DS Villager 4 Illustrated Parts List Gasoline and Electric Vehicles

Transcription

1 S Villager 4 Illustrated Parts List asoline and lectric Vehicles Manual Number dition Code 0508H0112

2

3 USIN TH ILLUSTRAT PARTS LIST ý WARNIN This manual is to be used only for identification and ordering of service parts. Be sure to read and use the maintenance and service manual before attempting any vehicle repairs. This manual covers all Villager LSV vehicles built during the model years. The manual is divided into sections. Note that there are two or three flags on the outside edge of each page. The first flag contains the section number of which that page is a part. The other flag (or flags) contains the letter or, signifying that the page pertains to the electric or gasoline vehicles only. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that section. The index can be used to find specific parts and assemblies. The index is divided into numerical and alphabetical listings with the page numbers in italic text. There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread. HOW TO ORR PARTS Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our web site at and clicking on the istributor Search link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) or (706) , extension P. O. Box Augusta, eorgia USA Telephone Service Parts Fax

4 NOT: This illustrated parts list represents the most current information at the time of publication. Club Car, LLC. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, LLC. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright 2010 Club Car, LLC. Club Car and ArmorFlex are registered trademarks of Club Car, LLC. This manual effective October 1, S Villager 4 asoline and lectric Vehicle Illustrated Parts List

5 CONTNTS SCTION 1 BOY AN TRIM Front Body and Trim ash Components Beverage Holder Front Seat Bottom and Armrests Rear-Facing Seat Bottom Villager Rear-Facing Seat Backs and Supports Rear Body and Fenders asoline Vehicle Rear Access oor Rear Body and Fenders lectric Vehicle Rear Footrest and Handrails SCTION 2 WHLS AN TIRS Wheels and Tires (White Rims) Wheels and Tires (Beige Rims) SCTION 3 CALS ecals asoline and lectric Vehicles ecals S Villager 4 lectric Vehicles ecals lectric Vehicles ecals asoline Vehicles Logo ecals Villager 4 asoline and lectric Vehicles SCTION 4 BRAKS, PAL, AN CABLS Rear Brake Assembly, Self-Adjusting Vehicle with 2-Wheel Brakes Brake Pedal Assembly Brake Cable, qualizer, and qualizer Rod Accelerator Pedal Assembly asoline Vehicle Accelerator Pedal Assembly lectric Vehicles with MCOR Accelerator Rod SCTION 5 STRIN, FRONT AN RAR SUSPNSION Steering Column Steering Wheel Steering ear Assembly Front Suspension, Upper Front Suspension, Lower Front Spindles and Hubs S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1

6 CONTNTS Rear Suspension Components Rear Suspension Components asoline Vehicle SCTION 6 LCTRICAL SYSTM ASOLIN VHICLS Wiring asoline S Villager lectrical Component Box asoline S Villager Controls and Indicators Starter/enerator Assembly Model asoline Vehicles Starter/enerator Assembly Model asoline Vehicles F290 Starter/enerator Mounting asoline S Villager Battery asoline Vehicle SCTION 7 F290 NIN F290 ngine Shrouds and Brackets F290 ngine Ignition Components and Flywheel F290 ngine Oil Circulation F290 ngine Cylinder Head F290 ngine Crankcase, Camshaft, and Oil Sensor F290 ngine Crankcase and Crankshaft F290 ngine Mounting SCTION 8 FUL, INTAK, AN OVRNOR SYSTMS Fuel System Fuel Tank with Fuel Level Sending Unit Carburetor Assembly F Carburetor Installation F overnor and Accelerator Cables Air Box and Intake Hose Intake System SCTION 9 XHAUST SYSTM xhaust System F290 ngine SCTION 10 TORQU CONVRTR rive Clutch rive Belt F riven Clutch Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

7 CONTNTS SCTION 11 UNITIZ TRANSAXL AN FNR SHIFTR Transaxle asoline Vehicles, ear Cases and Brackets Transaxle asoline Vehicles, Transmission and ear Reduction Transaxle asoline Vehicles, ifferential and Axles Forward/Reverse Shifter Assembly asoline Vehicles Forward/Reverse Shifter Cable asoline Vehicles SCTION 12 LCTRICAL SYSTM LCTRIC VHICL Wiring Wiring Instrument Panel Components Motor Controller Output Regulator (MCOR) Battery Charger Receptacle Batteries, lectric Vehicle Batteries 6 X 8V, lectric Vehicle OBC, Controller, and Solenoid lectric Vehicle Forward/Reverse Switch, Tow/Run Switch SCTION 13 LCTRIC MOTOR Motor (Model 5BC59JBS6390) lectric Vehicle Motor (Model J4-4001) lectric Vehicle Motor (Model J8-4001A) lectric Vehicle SCTION 14 TRANSAXL LCTRIC VHICLS Transaxle lectric Vehicles SCTION 15 BATTRY CHARR Powerrive 3 Battery Charger, omestic Powerrive 2 Battery Charger (Model 22110), omestic Powerrive Battery Charger (Model 17930), omestic Powerrive Battery Charger (Model 18780), xport Powerrive Battery Charger (Model 20310), uropean SCTION 16 MAINTNANC AN SRVIC TOOLS Maintenance and Service Tools Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 3

