2007 Villager 6 and 8 Illustrated Part List Gasoline and Electric Vehicles

Transcription

1 2007 Villager 6 and 8 Illustrated Part List asoline and lectric Vehicles Manual Number dition Code 1206H1110

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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 6 and 8 vehicles built during the 2007 model year. 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, Inc. 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, Inc. 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 2006 Club Car, Inc. Club Car and ArmorFlex are registered trademarks of Club Car, Inc. This manual effective July 31, Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

5 CONTNTS SCTION 1 BOY AN TRIM Front Body and Trim ash Pockets and Floormat Beverage Holder Front and Center Seat Bottoms Seat Backs and Armrests Front Center Body and Floormat asoline Vehicles Front Center Body and Floormat IQ Plus Vehicles Second Center Body and Floormat Villager 8 asoline Vehicles Second Center Body and Floormat Villager 8 IQ Plus Vehicles Rear Forward-Facing Seat Bottom Rear Forward-Facing Seat Bottom, Continued Rear-Facing Seat Bottom Villager Vehicles Rear Seat Backs and Forward-Facing Armrests Rear-Facing Seat Backs and Supports Rear Access oor Rear Body and Fender Heat Shield asoline Vehicles Battery Insulator lectric Vehicles Rear Footrest and Handrails SCTION 2 WHLS AN TIRS Wheels and Tires Wheels and Tires (Front Only) SCTION 3 CALS ecals Villager ecals Villager 6 IQ Plus Vehicles ecals Villager 6 asoline Vehicles ecals Villager ecals Villager 8 IQ Plus Vehicles ecals Villager 8 asoline Vehicles Logo ecals Villager 6 and IQ Plus Logo ecal IQ Plus Vehicles SCTION 4 BRAKS, PALS, AN CABLS Rear Brake Assembly Brake Pedal Assembly IQ Plus Vehicles Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1

6 CONTNTS Front Brake Assembly Front Brake Cables and qualizer Front Brake Cable Clips and Hardware Vehicles with Front-Wheel Brakes Front Brake Cable Clips IQ Plus Vehicles Rear Brake Cables and qualizer Villager 6 Vehicles Rear Brake Cables and qualizer Villager 8 Vehicles Accelerator Pedal Assembly asoline Vehicle Accelerator Pedal Assembly lectric Vehicles with MCOR Accelerator Rod asoline Villager Accelerator Rod asoline Villager SCTION 5 STRIN, FRONT AN RAR SUSPNSION Steering Column Steering Wheel Steering ear Assembly Front Suspension, Upper Villager Front Suspension, Lower Villager Front Suspension, Upper Villager Front Suspension, Lower Villager Front Spindles and Hubs Steering ear Assembly Rear Suspension asoline Vehicles Rear Suspension IQ Plus Vehicles Stabilizer Bar asoline Vehicles SCTION 6 LCTRICAL SYSTM ASOLIN VHICLS Wiring Villager Wiring Villager Front Body lectrical Components Headlights lectrical Component Box Villager lectrical Component Box Villager Instrument Panel and lectrical Components asoline Vehicles Horn and Brake Switches Starter/enerator Assembly F350 Starter/enerator Mounting Battery asoline Vehicle Operation and Maintenance Switch lectrical Components, Rear Body Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

7 CONTNTS SCTION 7 F350 NIN WITH ACR (KY-START VHICLS) F350 ngine with ACR (Automatic Compression Release) Shrouds and Brackets AS11 F350 ngine Ignition Components and Flywheel F350 ngine Oil Circulation AS11 F350 ngine Cylinder Head F350 ngine with ACR Crankcase, Camshaft, and Oil Sensor AS11 F350 ngine Crankcase and Crankshaft F350 ngine Mounting SCTION 8 FUL, INTAK, AN OVRNOR SYSTM Splash uard 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 Villager Intake System Villager SCTION 9 XHAUST SYSTM xhaust System F350 ngine SCTION 10 TORQU CONVRTR rive Clutch rive Belt F riven Clutch SCTION 11 UNITIZ TRANSAXL ASOLIN VHICLS Unitized Transaxle ear Cases and Brackets Transaxle Transmission and ear Reduction Transaxle ifferential and Axles Forward/Reverse Shifter Forward/Reverse Shifter Cable Villager Forward/Reverse Shifter Cable Villager Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3

