FrontWheelBearingsandHubs...................................................................................................................7-14
FrontWheelFreePlayInspection.............................................................................................................7-14
FrontHubRemoval..................................................................................................................................7-14
HubInstallation........................................................................................................................................7-14
Pageiv2019PrecedentVillager2MaintenanceandServiceManual
SECTION8—WheelsandTires........................................................................................................................8-1
GeneralInformation.......................................................................................................................................8-1
Wheels.........................................................................................................................................................8-1
WheelRemoval.........................................................................................................................................8-1
WheelInstallation......................................................................................................................................8-1
Tires.............................................................................................................................................................8-2
TireRemoval.............................................................................................................................................8-2
TireRepair................................................................................................................................................8-2
TireInstallation..........................................................................................................................................8-3
SECTION9—RearSuspension........................................................................................................................9-1
GeneralInformation.......................................................................................................................................9-1
ShockAbsorbers...........................................................................................................................................9-1
ShockAbsorberRemovalandInspection....................................................................................................9-1
ShockAbsorberInstallation........................................................................................................................9-1
LeafSprings..................................................................................................................................................9-2
LeafSpringRemoval.................................................................................................................................9-2
LeafSpringInstallation...............................................................................................................................9-3
SECTION10—PeriodicMaintenance..............................................................................................................10-1
GeneralInformation.....................................................................................................................................10-1
Pre-OperationandDailySafetyChecklist......................................................................................................10-1
..............................................................................................................................................................10-1
PerformanceInspection...........................................................................................................................10-2
Maintenance...............................................................................................................................................10-3
PeriodicServiceSchedules..........................................................................................................................10-4
PeriodicLubricationSchedules.....................................................................................................................10-8
SECTION11—ControllerDiagnosticT ool(CDT)...............................................................................................11-1
GeneralInformation......................................................................................................................................11-2
Features..................................................................................................................................................11-2
PluggingtheCDTintotheVehicle..................................................................................................................11-3
IntroductoryDisplay..................................................................................................................................11-3
QuickReferenceGuide–ExcelwithERICChargingSystem...........................................................................11-4
SystemInfo..................................................................................................................................................11-5
ModelNumber..........................................................................................................................................11-5
SerialNumber..........................................................................................................................................11-5
HardwareVersion.....................................................................................................................................11-5
ProtocolVersion.......................................................................................................................................11-5
ParamBlockVersion.................................................................................................................................11-5
MFGDateCode.......................................................................................................................................11-5
OSVersion...............................................................................................................................................11-5
SMVersion..............................................................................................................................................11-5
VCLAppVersion......................................................................................................................................11-5
Parameters..................................................................................................................................................11-6
Settings...................................................................................................................................................11-6
AmpHours...............................................................................................................................................11-8
AccessCodes..........................................................................................................................................11-8
VehicleID................................................................................................................................................11-9
MonitorMenu...............................................................................................................................................11-9
BattVoltage............................................................................................................................................11-10
VminI...................................................................................................................................................11-10
SignedBatteryCurrent............................................................................................................................11-10
BDIPercent............................................................................................................................................11-10
Speed....................................................................................................................................................11-10
Throttle..................................................................................................................................................11-10
Temperature...........................................................................................................................................11-10
ArmCurrent...........................................................................................................................................11-10
FieldCurrent..........................................................................................................................................11-10
ArmaturePWM.......................................................................................................................................11-11
2019PrecedentVillager2MaintenanceandServiceManualPagev
FieldPWM.............................................................................................................................................11-11
SpeedPulses.........................................................................................................................................11-11
FootInput..............................................................................................................................................11-11
KeyInput...............................................................................................................................................11-11
ForwardInput.........................................................................................................................................11-11
ReverseInput.........................................................................................................................................11-11