8 CONTNTS Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued SCTION i INX Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

9 BOY AN TRIM 1

10 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

11 ITM PART NO. SCRIPTION FRONT BOY AN TRIM Barrel - Plastic Bolt, Carriage, 5/16-18 X Trim, Cowl Screw, #8-32 X T-Nut Package (Set of 4) Washer, 5/16 Flat Type A Cowl, TPO, Beige Cowl, TPO, White Cowl, TPO, Red Cowl, TPO, Pacific Blue (Royal Blue) Cowl, TPO, ark reen Cowl, TPO, Black Cowl, TPO, Classic Blue (Navy) Cowl, TPO, Burgundy Cowl, TPO, ark ray Cowl, TPO, Safety Yellow Cowl with Headlight Opening, TPO, Beige Cowl with Headlight Opening, TPO, White Cowl with Headlight Opening, TPO, Red Cowl with Headlight Opening, TPO, Pacific Blue (Royal Blue) Cowl with Headlight Opening, TPO, ark reen Cowl with Headlight Opening, TPO, Black Cowl with Headlight Opening, TPO, Classic Blue (Navy) Cowl with Headlight Opening, TPO, Burgundy Cowl with Headlight Opening, TPO, ark ray Cowl with Headlight Opening, TPO, Safety Yellow Kit, Front Bumper (includes items 28 through 31) Front Bumper Blind Rivet, Push Type Screw, 5/16-18 x 1.0 Truss-Head Locknut, 5/16-18 Nylon Insert Fender xtrusion Washer, 5/16 Type A Flat Screw, 5/16-18 x 1.0 Truss-Head Locknut, 5/16-18 Nylon Insert... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-3

12 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

13 ITM PART NO. SCRIPTION ASH COMPONNTS ash Component, Passenger-Side, Black ash Component, river-side Snap Washer Kit, Black (includes items 4 through 7) Nut, Speed Washer, #10 Pan-Head Screw Cover, Screw Head Screw, #10-16 X 0.75 Pan-Head Tap Floormat ash Panel, Black Center Rivet, 3/16 X.400 Blind... 5 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-5

14 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

15 ITM PART NO. SCRIPTION BVRA HOLR rink Holder Kit (includes items 2 through 5) Holder, ual Cup (includes items 3 and 4) U-Nut, 1/ N/A Cup Holder, ual Screw, 1/4-20 X 0.75 Hex-Head Cap... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-7

16 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

17 ITM PART NO. SCRIPTION FRONT SAT BOTTOM AN ARMRSTS Insert - Wood Hinge Plate Screw, 1/4-20 X 1.50 Hex-Head Cap Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Buff (includes items 6 through 9) N/A Plywood Assy Vinyl Cover Seat Btm - Buffsvc N/A Foam, Seat asket, Seat Seat Bottom Assembly, White (includes items 11 through 14) N/A Plywood Assy Vinyl Cover, Seat Bottom, White N/A Foam, Seat asket, Seat Seat Bottom Assembly, Black (includes items 16 through 19) N/A Plywood Assy Vinyl Cover, Seat Bottom, Black N/A Foam, Seat asket, Seat Seat Bottom Assembly, ray (includes items 21 through 24) N/A Plywood Assy Vinyl Cover, Seat Bottom, ray N/A Foam, Seat asket, Seat Hip Restraint, rvr Side Hip Restraint, Pass Side Washer, 1/4 Type A Narrow Flat... 8 QTY 1 Note: Sub-components contained in items 10, 15, and 20 are the same as those shown for item 5, except for the vinyl seat covers S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-9

18 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

19 ITM PART NO. SCRIPTION RAR-FACIN SAT BOTTOM VILLAR Bumper, Rubber Insert - Wood Seat Support 4-Passenger Hinge Assembly 4 Passenger (includes items 5 through 10) Hinge Long 4 Passenger Hinge Short 4 Passenger Pin, Hinge, Long, 4-Pass Nut, 1/4-20 Stainless-Steel Center-Lock Cap Washer, 1/4 Type A Narrow Flat Rotor Stop, FNR Washer, 5/16 Type B Flat Washer, 1/4 Flat Seat Bottom Assembly, Buff (includes items 14 through 16) N/A Foam, Seat Vinyl Cover, Seat Bottom, Buff N/A Plywood Assy Seat Bottom Assembly, White (includes items 18 through 20) N/A Foam, Seat Vinyl Cover, Seat Bottom, White N/A Plywood Assy Seat Bottom Assembly, ray (includes items 22 through 24) N/A Foam, Seat Vinyl Cover, Seat Bottom, ray N/A Plywood Assy Seat Bottom Assembly, Black (includes items 26 through 28) N/A Foam, Seat Vinyl Cover, Seat Bottom, Black N/A Plywood Assy Screw, 1/4-20 X 1.50 Hex-Head Cap Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine Lockwasher, 1/4 Type A Int.tth Screw, 5/16-18 X 1.75 Hex-Head Cap... 2 QTY 1 Note: Sub-components contained in items 17, 21, and 25 are the same as those shown for item 13, except for the vinyl seat covers S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-11