8 CONTNTS SCTION 12 LCTRICAL SYSTM LCTRIC VHICLS Wiring Villager Headlights Wiring Villager Front Body lectrical Components Villager Front Body lectrical Components Villager Instrument Panel with lectrical Components Horn and Brake Switches Motor Controller Output Regulator (MCOR) Battery Charger Receptacle lectrical Components IQ Plus Villager lectrical Components Villager lectrical Installation Carryall Tow/Run Switch IQ Plus Vehicles Batteries Villager 6 IQ Plus with T-105 Batteries Rear Reverse Buzzer Batteries Villager 6 IQ Plus with T-145 Batteries Batteries Villager 8 IQ Plus with T-105 Batteries Batteries Villager 8 IQ Plus with T-145 Batteries SCTION 13 LCTRIC MOTOR Motor (Model A5-4006) SCTION 14 TRANSAXL LCTRIC VHICLS Transaxle SCTION 15 BATTRY CHARR IQ Plus omestic Battery Charger (Model 25730) IQ Plus Battery Charger (Model 25880), xport and uropean IQ Plus Onboard Battery Charger (Model 25660), xport SCTION 16 MAINTNANC AN SRVIC TOOLS Maintenance and Service Tools Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

9 CONTNTS SCTION i INX 2007 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 5

10

11 BOY AN TRIM 1

12 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

13 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 N/A 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-3

14 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

15 ITM PART NO. SCRIPTION ASH POCKTS AN FLOORMAT ash Component, Passenger-Side, Black ash Component, river-side Floormat Rivet, 3/16 X.400 Blind... 5 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-5

16 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

17 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-7

18 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

19 ITM PART NO. SCRIPTION FRONT AN CNTR SAT BOTTOMS Insert - Wood Seat Bottom Assembly, Front, White (includes items 3 through 11) Hinge Plate Bumper, Seat, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, White N/A Plywood Assy Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Front, Beige (includes items 13 through 21) Hinge Plate Bumper, Seat, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, Buff N/A Plywood Assy Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Front, Black (includes items 23 through 31) Hinge Plate Bumper, Seat, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, Black N/A Plywood Assy Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Rear, ray (includes items 33 through 41) Hinge Plate Bumper, Seat, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, ray N/A Plywood Assy Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap... 8 QTY 1 Note: Sub-components contained in items 12, 22, and 32 are the same as those shown for item 2, except for the vinyl seat covers Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-9

20 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

21 ITM PART NO. SCRIPTION SAT BACKS AN ARMRSTS Screw, 1/4 X Hex-Head Washer, 1/4" Type B Flat Screw, 1/4-20 X 1.25 Truss-Head Seat Back Assembly, White (includes items 5 and 6) Cap, Seat Back Vinyl Seat Back, White Seat Back Assembly, Black (includes items 8 and 9) Cap, Seat Back Vinyl Seat Back, Black Seat Back Assembly, Beige (includes items 11 and 12) Cap, Seat Back Vinyl Seat Back, Beige Seat Back Assembly, ray (includes items 14 and 15) Cap, Seat Back Vinyl Seat Back-nstd Svc Armrest Weld Asm Front Armrest Mounting Weldment Washer, Lock, xternal-tooth Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 6 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-11

22 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

23 FRONT CNTR BOY AN FLOORMAT ASOLIN VHICLS ITM PART NO. SCRIPTION Barrel - Plastic Body, Hinge Plate Washer, inch O, Nylon Cup Rear Floormat Limo Body, Beige, Center Body, White, Center Body, ray, Center Body, Red, Center Body, Pacific Blue, Center Body, ark reen, Center Body, Black, Center Body, Classic Blue, Center Body, Burgundy, Center Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-13

24 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

25 FRONT CNTR BOY AN FLOORMAT IQ PLUS VHICLS ITM PART NO. SCRIPTION Barrel - Plastic Body Kick Plate Body, Hinge Plate Washer, inch O, Nylon Cup Rear Floormat Limo Body, Beige, Center Body, White, Center Body, ray, Center Body, Red, Center Body, Pacific Blue, Center Body, ark reen, Center Body, Black, Center Body, Classic Blue, Center Body, Burgundy, Center 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-15

26 1 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

27 SCON CNTR BOY AN FLOORMAT VILLAR 8 ASOLIN VHICLS ITM PART NO. SCRIPTION Barrel - Plastic Body, Hinge Plate Washer, inch O, Nylon Cup Rear Floormat Limo Body, Beige, Center Body, White, Center Body, ray, Center Body, Red, Center N/A Body, Pacific Blue, Center Body, ark reen, Center Body, Black, Center Body, Classic Blue, Center Body, Burgundy, Center Bumper uard Vinyl Trim Screw, #8-18 x 0.375, Hex-Head Washer Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-17