ModeSwitchInput..................................................................................................................................11-11
ChargerInhibit........................................................................................................................................11-11
MainContDriver....................................................................................................................................11-11
LEDDriver.............................................................................................................................................11-11
PasswordTries(OEMAccessLevelOnly)................................................................................................11-12
Odometer...............................................................................................................................................11-12
BDIInfo.................................................................................................................................................11-12
BatteryMonitor.......................................................................................................................................11-12
ChargingTotals......................................................................................................................................11-12
AmpHoursDisplay.................................................................................................................................11-13
LIN........................................................................................................................................................11-13
VehicleSpeeds.......................................................................................................................................11-13
PedalCounters.......................................................................................................................................11-13
FaultCounters........................................................................................................................................11-13
FaultCountOdometers...........................................................................................................................11-13
DiagnosticsMenu.......................................................................................................................................11-14
PresentErrorsFolder..............................................................................................................................11-14
FaultHistoryFolder................................................................................................................................11-14
CausesofFaults....................................................................................................................................11-15
FaultRecovery.......................................................................................................................................11-17
FaultDescriptions.......................................................................................................................................11-18
IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-18
MaxPasswordTries(OEMAccessLevelOnly)........................................................................................11-18
ThrottleFault..........................................................................................................................................11-18
LowBatteryVoltage(Undervoltage).........................................................................................................11-18
Overvoltage............................................................................................................................................11-18
ThermalCutback....................................................................................................................................11-19
Anti-TamperFault...................................................................................................................................11-19
HPD......................................................................................................................................................11-19
MainDrvrOverCurrent............................................................................................................................11-19
LockoutFault.........................................................................................................................................11-19
LowSOC...............................................................................................................................................11-19
MainWelded..........................................................................................................................................11-20
HighSpeedWalkAway............................................................................................................................11-20
Speedsensor.........................................................................................................................................11-20
MainDriverOn.......................................................................................................................................11-20
MainCoilOpen.......................................................................................................................................11-20
MainDropout(1or2)..............................................................................................................................11-21
MotorStall..............................................................................................................................................11-21
MainDriverOff.......................................................................................................................................11-21
CurrentSenseFault................................................................................................................................11-21
M–Shorted............................................................................................................................................11-21
FLD(Field)Missing.................................................................................................................................11-22
HWFailsafe...........................................................................................................................................11-22
FaultHistory...........................................................................................................................................11-22
ClearFaultHistory..................................................................................................................................11-22
Programming.............................................................................................................................................11-22
Cloning..................................................................................................................................................11-23
Favorites....................................................................................................................................................11-23
HHPSettings.............................................................................................................................................11-23
Plot&Log..................................................................................................................................................11-25
Plot........................................................................................................................................................11-25
Log........................................................................................................................................................11-25
CDTTroubleshooting..................................................................................................................................11-26
ConnectionTests........................................................................................................................................11-27
Pagevi2019PrecedentVillager2MaintenanceandServiceManual
SECTION12—ElectricVehicle-ExcelSystemTroubleshooting........................................................................12-1
GeneralInformation.....................................................................................................................................12-1
Accessories.............................................................................................................................................12-1
ChargeIndicatorLight..............................................................................................................................12-1
Features.................................................................................................................................................12-1
BatteryWiringDiagram................................................................................................................................12-3
SonicWeld,Fuse,and10kOhmResistorLocations......................................................................................12-4
Troubleshooting...........................................................................................................................................12-5
TroubleshootingtheVehiclewiththeCDT.................................................................................................12-5
TroubleshootingGuide1..........................................................................................................................12-5
TroubleshootingGuide2..........................................................................................................................12-8
TestProcedures.........................................................................................................................................12-11
TestingBasics........................................................................................................................................12-11
SECTION13—ElectricVehicle-ElectricalComponents...................................................................................13-1