20 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

21 ITM PART NO. SCRIPTION RAR-FACIN SAT BACKS AN SUPPORTS Bolt, Hex-Head, 5/16-18 X Seat Back Assy19804-pass' Seat Back Assembly, White w/black Cap Seat Back Assembly, Beige w/black Cap Seat Back Assembly, Black w/black Cap Seat Back Assembly, ray w/black Cap Body Spacer Screw, 5/16-18 X 1.25 Thrd Frm Screw, 1/4-20 X 0.75 Hex-Head Cap Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-13

22 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

23 ITM PART NO. SCRIPTION RAR BOY AN FNRS ASOLIN VHICL Barrel - Plastic Body Kick Plate Body, Hinge Plate Bumper, Side Trim Washer, 1/4" Type B Flat Bag Rest Mat Body, Beige, TPO, Rear Body, White, TPO, Rear Body, ray, TPO, Rear Body, Red, TPO, Rear Body, Pacific Blue (Royal Blue), TPO, Rear Body, ark reen, TPO, Rear Body, Black, TPO, Rear Body, Classic Blue, (Navy) TPO, Rear Body, Burgundy, TPO, Rear Body Support Weldment Body Keeper Clip Fender, Inner Screw, #8-18 x 0.375, Hex-Head Washer Screw, 1/4-20 X 1.0 Hex-Head Cap Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 8 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-15

24 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

25 ITM PART NO. SCRIPTION RAR ACCSS OOR Kit, Access oor Black (includes items 2 through 7) Washer, inch O, Nylon Cup Molded Access oor Black Plug, Button N/A Instruction Sheet Access oor Nut, 1/4-20 Blind Screw, 1/4-20 X 1.0 Truss-Head Machine... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-17

26 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

27 ITM PART NO. SCRIPTION RAR BOY AN FNRS LCTRIC VHICL Barrel - Plastic Body Kick Plate Bolt, 1/4-20 X 2.75 Hex-Head Body, Hinge Plate Bumper, Side Trim Washer, 1/4" Type B Flat Bag Rest Mat Body, Beige, TPO, Rear Body, White, TPO, Rear Body, ray, TPO, Rear Body, Red, TPO, Rear Body, Pacific Blue (Royal Blue), TPO, Rear Body, ark reen, TPO, Rear Body, Black, TPO, Rear Body, Classic Blue, TPO, Rear Body, Burgundy, TPO, Rear Body Support Weldment Body Keeper Clip Spacer, 1.88-inch Spacer, 0.5-inch Fender, Inner Screw, #8-18 x 0.375, Hex-Head Washer Washer, 1/4 Type A Narrow Flat Screw, 1/4-20 X 1.25 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 8 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-19

28 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

29 ITM PART NO. SCRIPTION RAR FOOTRST AN HANRAILS Screw, 1/4-20 X 2.00 Phillips Truss-Head Rear Seat Handrail Weldment Rear Foot Rest Asm (includes items 4 through 9) Barrel - Plastic Bolt, Carriage, 5/16-18 X Connecting Bar Bumper, Side Trim Foot Rest Mat Locknut, 5/16-18 Nylon Insert Armrest, Seat, Rear, Right-Hand Armrest, Seat, Rear, Left-Hand Armrest Bracket Screw, 5/16-18 X 1.25 Hex-Head Cap Washer, 5/16 Type A Flat Washer, 1/4 Type A Narrow Flat Screw, 5/16-18 X 1.25 Truss Hd Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert... 8 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 1-21

30 1

31 WHLS AN TIRS 2

32 2 FOR FRONT OR RAR TIR RIM VALV STM PRMIUM TRA 1 8 TIR FOR FRONT OR RAR 6 7 RIM PRMIUM TRA 9 VALV STM 12 TIR FOR RAR ONLY RIM VALV STM XTRA TRACTION TRA 15 TIR FOR FRONT OR RAR RIM PRMIUM TRA 17 VALV STM 20 TIR 25 TIR RIM RIM PRMIUM TRA 21 VALV STM FOR FRONT OR RAR 24 VALV STM FOR FRONT OR RAR Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