28 1 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

29 SCON CNTR BOY AN FLOORMAT VILLAR 8 IQ PLUS VHICLS ITM PART NO. SCRIPTION Barrel - Plastic Body Kick Plate Body, Hinge Plate Washer, inch O, Nylon Cup Rear Floormat Limo Bumper uard Vinyl Trim Screw, #8-18 x 0.375, Hex-Head Washer Body, Beige, Center Body, White, Center Body, ray, Center Body, Red, Center Body, Pacific Blue, Center Body, ark reen, Center Body, Black, Center Body, Classic Blue, Center Body, Burgundy, Center 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-19

30 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

31 ITM PART NO. SCRIPTION RAR FORWAR-FACIN SAT BOTTOM Insert - Wood Seat Bottom Assembly, Rear, White (includes items 3 through 14) Hinge Plate Seat Bumper Seat asket, Short Seat asket, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, White N/A Plywood Assy Screw, #12 X.50 Hex, Washer-Head Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Rear, Beige (includes items 16 through 27) Hinge Plate Seat Bumper Seat asket, Short Seat asket, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, Buff N/A Plywood Assy Screw, #12 X.50 Hex, Washer-Head Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap... 8 QTY 1 Note: Sub-components contained in item 15 are the same as those shown for item 2, except for the vinyl seat cover Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-21

32 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

33 RAR FORWAR-FACIN SAT BOTTOM, CONTINU ITM PART NO. SCRIPTION Insert - Wood Seat Bottom Assembly, Rear, Black (includes items 3 through 14) Hinge Plate Seat Bumper Seat asket, Short Seat asket, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, Black N/A Plywood Assy Screw, #12 X.50 Hex, Washer-Head Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Rear, ray (includes items 16 through 27) Hinge Plate Seat Bumper Seat asket, Short Seat asket, Long N/A Foam, Seat Vinyl Cover, Seat Bottom, ray N/A Plywood Assy Screw, #12 X.50 Hex, Washer-Head Seat Support Bracket Rivet, 3/16, Stainless-Steel, Pop Washer, #8 Stainless-Steel Flat Screw, 1/4-20 X 0.75 Hex-Head Cap... 8 QTY 1 Note: Sub-components contained in item 15 are the same as those shown for item 2, except for the vinyl seat cover Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-23

34 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

35 ITM PART NO. SCRIPTION RAR-FACIN SAT BOTTOM VILLAR VHICLS 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-25

36 1 VILLAR 8 VILLAR Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

37 RAR SAT BACKS AN FORWAR-FACIN ARMRSTS ITM PART NO. SCRIPTION Bolt, Hex-Head, 5/16-18 X Screw, 1/4 X Hex-Head Screw, 1/4-20 X 1.25 Truss-Head Seat Back Assembly, White (includes items 5 and 6) Cap, Seat Back Vinyl Seat Back, White Seat Back Assembly, Black (includes items 8 and 9) Cap, Seat Back Vinyl Seat Back, Black Seat Back Assembly, Beige (includes items 11 and 12) Cap, Seat Back Vinyl Seat Back, Beige Seat Back Assembly, ray (includes items 14 and 15) Cap, Seat Back Vinyl Seat Back-nstd Svc Armrest Mounting Weldment Body Spacer Armrest Weldment Rear 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 Washer, 1/4 Type A Narrow Flat Lockwasher, 1/4 Split Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert... 4 QTY 1 Note: Sub-components contained in items 7, 10, and 13 are the same as those shown for item 4, except for the vinyl seat covers Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-27

38 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

39 ITM PART NO. SCRIPTION RAR-FACIN SAT BACKS AN SUPPORTS Seat Back Assembly, White (includes items 2 and 3) Cap, Seat Back Vinyl Seat Back, White Seat Back Assembly, Black (includes items 5 and 6) Cap, Seat Back Vinyl Seat Back, Black Seat Back Assembly, Beige (includes items 8 and 9) Cap, Seat Back Vinyl Seat Back, Beige Seat Back Assembly, ray (includes items 11 and 12) Cap, Seat Back Vinyl Seat Back-nstd Svc Body Spacer Screw, 5/16-18 X 1.25 Thrd Frm Screw, 5/16-18 X 1.25 Hex-Head Cap Washer, 5/16 Type A Flat Screw, 1/4-20 X 1.0 Hex-Head Cap Washer, 1/4 Type A Narrow Flat Lockwasher, 1/4 Split Locknut, 5/16-18 Nylon Insert... 2 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-29

