Service Engine
Engine Warranty Maintenance Statement
Maintenance, repair, or replacement of the emission control devices and systems on this engine, which are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.
Avoid Fumes
Engine Oil - Gasoline Model
Use oil viscosity based on the expected air temperature range during the period between oil changes.
The following John Deere oils are preferred:
If the above John Deere oils are not available, other oils may be used, provided they meet the following specifications:
ˇ API Service Classification SG or higher
Checking Engine Oil Level
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Raise and secure cargo box.
3. Remove dipstick (A) and wipe it clean.
ˇ Oil level must be between fill marks on dipstick.
ˇ If oil level is low, add oil to bring oil level no higher than upper mark on dipstick.
ˇ If oil level is above upper mark, drain to proper level. Determine cause of this condition and correct.
Changing Engine Oil and Filter
IMPORTANT: Avoid damage! Change the oil more often if the vehicle is used in extreme conditions: |
1. Run engine to warm the oil.
2. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
3. Raise and secure cargo box.
4. Place drain pan under engine drain valve.
5. Clean any debris from drain funnel under oil filter.
6. Route drain tube (A) below skid plate.
7. Open drain valve (B) on the left side of engine and drain oil into oil drain pan. Allow oil to drain completely.
8. Remove and discard oil filter (C) on front of engine. Wipe off filter base on engine.
9. Put a light coat of clean engine oil on gasket of new oil filter.
10. Install new filter until rubber gasket contacts filter base. Tighten filter an additional one-half turn.
11. Close drain valve and route drain tube above skid plate.
12. Pull off oil fill cap from filler opening (D).
IMPORTANT: Avoid damage! Do not overfill crankcase with oil. Oil capacities given are with engine and crankcase completely dry. Some oil will remain in engine after draining. |
13. Add oil no higher than upper mark on dipstick. Use approximately 1.3L (1.37 qt) of oil. Do not overfill.
15. Start and run engine at idle to check for leaks. Stop engine. Fix any leaks before operating.
16. Check oil level, add oil if necessary.
Cleaning Rubber Dust Unloading Valve
IMPORTANT: Avoid damage! Do not operate engine without air cleaner element and rubber dust unloading valve installed. |
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
Picture Note: The air cleaner canister cover is removed for clarity only. Removal of the canister cover or dust unloading valve is not required.
2. Locate dust unloading valve (A) attached to the front of the air cleaner canister.
3. Visually check dust unloading valve (A). Replace with new valve if worn, damaged, or missing.
4. Pinch corners (B) to allow any dirt or debris to fall out of the valve.
Servicing Air Cleaner Element
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
3. Release latches (A) and remove air cleaner canister cover (B).
4. Remove and discard filter element (C). Replace with a new filter element.
5. Install air cleaner canister cover with rubber dust unloading valve pointing downward. Check instruction molded into canister cover for proper installation.
6. Hook the canister cover latches.
Checking Air Intake, Hoses and Clamps
1. Park the machine safely. (See Parking Safely in the SAFETY section.)
2. Tip passenger seat forward.
3. Raise and secure cargo box.
4. Check intake hose (A) for damage or cracking. Replace if necessary.
5. Check and tighten air intake hose clamps (B) as needed.
Checking Spark Plug
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Raise and secure cargo box.
3. Disconnect spark plug wire(s).
4. Remove spark plug(s) using appropriate spark plug socket.
ˇ Pitted or damaged electrodes.
6. Clean spark plug(s) carefully with a wire brush.
NOTE: In Canada, replace with resistor spark plug only.
7. Replace spark plug(s) if necessary.
8. Check and adjust spark plug gap (A):
ˇ Gap must be 0.80 mm (0.031 in.).
9. Install and tighten spark plug(s). Tighten to 25 Nˇm (18 lb-ft).
10. Install spark plug wire(s).
Replacing Fuel Filter
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Raise and secure cargo box.
3. Locate the fuel filter (A) at the front of the engine compartment.
4. Check element of fuel filter for debris. Replace if dirt or sediment is visible on element.
5. Slide hose clamps away from the fuel filter.
6. Place a drain pan or cloth under hoses to catch any fuel left in hoses.
7. Disconnect hoses from the filter.
NOTE: Install fuel filter with arrow pointing in direction of fuel flow towards the engine.