33 ITM PART NO. SCRIPTION WHLS AN TIRS (WHIT RIMS) Unf Lug Nut Tire/Wheel Asm, White, Premium Tread (includes items 3 through 5) Wheel Rim, White Tire, Unmounted, Links 18 x Valve Stem Tire/Wheel Asm, White, Premium Tread, 6-Ply (includes items 7 through 9) Wheel Rim, White Tire, Unmounted Valve Stem Tire/Wheel Asm, White, xtra-traction, 6-Ply (includes items 11 through 13) Wheel Rim, White N/A Tire, Unmounted Xtrac 18 x Valve Stem Tire/Wheel Asm, White, Premium Tread, 6.5-inch (includes items 15 through 17) Tire, Unmounted, Power Rib 18 x Wheel Rim, Beige Valve Stem Tire/Wheel Asm, White, uro Premium Tread (includes items 19 through 21) Wheel Rim, White uro 18 X 8.5 X 8, 4-Ply Valve Stem Tire/Wheel Asm, White, Kenda Premium Tread (includes items 23 through 25) Wheel Rim, White Valve Stem AM10682 Unmounted Prem Tire 18x8.50x QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 2-3

34 2 FOR FRONT OR RAR TIR RIM VALV STM PRMIUM TRA 1 8 TIR FOR FRONT OR RAR 6 7 RIM PRMIUM TRA 9 VALV STM 12 TIR FOR RAR ONLY RIM VALV STM XTRA TRACTION TRA 15 TIR FOR FRONT OR RAR RIM PRMIUM TRA 17 VALV STM 20 TIR 25 TIR RIM RIM PRMIUM TRA 21 VALV STM FOR FRONT OR RAR 24 VALV STM FOR FRONT OR RAR Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

35 ITM PART NO. SCRIPTION WHLS AN TIRS (BI RIMS) Unf Lug Nut Tire/Wheel Asm, Beige, Premium Tread (includes items 3 through 5) Tire, Unmounted, Links 18 x Wheel Rim, Beige Valve Stem Tire/Wheel Asm, Beige, Premium Tread, 6-ply (includes items 7 through 9) Wheel Rim, Beige Tire, Unmounted Valve Stem Tire/Wheel Asm, Beige, Xtrac Tread, 6-ply (includes items 11 through 13) Wheel Rim, Beige N/A Tire, Unmounted Xtrac 18 x Valve Stem Tire/Wheel Asm, Beige, Premium Tread, 6.5 (includes items 15 through 17) Tire, Unmounted, Power Rib 18 x Wheel Rim, Beige Valve Stem Tire/Wheel Asm, Beige, uro Premium Tread (includes items 19 through 21) Wheel Rim, Beige uro 18 X 8.5 X 8, 4-Ply Valve Stem Tire/Wheel Asm, Beige, Kenda Premium Tread (includes items 23 through 25) Wheel Rim, Beige Valve Stem AM10682 Unmounted Prem Tire 18x8.50x QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 2-5

36 2

37 CALS 3

38 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

39 ITM PART NO. SCRIPTION CALS ASOLIN AN LCTRIC VHICLS ecal, Warning ecal, Off/On ecal, ash Warning ecal, Operating Instr, lec... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 3-3

40 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

41 ITM PART NO. SCRIPTION CALS S VILLAR 4 LCTRIC VHICLS ecal, Warning ecal, Off/On ecal, ash Warning ecal, Operating Instr, lec... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 3-5

42 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

43 ITM PART NO. SCRIPTION CALS LCTRIC VHICLS ecal, Battery anger ecal, Tow/Run Switch Warning ecal, Component Cover ecal, Private Speed... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 3-7

44 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

45 ITM PART NO. SCRIPTION CALS ASOLIN VHICLS ecal, asoline xplosion/fire Warning ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 3-9

46 3 1 (ON FRONT OF COWL) 2 (ON RAR BOY) 3 (ON RAR BOY) Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

47 LOO CALS VILLAR 4 ASOLIN AN LCTRIC VHICLS ITM PART NO. SCRIPTION Nameplate Kit (gold) ecal, Villager ecal, Badge, IR - old... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 3-11