40 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

41 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-31

42 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

43 ITM PART NO. SCRIPTION RAR BOY AN FNR Barrel - Plastic Body Kick Plate Body, Hinge Plate Washer, 1/4" Type B Flat Bag Rest Mat Body Support Weldment Body, Beige, TPO, Rear Body, White, TPO, Rear Body, ray, TPO, Rear Body, Red, TPO, Rear Body, Royal Blue, TPO, Rear Body, ark reen, TPO, Rear Body, Black, TPO, Rear Body, Classic Blue, TPO, Rear Body, Burgundy, TPO, Rear Body Keeper Clip Fender, Inner Screw, #8-18 x 0.375, Hex-Head Washer Washer, 1/4 Type A Narrow Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 8 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-33

44 1 1 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

45 ITM PART NO. SCRIPTION QTY HAT SHIL ASOLIN VHICLS Shield, Heat Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-35

46 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

47 ITM PART NO. SCRIPTION BATTRY INSULATOR LCTRIC VHICLS Rivet, 5/32 Aluminum Pop Battery Insulator... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-37

48 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

49 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 1-39

50 1

51 WHLS AN TIRS 2

52 2 1 FOR FRONT OR RAR BI RIMS WHIT RIMS 4 TIR 16 TIR 2 3 RIM RIM PRMIUM TRA 5 VALV STM 17 VALV STM BI RIMS FOR RAR ONLY WHIT RIMS 8 TIR 20 TIR RIM VALV STM RIM VALV STM XTRA TRACTION TRA BI RIMS FOR FRONT ONLY WHIT RIMS 13 TIR 25 TIR RIM RIM URO HF 232 TRA 12 VALV STM 24 VALV STM Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

53 ITM PART NO. SCRIPTION WHLS AN TIRS Unf Lug Nut Tire/Wheel Asm, Beige, Premium Tread, 6-ply (includes items 3 through 5) Wheel Rim, Beige Tire, Unmounted Valve Stem Tire/Wheel Asm, Beige, Xtrac Tread, 6-ply (includes items 7 through 9) Wheel Rim, Beige Tire, Unmounted Xtrac 18 x Valve Stem Tire/Wheel Asm, Beige, uro HF 232 Tread (includes items 11 through 13) Wheel Rim, Beige Valve Stem **** Tire, Unmounted, 6-Ply Rated (18.5 x 8.5-8) (uro) Tire/Wheel Asm, White, Premium Tread, 6-Ply (includes items 15 through 17) Wheel Rim, White Tire, Unmounted Valve Stem Tire/Wheel Asm, White, xtra-traction, 6-Ply (includes items 19 through 21) Wheel Rim, White Tire, Unmounted Xtrac 18 x Valve Stem Tire/Wheel Asm, White, uro HF 232 (includes items 23 through 25) Wheel Rim, White Valve Stem **** Tire, Unmounted, 6-Ply Rated (18.5 x 8.5-8) (uro)... 1 QTY 2 **** Special order item available upon request Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 2-3

54 2 1 BI RIMS FOR FRONT ONLY WHIT RIMS 3 TIR 7 TIR 2 4 RIM 6 8 RIM PRMIUM TRA 5 VALV STM 9 VALV STM Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

55 ITM PART NO. SCRIPTION WHLS AN TIRS (FRONT ONLY) Unf Lug Nut Tire/Wheel Asm, Beige, Premium Tread, 6.5 (includes items 3 through 5) Tire, Unmounted, Power Rib 18 x Wheel Rim, Beige Valve Stem Tire/Wheel Asm, White, Premium Tread, 6.5-inch (includes items 7 through 9) Tire, Unmounted, Power Rib 18 x Wheel Rim, Beige Valve Stem... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 2-5

56 2

57 CALS 3

58 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

59 ITM PART NO. SCRIPTION CALS VILLAR ecal, Warning ecal, Warning, Rollover, Utl... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-3

60 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

61 ITM PART NO. SCRIPTION CALS VILLAR 6 IQ PLUS VHICLS ecal, Battery anger ecal, Off/On ecal, Operating Instr, lec ecal, Caution, lectrical Component Cover ecal, Tow Switch ecal, Warning, 4 auge Wire ecal, Forward/Reverse, lectric... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-5