KeySwitch..................................................................................................................................................13-1
TestingtheKeySwitch.............................................................................................................................13-1
KeySwitchRemoval................................................................................................................................13-1
KeySwitchInstallation.............................................................................................................................13-1
ChargeIndicatorLight..................................................................................................................................13-2
TestingtheChargeIndicatorLight.............................................................................................................13-2
ChargeIndicatorLightRemoval................................................................................................................13-2
ChargeIndicatorLightInstallation.............................................................................................................13-2
Forward/ReverseRockerSwitch...................................................................................................................13-3
TestingtheForward/ReverseRockerSwitch..............................................................................................13-3
Forward/ReverseRockerSwitchRemoval.................................................................................................13-3
Forward/ReverseRockerSwitchInstallation..............................................................................................13-4
ElectronicsModuleCover.............................................................................................................................13-5
ElectronicsModuleCoverRemoval..........................................................................................................13-5
ElectronicsModuleCoverInstallation........................................................................................................13-5
Tow/RunSwitch...........................................................................................................................................13-6
TestingtheTow/RunSwitch......................................................................................................................13-6
Tow/RunSwitchRemoval.........................................................................................................................13-6
Tow/RunSwitchInstallation......................................................................................................................13-6
MotorControllerOutputRegulator(MCOR)...................................................................................................13-7
TestingtheMCOR...................................................................................................................................13-7
MCORRemoval......................................................................................................................................13-7
MCORInstallation...................................................................................................................................13-7
ReverseBuzzer...........................................................................................................................................13-8
TestingtheReverseBuzzer......................................................................................................................13-8
ReverseBuzzerRemoval.........................................................................................................................13-8
ReverseBuzzerInstallation......................................................................................................................13-8
ElectronicsModule......................................................................................................................................13-9
ElectronicsModuleRemoval....................................................................................................................13-9
ElectronicsModuleInstallation................................................................................................................13-10
SpeedController........................................................................................................................................13-11
TestingtheSolidStateSpeedController..................................................................................................13-11
SpeedControllerRemoval......................................................................................................................13-11
SpeedControllerInstallation....................................................................................................................13-11
Solenoid.....................................................................................................................................................13-12
TestingtheSolenoid...............................................................................................................................13-12
SolenoidRemoval..................................................................................................................................13-12
SolenoidInstallation................................................................................................................................13-13
ChargerReceptacle....................................................................................................................................13-13
TestingtheChargerReceptacle...............................................................................................................13-13
ChargerReceptacleInspection................................................................................................................13-13
ChargerReceptacleRemoval..................................................................................................................13-13
ChargerReceptacleInstallation...............................................................................................................13-14
SECTION14—ElectricVehicle-Batteries.......................................................................................................14-1
GeneralInformation.....................................................................................................................................14-1
2019PrecedentVillager2MaintenanceandServiceManualPagevii
BatteryTestingBasics–8Volt......................................................................................................................14-2
Observation.............................................................................................................................................14-2
MeasuringVoltageofBatterySet..............................................................................................................14-2
BatteryCellNumbering............................................................................................................................14-2
BatteryTesting–8Volt................................................................................................................................14-3
BatteryRegrouping......................................................................................................................................14-3
BatteryReplacement...................................................................................................................................14-5
BatteryCare................................................................................................................................................14-6
WaterQuality..........................................................................................................................................14-6
BatteryCare–VehiclesEquippedwiththeOptionalSingle-PointWateringSystem(SPWS).........................14-7
BatteryCare–VehiclesWithouttheSingle-PointWateringSystem(SPWS)................................................14-8
Self-Discharge.........................................................................................................................................14-9
ElectrolyteLevel......................................................................................................................................14-9
VibrationDamage...................................................................................................................................14-10
SinglePointWateringSystem(SPWS).........................................................................................................14-10
InitialMaintenanceoftheSPWS..............................................................................................................14-10
WateringBatterieswiththeSPWS...........................................................................................................14-10
BatteryStorage..........................................................................................................................................14-11
Deep-Discharge.........................................................................................................................................14-11
EarlyExcessiveDischarging.......................................................................................................................14-11
SECTION15—ElectricVehicle-BatteryCharger.............................................................................................15-1
GeneralInformation.....................................................................................................................................15-2
USBServicePort.....................................................................................................................................15-3
ULandCSAListing.................................................................................................................................15-3
CECompliance.......................................................................................................................................15-3