48 3

49 BRAKS, PAL, AN CABLS 4

50 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

51 RAR BRAK ASSMBLY, SLF-AJUSTIN VHICL WITH 2- WHL BRAKS ITM PART NO. SCRIPTION Nut, 5/16-24 Hex Head Cone Bolt, Brake Cluster Mounting rum without Center Hole, Brake Asm, Brake Cluster, Mech, rvr (includes items 5 through 17) Lever Assembly, Self-Adjusting Brake, Right (Passenger) Adj Mechanism, S.A. Brakes, Right (Passenger) Package, Brake Shoe, Self-Adjusting Plate, Washer, Brake, Self-Adjusting Back Plate, Rh Kit, Shoe Retainer (includes items 11 and 12) Pin Spring, Shoe, Clamp Package Brake Spring Self Adj (includes items 14 and 15) Brake Spring Self Adj Spring Brake Cover, ust Brake Block Asm, Brake Cluster, Mech, Pass (includes items 19 through 31) Lever Assembly, Self-Adjusting Brake, Left Adjusting Mechanism, Self-Adjusting Brake, Left Package, Brake Shoe, Self-Adjusting Plate, Washer, Brake, Self-Adjusting Back Plate, Lh Kit, Shoe Retainer (includes items 25 and 26) Pin Spring, Shoe, Clamp Package Brake Spring Self Adj (includes items 28 and 29) Brake Spring Self Adj Spring Brake Cover, ust Brake Block... 1 QTY 4 Note: river-side brake cluster not shown. Components have a similar appearance to passenger-side brake cluster components S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 4-3

52 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

53 ITM PART NO. SCRIPTION BRAK PAL ASSMBLY Bumper, Rubber Screw, 5/16-18 X 2.50 Hex Cap Hill Brake Spacer Spring, Hill Brake Torsion Package, Brake Mounting Block Kit, Hill Brake Pedal (includes items 7 through 11) Pad, Hill Brake Pushnut, 3/ N/A Hill Brake Weld Assembly Bushing, Nylon Screw, #10-16 Type AB, Sheet Metal Kit, Hill Brake Latch (includes items 13 through 19) Sleeve, Hill Brake Rod Pushnut, 3/ Ball Joint, 1/ N/A Rod, Hill Brake Pin, Cotter, 7/64 x 1/2 Stainless-Steel N/A Pawl, Hill Brake Ratchet Assembly Brake Pedal Kit (includes items 21 through 23) Pad, Brake Pedal N/A Weldment, Brake Pedal 4wb Std Screw, #10-16 Type AB, Sheet Metal Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Nut, 1/4-20 Hex Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 4 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 4-5

54 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

55 ITM PART NO. SCRIPTION BRAK CABL, QUALIZR, AN QUALIZR RO Spring, Brake Return Hanger, Brake Cable Rod, qualizer, 8.91" qualizer Bracket Brake Cable Kit (includes items 6 through 9) Pin, Clevis, 5/16 X 3/ Clip, 1/ N/A Cable, Brake, 41" Cotter Pin, 3/32 x Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert... 5 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 4-7

56 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

57 ACCLRATOR PAL ASSMBLY ASOLIN VHICL ITM PART NO. SCRIPTION Accelerator Bracket and Bearing Assembly Washer, 1/4 Flat Washer, 1/4 Flat Cup, Spring Bumper, Spring Return Bearing, Pivot Support Sub Asm, Accelerator Pedal (includes items 8 through 10) Pad, Accelerator Pedal N/A Accelerator Pedal Weldment Screw, #10-16 Type AB, Sheet Metal Spring, Accelerator Return Retainer, Spring Stud, 1/4-28 X 1.35 Ball Screw, 1/4-20 X Hex Cap Kit, Accelerator Pivot Rod Assembly (includes items 16 through 18) Spacer Assembly (includes item 17) Spacer, Accelerator N/A Pivot Rod Weldment Washer, 5/16 Type A Flat Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Locknut, 1/4-28 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 4-9

58 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

59 ITM PART NO. SCRIPTION ACCLRATOR PAL ASSMBLY LCTRIC VHICLS WITH MCOR Accelerator Bracket and Bearing Assembly Washer, 1/4 Flat Washer, 1/4 Flat Cup, Spring Bumper, Spring Return Bearing, Pivot Support Sub Asm, Accelerator Pedal (includes items 8 through 10) Pad, Accelerator Pedal N/A Accelerator Pedal Weldment Screw, #10-16 Type AB, Sheet Metal Spring, Accelerator Return Retainer, Spring Screw, 1/4-20 X Hex Cap Screw, 1/4-20 X Flange Kit, Accelerator Pivot Rod Assembly (includes items 16 through 18) Spacer Assembly (includes item 17) Spacer, Accelerator N/A Pivot Rod Weldment Washer, 5/16 Type A Flat Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Locknut, 1/4-28 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 4-11

60 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

61 ITM PART NO. SCRIPTION ACCLRATOR RO Rod, Accelerator (includes items 2 through 4) Nut, 1/4-28 Hex Jam Joint, Ball N/A Accelerator Rod... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 4-13