62 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

63 ITM PART NO. SCRIPTION CALS VILLAR 6 ASOLIN VHICLS ecal, asoline xplosion/fire Warning ecal, Operating Instructions, Key-Start ecal, Off/On/Start ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold ecal, Run/Service Switch ecal, Forward/Reverse, as... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-7

64 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

65 ITM PART NO. SCRIPTION CALS VILLAR ecal, Warning ecal, Warning, Rollover, Utl... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-9

66 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

67 ITM PART NO. SCRIPTION CALS VILLAR 8 IQ PLUS VHICLS ecal, Off/On ecal, Operating Instr, lec ecal, Caution, lectrical Component Cover ecal, Tow Switch ecal, Warning, 4 auge Wire ecal, Forward/Reverse, lectric... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-11

68 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

69 ITM PART NO. SCRIPTION CALS VILLAR 8 ASOLIN VHICLS ecal, asoline xplosion/fire Warning ecal, Operating Instructions, Key-Start ecal, Off/On/Start ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold ecal, Run/Service Switch ecal, Forward/Reverse, as... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-13

70 3 1 (ON FRONT OF COWL) 2 (ON RAR BOY) 3 (ON RAR BOY) Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

71 ITM PART NO. SCRIPTION LOO CALS VILLAR 6 AN Nameplate Kit (gold) ecal, Villager ecal, Badge, IR - old... 2 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-15

72 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

73 ITM PART NO. SCRIPTION QTY IQ PLUS LOO CAL IQ PLUS VHICLS ecal, IQ Plus Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 3-17

74 3

75 BRAKS, PALS, AN CABLS 4

76 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

77 ITM PART NO. SCRIPTION RAR BRAK ASSMBLY Kit, Non-Asbestos Brake Shoe (includes item 2) Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) Package, Brake Spring (includes item 4) N/A Brake Spring Nut, 5/16-24 Hex Head Cone Bolt, Brake Cluster Mounting Cluster, Brake, river-side (includes items 8 through 23) ust Cover N/A Brake Spring Kit, Brake Actuator Kit, Shoe Retainer (includes items 12 and 13) N/A Pin N/A Shoe Clamp Spring Kit, Anchor Body (includes items 15 through 20) Nut, M Hex N/A Anchor Piston N/A Adjustment Bolt N/A Anchor Body Component Adjustment Bolt Cap Lockwasher, 1/4 Split N/A Backing Plate, Left-Hand Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) N/A Arm, Brake Lever Cluster, Brake, Passenger-Side (includes items 25 through 40) ust Cover N/A Backing Plate, Right-Hand N/A Brake Spring Kit, Brake Actuator Kit, Shoe Retainer (includes items 30 and 31) N/A Pin N/A Shoe Clamp Spring Kit, Anchor Body (includes items 33 through 38) Nut, M Hex N/A Anchor Piston N/A Adjustment Bolt N/A Anchor Body Component Adjustment Bolt Cap Lockwasher, 1/4 Split Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) N/A Arm, Brake Lever rum without Center Hole, Brake... 2 QTY 4 Note: Passenger-side brake cluster not shown. Components have a similar appearance to driver-side brake cluster components Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-3

78 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

79 ITM PART NO. SCRIPTION BRAK PAL ASSMBLY IQ PLUS VHICLS Screw, 5/16-18 X 2.50 Hex Cap Package, Brake Mounting Block N/A Subasm, Pedal roup, 4-Wheel Brake (includes items 4 through 24) Bumper, Rubber Hill Brake Spacer Spring, Hill Brake Torsion Kit, Hill Brake Pedal (includes items 8 through 12) 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 14 through 20) 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 Pad, Brake Pedal N/A Brake Pedal Weldment Nut, 1/4-20 Hex Screw, #10-16 Type AB, Sheet Metal Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 4 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-5

80 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

81 ITM PART NO. SCRIPTION FRONT BRAK ASSMBLY rum, Brake Kit, Non-Asbestos Brake Shoe (includes item 3) Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) Package, Brake Spring (includes item 5) N/A Brake Spring Nut, 5/16-24 Hex Head Cone Bolt, Brake Cluster Mounting Cluster, Brake, river-side (includes items 9 through 24) ust Cover N/A Brake Spring Kit, Brake Actuator Kit, Shoe Retainer (includes items 13 and 14) N/A Pin N/A Shoe Clamp Spring Kit, Anchor Body (includes items 16 through 21) Nut, M Hex N/A Anchor Piston N/A Adjustment Bolt N/A Anchor Body Component Adjustment Bolt Cap Lockwasher, 1/4 Split N/A Backing Plate, Left-Hand Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) N/A Arm, Brake Lever Cluster, Brake, Passenger-Side (includes items 26 through 41) ust Cover N/A Backing Plate, Right-Hand N/A Brake Spring Kit, Brake Actuator Kit, Shoe Retainer (includes items 31 and 32) N/A Pin N/A Shoe Clamp Spring Kit, Anchor Body (includes items 34 through 39) Nut, M Hex N/A Anchor Piston N/A Adjustment Bolt N/A Anchor Body Component Adjustment Bolt Cap Lockwasher, 1/4 Split Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) N/A Arm, Brake Lever... 1 QTY 4 Note: Passenger-side brake cluster not shown. Components have a similar appearance to driver-side brake cluster components Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-7