PlugandReceptacle................................................................................................................................15-3
ChargerPowerConnectionFuse..............................................................................................................15-4
ChargerInterlock.....................................................................................................................................15-4
ACInputVoltageDetection......................................................................................................................15-4
ThermalCutback.....................................................................................................................................15-4
ChargeIndicatorLight..............................................................................................................................15-4
ChargerStatusIndicators.........................................................................................................................15-4
Long-termStorage...................................................................................................................................15-5
ExternalChargerMounting...........................................................................................................................15-6
ACPowerConnection..................................................................................................................................15-7
TheChargeCircuit.......................................................................................................................................15-8
ChargerOperation.......................................................................................................................................15-9
ChargingBatteries...................................................................................................................................15-9
ChargerMaintenance.................................................................................................................................15-11
USBServicePortCleaningandCare.......................................................................................................15-11
ChargerTroubleshooting.............................................................................................................................15-12
NumberingVehiclesandChargers...........................................................................................................15-12
USBServicePort....................................................................................................................................15-12
IncomingACService..............................................................................................................................15-12
TerminalBlockCover..............................................................................................................................15-12
ResettingPower–ExternalCharger........................................................................................................15-13
ChargerTroubleshootingIndicators.........................................................................................................15-14
TestProcedures.........................................................................................................................................15-16
ExternalChargerRepairs............................................................................................................................15-19
TerminalBlockCoverRemoval................................................................................................................15-19
TerminalBlockCoverInstallation.............................................................................................................15-20
DCCordandStrainReliefRemoval.........................................................................................................15-20
DCCordandStrainReliefInstallation......................................................................................................15-20
HandleRemoval.....................................................................................................................................15-20
HandleInstallation..................................................................................................................................15-21
FootRemoval.........................................................................................................................................15-21
FootInstallation......................................................................................................................................15-21
SECTION16—ElectricVehicle-Motor............................................................................................................16-1
GeneralInformation.....................................................................................................................................16-1
ExternalMotorTesting.................................................................................................................................16-1
Pageviii2019PrecedentVillager2MaintenanceandServiceManual
Motor..........................................................................................................................................................16-4
MotorRemoval........................................................................................................................................16-4
MotorDisassembly..................................................................................................................................16-5
MotorComponentTestingandInspection......................................................................................................16-8
ArmatureInspectionandTesting...............................................................................................................16-8
MotorFrameandFieldWindingsInspection.............................................................................................16-10
MotorBrush,Spring,andTerminalInsulatorInspection.............................................................................16-10
ReconditioningtheMotor............................................................................................................................16-13
MotorSpecications...............................................................................................................................16-13
MotorAssembly..........................................................................................................................................16-13
MotorInstallation........................................................................................................................................16-15
SECTION17—ElectricVehicle-Transaxle......................................................................................................17-1
Lubrication..................................................................................................................................................17-1
AxleBearingandShaft................................................................................................................................17-1
AxleShaft...............................................................................................................................................17-1
AxleBearing............................................................................................................................................17-4
TransaxleRemoval......................................................................................................................................17-5
TransaxleDisassembly,Inspection,andAssembly.........................................................................................17-7
TransaxleDisassemblyandInspection......................................................................................................17-7
TransaxleAssembly.................................................................................................................................17-9
TransaxleInstallation..................................................................................................................................17-10
SECTION18—GasolineVehicle-TroubleshootingandElectricalSystem..........................................................18-1
GeneralInformation.....................................................................................................................................18-1
Accessories.............................................................................................................................................18-1
LowOilWarningLight..............................................................................................................................18-1
GroundLocations....................................................................................................................................18-1
FeaturesoftheElectronicFuelInjection(EFI)System...............................................................................18-2
TroubleshootingGuide.................................................................................................................................18-2
ECUErrorCodes(DisplayedbytheLowOilWarningLight).......................................................................18-2
GasolinePowertrain................................................................................................................................18-4
SonicWeld,Fuse,andDiodeLocations........................................................................................................18-8
ElectricalSystem.........................................................................................................................................18-9
TestProcedures.........................................................................................................................................18-10
TestingBasics........................................................................................................................................18-10
SECTION19—GasolineVehicle-ElectricalComponents.................................................................................19-1