62 4

63 STRIN, FRONT AN RAR SUSPNSION 5

64 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

65 ITM PART NO. SCRIPTION STRIN COLUMN Washer, 5/16 Flat Steering Column Rebuild Kit (includes items 3 through 11) ust Cover Ring, Internal Retaining Wedge, Molded Seat, Plastic Bearing Seal, Bearing Spacer, Shaft Bearing, Ball Ring, Retaining Spring, Steering Shaft Screw, 5/16-18 X 0.75 Thread-Forming Steering Shaft Assembly (includes items 14 through 22) Washer, I X 1.19 O Ring, Internal Retaining Wedge, Molded Seat, Plastic Bearing Bearing, Ball Ring, Retaining Spring, Steering Shaft Shaft, Steering Column Column, Aluminum Steering Screw, 3/8-16 X 7.00 Hex Cap Cover, Steering Column Tube Screw, 5/16-18 Thrd Forming Kit, Steering Column Mounting Bracket (includes items 27 and 28) N/A Bracket, RH Steering Column Mount N/A Bracket, LH Steering column mount Boot, Steering Column Round Shaft, Intermediate Steering (includes items 31 and 32) Bolt, Hex-Head, 8mm X Lockwasher, 5/16 Split Washer, 3/8 Type A Flat Locknut, 3/8-16 Hex... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-3

66 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

67 ITM PART NO. SCRIPTION STRIN WHL Wheel, Steering Plate, Scorecard (includes items 3 through 7) Screw, #12 Phillips Round Head Tapered Compression Spring Clip, Scorecard N/A Plate, Score Card N/A Pencil rip Screw, #12-14 X Nut, 5/8-18 Nylon Insert Jam... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-5

68 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

69 ITM PART NO. SCRIPTION STRIN AR ASSMBLY Link, Rack and Pinion rag Nut, 12mm Hex Steering ear Assembly (without yoke) (includes items 4 through 23) Bellows, Long Rack Screw Locknut Snap Ring Seal, Steering Pinion ust Bearing, Ball Stop Washer Stop Ring, C-Type Support Yoke Rack uide Pressure Spring Ring, Stop, C-Type Bellows, Short ust Seal Retaining Ring Inner Ball Joint Asm Washer, Tab N/A Box, Steering ear N/A Bearing, Lower Pinion N/A Pinion, Steering N/A Screw, Rack uide N/A Rack, Steering Tie Wrap, 8" Nylon Cotter Pin, 3/32 x Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Ball Joint, Left (includes items 28 through 31) Socket, LH Vertical Seal, Vertical Socket ust Fitting, 1/4-28 Thread-Forming rease Nut, 3/8-24 UNF Hex Nut, 1/2-20 Hex, Left-Hand Thread Locknut, 3/8-16 Hex... 3 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-7

70 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

71 ITM PART NO. SCRIPTION FRONT SUSPNSION, UPPR 1 N/A Sub, Fr Susp. -1 Lf-2wb olf (includes items 2 through 21) Locknut, 3/8-16 impled Sub-Assembly, elta A-Plate (includes items 4 through 7) Bushing, Urethane Sleeve, elta Inner Sleeve, elta Outer elta A-Plate elta Shock and ear Support Assembly Screw, 3/8-16 X 2.75 Hx Hd Cap A-Plate Strap Nut - Hex Locking, M12 X Shock Absorber, Front, Common N/A Asm, Tie Rod (includes items 14 through 18) Nut, 12mm Hex nd, Tie Rod M12 X 1.25 Rh nd, Tie Rod, M12 X 1.25, Lh Rod, Tie, Male Thd Nut, Jam, M , Lh Screw, 3/8-16 X 2.25 Hx Hd Cap Locknut, 3/8-16 Hex Bolt, 3/8-16 X 1.75 Hex... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-9

72 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

73 ITM PART NO. SCRIPTION FRONT SUSPNSION, LOWR Plate, Spring Mount Bearing, Thrust Bolt, 3/8-16 X 2.00 Hex Head Plate, Front Spring Retainer Clevis, elta Upper King Pin Assembly Screw, 3/8-16 X 2.75 Hx Hd Cap Washer, Od Wave Screw, 3/8-16 X 4.75 Hx Hd Cap Washer-1/2 Conical, Yellow Washer, M12 Hard Regular Nut, 1/2-20, Center Lock ccentric Bolt Common N/A Spring Asm, Front, 1 Leaf (includes items 15 through 17) Bushing, Steel Bushing, Urethane N/A Spring, Front, 1 Leaf Lockwasher, 3/8 Split Nut, Hex 3/ Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 2 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-11