82 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

83 ITM PART NO. SCRIPTION FRONT BRAK CABLS AN QUALIZR Kit, qualizer and Pivot Limiter (includes items 2 and 3) N/A qualizer Weld Assembly N/A qualizer, Pivot Limiter Spacer Kit, Brake Cable (includes items 6 through 9) Pin, Clevis, 5/16 X 3/ Clip, 1/ N/A Brake Cable Pin, Bow Tie Locking Rod, qualizer, 9.75" Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-9

84 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

85 FRONT BRAK CABL CLIPS AN HARWAR VHICLS WITH FRONT-WHL BRAKS ITM PART NO. SCRIPTION Clamp, Brake Cable Tie Wrap, Heavy uty Screw, 3/8-16 X 1.00 Hex-Head Cap Locknut, 3/8-16 Hex... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-11

86 TAIL See etail Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

87 ITM PART NO. SCRIPTION FRONT BRAK CABL CLIPS IQ PLUS VHICLS Clamp, Brake Cable Tie Wrap, Heavy uty Screw, 3/8-16 X 1.00 Hex-Head Cap Locknut, 3/8-16 Hex... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-13

88 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

89 RAR BRAK CABLS AN QUALIZR VILLAR 6 VHICLS ITM PART NO. SCRIPTION Spring, Brake Return Rod, qualizer qualizer Bracket Kit, Brake Cable Rear (includes items 5 through 8) Pin, Clevis, 5/16 X 3/ Clip, 1/ N/A Cable, Brake Pin, Bow Tie Locking Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-15

90 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

91 RAR BRAK CABLS AN QUALIZR VILLAR 8 VHICLS ITM PART NO. SCRIPTION Spring, Brake Return Rod, qualizer qualizer Bracket Kit, Brake Cable Rear (includes items 5 through 8) Pin, Clevis, 5/16 X 3/ Clip, 1/ N/A Cable, Brake Pin, Bow Tie Locking Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-17

92 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

93 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) N/A 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-19

94 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

95 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) N/A 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 Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-21

96 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

97 ITM PART NO. SCRIPTION ACCLRATOR RO ASOLIN VILLAR Rod, Accelerator (includes items 2 through 4) Nut, 1/4-28 Hex Jam Joint, Ball N/A Accelerator Rod lec Stretch... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-23

98 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

99 ITM PART NO. SCRIPTION ACCLRATOR RO ASOLIN VILLAR Accelerator Rod Assembly, RV XL (includes items 2 through 4) Nut, 1/4-28 Hex Jam Joint, Ball N/A Accelerator Rod, RV XL... 1 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 4-25

100 4

101 STRIN, FRONT AN RAR SUSPNSION 5

102 Page Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List

103 ITM PART NO. SCRIPTION STRIN COLUMN Washer, 5/16 Type B Flat Washer, 5/16 Flat Screw, 5/16-18 X 0.75 Thread-Forming Screw, 3/8-16 X 7.00 Hex Cap Screw, 5/16-18 Thrd Forming Steering Shaft Assembly (includes items 7 through 15) Washer, I X 1.19 O Ring, Internal Retaining Wedge, Molded Seat, Plastic Bearing Bearing, Ball Ring, Retaining Spring, Steering Shaft Column, Aluminum Steering Shaft Steering Column Tube Cover, Steering Column Kit, Steering Column Mounting Bracket (includes items 18 and 19) N/A Bracket, RH Steering Column Mount N/A Bracket, LH Steering column mount Boot, Steering Column Round Shaft, Intermediate Steering (includes items 22 and 23) Bolt, Hex-Head, 8mm X Lockwasher, 5/16 Split Washer, 3/8 Type A Flat Locknut, 3/8-16 Hex... 2 QTY Villager 6 and 8 asoline and lectric Vehicles Illustrated Part List Page 5-3