Starter/Generator.........................................................................................................................................19-1
Starter/GeneratorRemoval......................................................................................................................19-1
DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................19-1
BrushInspectionandReplacement...........................................................................................................19-2
BrushSpringInspectionandReplacement................................................................................................19-2
Starter/GeneratorAssembly.....................................................................................................................19-3
DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................19-4
BearingCleaningandInspection..............................................................................................................19-5
BearingRemoval.....................................................................................................................................19-6
FieldCoilAssembly.................................................................................................................................19-6
VisualInspectionofArmature...................................................................................................................19-6
CommutatorCleaningandInspection.......................................................................................................19-7
ArmatureGroundTest..............................................................................................................................19-8
VisualInspectionofFieldCoils.................................................................................................................19-9
Starter/GeneratorRework........................................................................................................................19-9
Starter/GeneratorAssembly.....................................................................................................................19-9
Starter/GeneratorInstallation...................................................................................................................19-12
BeltTensionAdjustmentforEFIEngines..................................................................................................19-13
VoltageRegulator.......................................................................................................................................19-15
VoltageRegulatorRemoval.....................................................................................................................19-15
VoltageRegulatorInstallation..................................................................................................................19-16
EngineControlUnit(ECU)..........................................................................................................................19-17
EngineControlUnitRemoval...................................................................................................................19-17
2019PrecedentVillager2MaintenanceandServiceManualPageix
EngineControlUnitInstallation................................................................................................................19-17
KeySwitch.................................................................................................................................................19-18
KeySwitchRemoval...............................................................................................................................19-18
KeySwitchInstallation............................................................................................................................19-19
Maintenance/OperateSwitch.......................................................................................................................19-19
Maintenance/OperateSwitchRemoval.....................................................................................................19-19
Maintenance/OperateSwitchInstallation..................................................................................................19-19
NeutralLockoutLimitSwitch.......................................................................................................................19-20
NeutralLockoutLimitSwitchRemoval.....................................................................................................19-20
NeutralLockoutLimitSwitchInstallation...................................................................................................19-20
Solenoid.....................................................................................................................................................19-21
TestingtheSolenoid...............................................................................................................................19-21
SolenoidRemoval..................................................................................................................................19-21
SolenoidInstallation................................................................................................................................19-21
Fuse..........................................................................................................................................................19-22
FuseRemoval........................................................................................................................................19-22
FuseInstallation.....................................................................................................................................19-22
AcceleratorPedalLimitSwitch....................................................................................................................19-23
TestingtheAcceleratorPedalLimitSwitch...............................................................................................19-23
KillLimitSwitch..........................................................................................................................................19-23
TestingtheKillLimitSwitch.....................................................................................................................19-23
ReverseWarningBuzzer.............................................................................................................................19-23
ReverseWarningBuzzerRemoval..........................................................................................................19-23
ReverseWarningBuzzerInstallation........................................................................................................19-24
ReverseBuzzerLimitSwitch.......................................................................................................................19-25
ReverseBuzzerLimitSwitchRemoval.....................................................................................................19-25
ReverseBuzzerLimitSwitchInstallation..................................................................................................19-25
LowOilWarningLight.................................................................................................................................19-27
LowOilWarningLightRemoval...............................................................................................................19-27
LowOilWarningLightInstallation............................................................................................................19-27
FuelGauge................................................................................................................................................19-28
FuelGaugeRemoval..............................................................................................................................19-28
FuelGaugeInstallation...........................................................................................................................19-28
FuelLevelSendingUnit..............................................................................................................................19-29
HourMeter.................................................................................................................................................19-29
TestingtheHourMeter............................................................................................................................19-29
HourMeterRemoval...............................................................................................................................19-29
HourMeterInstallation............................................................................................................................19-29
OilLevelSensor.........................................................................................................................................19-30
OilLevelSensorRemoval.......................................................................................................................19-30
OilLevelSensorInstallation....................................................................................................................19-30
Battery.......................................................................................................................................................19-31
GeneralInformation................................................................................................................................19-31
TestingtheBattery..................................................................................................................................19-31
PreventiveMaintenance..........................................................................................................................19-31
Self-Discharge........................................................................................................................................19-32
VibrationDamage...................................................................................................................................19-32
BatteryRemoval.....................................................................................................................................19-33