74 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

75 ITM PART NO. SCRIPTION FRONT SPINLS AN HUBS 1 N/A Replacement Kit, Front Hub (includes items 2 through 4) Cap, Front Hub Hex Nut, Locking Flange, M14x N/A Asm, Front Hub, Bb, Long Stud (includes items 5 through 8) N/A Bearing, Ball, N/A Spacer, Bearing, Front Hub, Pm Lug Stud, 1/2-20 Unf, N/A Front Hub, Ball Brg, Long Stud N/A Asm, Frt Hub & Spndle, Rh (includes items 10 through 17) Cap, Front Hub Hex Nut, Locking Flange, M14x N/A Asm, Front Hub, Bb, Long Stud (includes items 13 through 16) N/A Bearing, Ball, N/A Spacer, Bearing, Front Hub, Pm Lug Stud, 1/2-20 Unf, N/A Front Hub, Ball Brg, Long Stud Asm, Spindle, Rh, Sp (includes items 18 through 21) Fitting, 1/4-28 Thread-Forming rease N/A Subasm, Spndle, Rh, 2wb Bushing, Flanged Bronze Bushing, Bronze Spindle N/A Asm, Frt Hub & Spndle, Lh (includes items 23 through 30) Cap, Front Hub Hex Nut, Locking Flange, M14x N/A Asm, Front Hub, Bb, Long Stud (includes items 26 through 29) N/A Bearing, Ball, N/A Spacer, Bearing, Front Hub, Pm Lug Stud, 1/2-20 Unf, N/A Front Hub, Ball Brg, Long Stud Asm, Spindle, Lh, Sp (includes items 31 through 34) Fitting, 1/4-28 Thread-Forming rease N/A Subasm, Spndle, Lh, 2wb Bushing, Flanged Bronze Bushing, Bronze Spindle... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-13

76 SHOCK ABSORBR CUSHION AN RTAINR RPLACMNT KIT 4 TYPICAL BOTH SIS OF VHICL RAR BRAK CABL RIVR S SI (SHOWN) PASSNR S SI (NOT SHOWN) TYPICAL 2 PLACS AT ACH LAF SPRIN Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

77 ITM PART NO. SCRIPTION RAR SUSPNSION COMPONNTS Nut, 3/8-24 Hex Kit, Shock Absorber Cushion (includes items 3 and 4) Cushion, Shock Absorber Retainer, Shock Absorber Cushion Bracket, Shock Mounting, Right (Passenger) Bracket, Shock Mounting, Left (river) Bushing, Steel Shackle, Rear Spring Shock Absorber Kit (includes items 10 through 12) Cushion, Shock Absorber Retainer, Shock Absorber Cushion Shock Absorber Rear Prv Spd Hanger, Brake Cable Bumper Mount, Angled Locknut, 7/16-14 Nylon Hex Spring Retainer Rear Leaf Spring Spacer, Overload Bumper U-Bolt Bushing, Urethane Bumper, Jounce Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 6 QTY 5 Note: Only the driver-side rear suspension is shown. Parts for the passengerside rear suspension are identical except for the leaf spring/shock mounting plate S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-15

78 5 SHOCK ABSORBR CUSHION AN RTAINR RPLACMNT KIT TYPICAL BOTH SIS OF VHICL RAR BRAK CABL RIVR S SI (SHOWN) TYPICAL 2 PLACS AT ACH LAF SPRIN PASSNR S SI (NOT SHOWN) Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

79 ITM PART NO. SCRIPTION RAR SUSPNSION COMPONNTS ASOLIN VHICL Nut, 3/8-24 Hex Kit, Shock Absorber Cushion (includes items 3 and 4) Cushion, Shock Absorber Retainer, Shock Absorber Cushion Bracket, Shock Mounting, Right (Passenger) Bracket, Shock Mounting, Left (river) Bushing, Steel Shackle, Rear Spring Shock Absorber Kit (includes items 10 through 12) Cushion, Shock Absorber Retainer, Shock Absorber Cushion Shock Absorber Rear Prv Spd Bumper Mount Locknut, 7/16-14 Nylon Hex Spring Retainer Rear Leaf Spring Spacer, Overload Bumper U-Bolt Bushing, Urethane Bumper, Jounce Hanger, Brake Cable Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 6 QTY 5 Note: Only the driver-side rear suspension is shown. Parts for the passengerside rear suspension are identical except for the leaf spring/shock mounting plate S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 5-17

80 5

81 LCTRICAL SYSTM ASOLIN VHICLS 6

82 18_BLK(W15) _OR(W17) 16_BLK(W19) FUL TANK SNIN UNIT CNTR ASH PANL ASM. OIL LIHT 18_YL(W08) 18_YL(W14) ( ) OIL SNIN UNIT FORWAR & RVRS LIMIT SWITCHS 18_BLK(W10) COM 18_RN(W11) NO NC 1 2 FUL/HOUR MTR UA RVRS BUZZR FRONT POS (+) 18_WHT(W03) COM N (-) 18_R_WHT(W05) NO 18_WHT(W16) 18_BLU(W18) 18_YL(W01) 18_WHT_BLK(W06) NO NC COM 1 16_BLU(W09) 16_OR(W27) 18_WHT_BLK(W04) M+ KY 1 SWITCH 2 18_BLK(W23) 16_OR(W02) 18_BLK(W25) NO COM 2 18_BLK(W24) ( ) M- 16_R(W07) TO NIN KILL HOOK UP FUS BLOCK 16_BLK(W22) 10_R(W26) Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