ChargingtheBattery...............................................................................................................................19-33
BatteryInstallation..................................................................................................................................19-33
BatteryStorage......................................................................................................................................19-34
ChargingaDeadBattery.........................................................................................................................19-34
GroundCables...........................................................................................................................................19-34
SECTION20—GasolineVehicle-Engine........................................................................................................20-1
GeneralInformation.....................................................................................................................................20-1
BeforeServicing......................................................................................................................................20-1
EngineRotation.......................................................................................................................................20-1
TorqueSpecications...............................................................................................................................20-2
AdjustmentsandSettings.........................................................................................................................20-2
EngineOil–GasolineVehicle...................................................................................................................20-2
SparkPlug..............................................................................................................................................20-5
Breather..................................................................................................................................................20-6
Pagex2019PrecedentVillager2MaintenanceandServiceManual
ValveClearanceCheckandAdjustment....................................................................................................20-7
EngineRemoval..........................................................................................................................................20-8
EngineRemoval......................................................................................................................................20-8
EngineInstallation.......................................................................................................................................20-9
EngineInstallation...................................................................................................................................20-9
Flywheel....................................................................................................................................................20-10
FlywheelRemoval..................................................................................................................................20-11
FlywheelInstallation...............................................................................................................................20-12
OilLevelSensor.........................................................................................................................................20-12
TestingtheOilLevelSensor....................................................................................................................20-12
OilLevelSensorRemoval.......................................................................................................................20-12
OilLevelSensorInstallation....................................................................................................................20-13
IgnitionCoil................................................................................................................................................20-14
TestingtheIgnitionCoil...........................................................................................................................20-14
IgnitionCoilRemoval..............................................................................................................................20-14
IgnitionCoilInstallation...........................................................................................................................20-14
Snubber.....................................................................................................................................................20-15
SnubberRemoval...................................................................................................................................20-15
SnubberInstallation................................................................................................................................20-15
SECTION21—GasolineVehicle-FuelSystem................................................................................................21-1
GeneralInformation.....................................................................................................................................21-1
EFISystemFeatures/Specications..........................................................................................................21-1
Refuel.........................................................................................................................................................21-3
RelievingFuelPressure...............................................................................................................................21-4
ToRelieveFuelPressure.........................................................................................................................21-4
ThrottleBody...............................................................................................................................................21-5
ThrottleBodyRemoval.............................................................................................................................21-5
ThrottleBodyInstallation..........................................................................................................................21-7
EngineControlLinkages..............................................................................................................................21-8
GeneralInformation.................................................................................................................................21-8
GroundSpeed.........................................................................................................................................21-9
GovernorCable.......................................................................................................................................21-9
AcceleratorCable...................................................................................................................................21-10
ClosedThrottleorIdleAdjustment–Pedal-StartVehicles.........................................................................21-12
HowtoMeasureGroundSpeed...............................................................................................................21-12
EngineRPMAdjustment.........................................................................................................................21-13
AirIntakeSystem.......................................................................................................................................21-14
GeneralInformation................................................................................................................................21-14
AirFilter.................................................................................................................................................21-14
AirIntakeSystemRemoval.....................................................................................................................21-15
AirIntakeSystemInstallation...................................................................................................................21-16
FuelLine....................................................................................................................................................21-17
FuelLineRemoval..................................................................................................................................21-17
FuelLineInstallation...............................................................................................................................21-18
FuelPumpModule......................................................................................................................................21-19
GeneralInformation................................................................................................................................21-19
FuelPumpModuleRemoval...................................................................................................................21-20
FuelPumpModuleInstallation.................................................................................................................21-20
FuelTank...................................................................................................................................................21-23
GeneralInformation................................................................................................................................21-23
FuelTankRemoval.................................................................................................................................21-23
FuelTankDisposal.................................................................................................................................21-24
FuelTankStorage..................................................................................................................................21-24
FuelTankInstallation..............................................................................................................................21-24