83 6 1 6_BLK(W29) NIN BAR 10_NON_INSUL(W21) 3 - BATTRY _R(W28) 6_WHT(W12) 18_WHT(W16) 16_BLU(W09) 16_OR(W27) SOLNOI VOLTA RULATOR 18_R(W32) 16_YL(W13) STARTR NRATOR F A1 A2 F2 F1 6_RN_HIH_TMP(W30) 7 10_R(W26) 18_YL(W20) 6_BLK(W31) 6 16_BLK(W22) 16_BLK(W22) 10_R(W26) 4 LCTRICAL COMPONNT BOX S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 6-3

84 6 See previous two pages for illustration. Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

85 ITM PART NO. SCRIPTION WIRIN ASOLIN S VILLAR Wire Assy, #6 Black Wire Assembly #6 Red Wire Assembly, #10, Uninsulated Wire Assy, #10 Red Wire Assy, #6 White round Wire Assembly Wire Assy, #6 reen Assy Wire Harness as V4 Kit... 1 QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 6-5

86 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

87 ITM PART NO. SCRIPTION LCTRICAL COMPONNT BOX ASOLIN S VILLAR Screw, #12-16 X Hi-Lo Fuse, 20-Amp N/A lec Component Box Asm, V4 (includes items 4 through 33) Stud, 1/4-28 X Ball Fuse, 10-Amp Washer, #4 Flat Ring, 0.338" Internal Retaining Solenoid, 12-Volt Washer, 0.38" I elrin Flat Wire Assembly #6 Red Bushing, Secondary Weight, Split Switch, Limit Switch, Limit iode Box, lectrical Component Cover, lectric Box Cam, lectric Box Bolt, Carriage, 5/16-18 X Wire Assy, #10 Red Fuse Block Screw, #12-16 X Hi-Lo Screw, #4-40 Hex Head Machine Wire Assy, #16 Orange Bell Crank Weld Asm Screw, 1/4-15 X 1.50 Hi-lo Hex Voltage Regulator Assy Wire Harness as V4 Kit Nut, 5/16-18 Hex Nut, #10-32 Hex Nut, #4-40 Hex Machine Lockwasher, #4 Split Locknut, 1/4-28 Nylon Insert Tie Wrap, 8" Nylon Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert Bolt, Carriage, 5/16-18 X QTY S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 6-7

88 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

89 ITM PART NO. SCRIPTION CONTROLS AN INICATORS Locknut, #6-32 Whiz Keys (set of 2) Lockwasher, M Screw, #6-32 X 1/2 Hex Washer-Head Light, Oil Kit, Reverse Buzzer (includes items 7 through 15) Locknut, #6-32 Whiz Washer, #4 Flat Screw, #6-32 X 1/2 Hex Washer-Head Screw, #4-24 X 0.33 Pan-Head Machine Buzzer, Reverse (9-48 VC) Wire Assembly Black # Screw, #4-40 X 0.75 Round-Head Machine Nut, #4-40 Hex Machine Lockwasher, #4 Split Key Switch, 12-Volt, Off/On Screw and Washer Assembly Nut, Key Switch Cap, Black Key Switch Washer, Key Switch Harness Retainer auge, Fuel/Hour, with Bracket (includes items 23 and 24) Bracket, Fuel auge/hour Meter N/A auge, Fuel/Hour Nut, M QTY 6 Note: Items 7 through 9, and 13 through 15 are included in the reverse buzzer kit, but are not used in this application S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 6-9

90 Page S Villager 4 asoline and lectric Vehicle Illustrated Parts List

91 ITM PART NO. SCRIPTION STARTR/NRATOR ASSMBLY MOL ASOLIN VHICLS Starter/enerator (cw) (includes items 2 through 33) Bearing, Output Shaft Ball Key, Starter/enerator Bearing, Ball Brush Holder Assembly (cw) (includes item 6) Brush Spring Set Brush and Screw Set (cw) Front Bracket Retainer Armature Field Coil Housing Pole Set Screw Set Field Stator Coil Assembly F Insulator Set F Insulator A Connector (cw) Screw and Mold Assembly Brush Connector Assembly (cw) Cover Set (includes items 21 and 22) Brush Inspection Port Cover Brush Port Cover w/rain Rear Bracket (cw) Nut and Screw Set (includes items 25 through 29) Brush Holder Asm Screw N/A Washer, M5 Flat N/A Washer, M14 Lock N/A Nut, Hex, M14 x N/A Screw, M5 x 0.8 x 18mm Nut and Washer Set Nut and Washer Set Through Bolt Set Spacer Armature Asm Conversion Kit (includes items 35 through 38) Key, Starter/enerator Pulley, Starter/enerator Armature Spacer... 1 QTY 6 Note: Item 36 will ONLY fit Model Starter/enerator S Villager 4 asoline and lectric Vehicle Illustrated Parts List Page 6-11