FuelFilter...................................................................................................................................................21-26
GeneralInformation................................................................................................................................21-26
FuelFilterRemoval.................................................................................................................................21-26
FuelFilterInstallation..............................................................................................................................21-26
CarbonCanister.........................................................................................................................................21-27
CarbonCanisterRemoval.......................................................................................................................21-27
CarbonCanisterInstallation....................................................................................................................21-27
2019PrecedentVillager2MaintenanceandServiceManualPagexi
SECTION22—GasolineVehicle-ExhaustSystem..........................................................................................22-1
Mufer........................................................................................................................................................22-1
MuferRemoval......................................................................................................................................22-1
MuferInstallation....................................................................................................................................22-1
SECTION23—GasolineVehicle-Clutches.....................................................................................................23-1
GeneralInformation.....................................................................................................................................23-1
Troubleshooting...........................................................................................................................................23-1
DriveBelt....................................................................................................................................................23-3
DriveBeltRemoval..................................................................................................................................23-3
DriveBeltInstallation...............................................................................................................................23-3
DriveClutch................................................................................................................................................23-4
DriveClutchRemoval..............................................................................................................................23-5
DriveClutchCleaningandInspection........................................................................................................23-6
DriveClutchDisassembly.........................................................................................................................23-6
InspectionofDriveClutchParts................................................................................................................23-9
DriveClutchAssembly............................................................................................................................23-10
DriveClutchInstallation..........................................................................................................................23-11
DrivenClutch.............................................................................................................................................23-13
DrivenClutchRemoval...........................................................................................................................23-14
DrivenClutchDisassembly......................................................................................................................23-14
DrivenClutchInspection.........................................................................................................................23-15
DrivenClutchAssembly..........................................................................................................................23-15
DrivenClutchInstallation.........................................................................................................................23-17
SECTION24—GasolineVehicle-Transaxle....................................................................................................24-1
GeneralInformation.....................................................................................................................................24-1
ShifterLever............................................................................................................................................24-1
NeutralLockout.......................................................................................................................................24-1
GovernorSystem.....................................................................................................................................24-2
TransaxleService....................................................................................................................................24-2
Lubrication..............................................................................................................................................24-2
ToolsRequiredForThisSection...............................................................................................................24-3
RearHubs...................................................................................................................................................24-4
RearHubRemoval..................................................................................................................................24-4
RearHubInstallation...............................................................................................................................24-4
AxleTubes,AxleShaftsandWheelBearings................................................................................................24-6
AxleTubeandAxleShaftRemoval...........................................................................................................24-6
AxleTubeandAxleShaftInstallation........................................................................................................24-7
RearWheelBearingRemoval..................................................................................................................24-7
RearWheelBearingInstallation................................................................................................................24-7
AxleShaftOilSealRemoval.....................................................................................................................24-7
AxleShaftOilSealInstallation..................................................................................................................24-8
TransaxleRemoval......................................................................................................................................24-9
TransaxleInstallation..................................................................................................................................24-12
Forward/ReverseHandle............................................................................................................................24-13
Forward/ReverseHandleRemoval..........................................................................................................24-13
Forward/ReverseHandleInstallation........................................................................................................24-13
ShifterCable..............................................................................................................................................24-13
ShifterCableRemoval............................................................................................................................24-13
ShifterCableInstallation.........................................................................................................................24-14
ShifterCableAdjustment.........................................................................................................................24-14
SECTION25—WiringDiagrams......................................................................................................................25-1
GeneralInformation.....................................................................................................................................25-1
Electric:AccessoryWiringDiagram..............................................................................................................25-3
Index..........................................................................................................................................................Index-1
Pagexii2019PrecedentVillager2MaintenanceandServiceManual
SECTION1—SAFETY1
Safety
SAFETYDETAILS
WARNING
•Thisowner’smanualshouldbereadcompletelybeforeattemptingtodriveorservicethevehicle.
Failuretofollowtheinstructionsinthismanualcouldresultinpropertydamage,severepersonal
injury,ordeath.
Itisimportanttonotethatsomevitalstatementsthroughoutthismanualandonthedecalsafxedtothevehicleare
precededbythewordsDANGER,WARNING,orCAUTION.Foryourprotection,werecommendthatyoutakespecial
noticeofthesesafetyprecautions.Safetyprecautionsareessentialandmustbefollowed.
Ifanyoftheoperationorsafetydecalsonthevehiclebecomedamaged,havebeenremovedorcannotbeeasily
read,theyshouldbereplacedimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contactyour
distributor/dealer.
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.
WARNING
•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin
minorpersonalinjury.
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould
resultinpropertydamage.
2019PrecedentVillager2MaintenanceandServiceManualPage1-1
1GeneralWarningsSAFETY
GENERALWARNINGS
Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.
Vehiclefeatureidenticationinformationisalsoincluded.Otherspecicsafetystatementsappearthroughoutthis
manualandonthevehicle.
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand
servicearea.Serviceonlyinawell-ventilatedarea.
•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon
monoxide,whichisanodorless,deadlypoison.
•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If
caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith
applicablesafetyguidelinesforyourlocation.
WARNING
•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and
CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.
•Childrenrequiringachildsafetyseatmustnotrideinvehicle.
•Donotleavechildrenunattendedonvehicle.
•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe
Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,
andremovethekey.Chockthewheelswhenservicingthevehicle.
•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle
performance,severepersonalinjury,ordeath.
•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandling
ofthevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,couldresultin
severepersonalinjuryordeath.
•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare
inplaceandareeasytoread.
•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven
simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.
Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory
installation.
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara
fullfaceshieldandrubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe
vehicleorbatterycharger.
WARNINGCONTINUEDONNEXTPAGE
Page1-22019PrecedentVillager2MaintenanceandServiceManual
SAFETYGeneralWarnings1
WARNING
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
Electricvehiclesonly:
•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto
heedthiswarningcouldresultinabatteryexplosionorseverepersonalinjury.
•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe
controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-4.
Gasolinevehiclesonly:
•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.
SeeDisconnectingtheBattery-GasolineVehiclesonpage1-3.
•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery
cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or
anyothermetalcomponent.
DISABLINGTHEVEHICLE
1.Settheparkbrake.
2.TurnthekeyswitchOFFandremovethekey.
3.PlacetheForward/ReversecontrolintheNEUTRALposition.
4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.
DISCONNECTINGTHEBATTERY-GASOLINEVEHICLES
1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.
2.Removepositiveterminalcover.
3.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-2).
4.Disconnectthesparkplugwire(s)fromthesparkplug(s).
CONNECTINGTHEBATTERY-GASOLINEVEHICLES
1.Connectthebatterycables,positive(+)cablerst.
2.Tightenbatteryterminalsto41in·lb(4.3N·m).
3.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.
4.Attachpositiveterminalcover.
5.Connectthesparkplugwire(s)tothesparkplug(s).
2019PrecedentVillager2MaintenanceandServiceManualPage1-3
1GeneralWarningsSAFETY
(Viewedfromdriversideofvehicle)
1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting
batterycables.
2.Removenegativebatterycable.
3.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
(Viewedfromdriversideofvehicle)
1.Removepositiveterminalcover.
2.Removenegativebatterycable.
3.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
49A
Figure1-1BatteryCableRemoval–ElectricVehicles
6x8-VoltBatteryConguration
3167
Figure1-2Top-Battery:BatteryCableRemoval-Gasoline
Vehicles
DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES
1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.
2.PlaceT ow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed
thiswarningcouldresultinabatteryexplosionorseverepersonalinjury.
3.Disconnectthebatteries,negative(–)cablerst,asshown(Figure1-1).
4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.
CONNECTINGTHEBATTERIES–ELECTRICVEHICLES
1.EnsuretheT ow/RunswitchisintheTOWposition.
2.Connectthebatterycables,positive(+)cablerst.
3.Tightenbatteryterminalsto110in·lb(12.4N·m).
4.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.
Page1-42019PrecedentVillager2MaintenanceandServiceManual
SAFETYGeneralWarnings1
RECYCLINGLEAD-ACIDBATTERIES
WARNING
•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,
theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.
Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1-3).They
cannotbedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotection
mustbeshared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Please
contactyournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.
1403
Figure1-3DisposeofLead-acidBatteriesProperly
INTERNATIONALSAFETYSYMBOLSONBATTERIES
Anyoneusing,repairing,orservicingthevehiclemustunderstandandheedthesafetysymbolsonthevehiclebattery
orbatteries.
_
1.Shieldeyes.3.Nosmoking,noopenames,nosparks.5.Batteryacidhazard.
2.Readandfollowoperatinginstructions.4.Keepawayfromchildren.6.Explosivegashazard.
RefertoGeneralWarningsformoreinformation.
1642
Figure1-4InternationalSafetySymbolsonBatteries
2019PrecedentVillager2MaintenanceandServiceManualPage1-5
PaginationPage
1GeneralWarningsSAFETY
Page1-62019PrecedentVillager2MaintenanceandServiceManual
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