9. Connect hoses to new filter.
Adjusting Carburetor
NOTE: The carburetor is calibrated by the engine manufacturer and should not require any adjustments.
If engine is operated at altitudes above 1829 m (6,000 ft.), some carburetors may require a special high altitude main jet. See your John Deere dealer.
If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.
After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your John Deere dealer.
Cleaning Engine Compartment
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Raise and secure cargo box.
IMPORTANT: Avoid damage! Do not spray water on a hot engine or transaxle. Damage may occur to cast aluminum parts. Allow engine to cool before servicing. |
3. Remove any debris in engine compartment.
4. Check and remove any obstructions around the control cables and linkages.
Cleaning Grille
IMPORTANT: Avoid damage! Grille screen must be clean to prevent engine from overheating and to allow adequate air intake. |
1. Check grille screen for dirt, grass clippings and debris.
2. Clean grille screen by washing or with a brush or cloth.
Cleaning Radiator Cooling Fins
c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.
ˇ Clear work area of bystanders. ˇ Wear eye protection when using compressed air for cleaning purposes. |
IMPORTANT: Avoid damage! Cooling fins must be clean to prevent engine from overheating and to allow adequate air intake. |
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
IMPORTANT: Avoid damage! High-pressure water or air can damage cooling fins or other engine components. Use water from a hose or reduce compressed air pressure to 210 kPa (30 psi). |
4. Remove all dirt and debris from radiator fins (A) and fan shroud using compressed air or water. Flow of compressed air or water should be from back to front.
Checking Coolant Level
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
4. Check recovery tank (A) coolant level:
ˇ If engine is warm, coolant level should be between the FULL line (B) and the LOW line (C).
ˇ If engine is cold, coolant level should be at the LOW line (C) on the recovery tank.
5. Remove recovery tank cap (D) if necessary to add coolant.
6. Add coolant mixture to recovery tank.
IMPORTANT: Avoid damage! Installing suction hose incorrectly will not allow coolant into the coolant system. Do not allow bottom of hose (E) to touch bottom of bottle or bend upwards out of coolant. |
7. Install and tighten recovery tank cap.
Service Cooling System Safely
Servicing Cooling System
IMPORTANT: Avoid damage! Follow all service procedures exactly. If not equipped to perform this work, see your John Deere dealer for service. |
Prepare Vehicle
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
6. When the coolant system service is completed:
Draining Cooling System
1. Make sure engine has cooled completely.
2. Place drain pan under engine.
3. Slowly open radiator cap (A) to the first stop to release all pressure.
4. Remove cap after all pressure is released.
5. Disconnect radiator hoses (B) from intermediate tubes.
6. Route radiator hoses over the drain pan and allow coolant to drain into drain pan.
NOTE: Engine block drain screws may be black in color.
7. Loosen engine block drain screw (C) on left side of engine. Allow coolant to drain into a drain pan.
8. After all coolant has drained, connect radiator hoses and tighten the engine block drain screw.
9. Remove overflow hose (D) from recovery tank.
10. Remove the screw (E) and lift recovery tank out of machine.
11. Remove cap and empty recovery tank into drain pan.
12. Check condition of all hoses. Replace as needed. Check all hose clamps and tighten as needed.
13. Install recovery tank in machine and secure with screw (E).
14. Install overflow hose (D) and cap (F).
15. Fill and bleed cooling system.
Filling and Bleeding Cooling System
NOTE: John Deere COOL-GARD coolant is recommended when adding coolant to the cooling system. Follow the directions on the container for correct mixture ratio.
Cooling system capacity is approximately 5.0 L (5.2 qt.) including recovery tank.
IMPORTANT: Avoid damage! Bleed screw uses a special aluminum seal washer. Do not lose or substitute with any other type of washer. |
NOTE: Engine block bleed screw may be black in color.
1. Remove bleed screw and seal washer (G) located by carburetor.
2. Remove radiator cap and add recommended coolant mixture to radiator until coolant runs out of bleed port.
3. Install and tighten bleed screw with seal washer.
4. Add additional coolant mixture to radiator until coolant run out of overflow port and into the recovery tank.
IMPORTANT: Avoid damage! Position hose slightly above bottom of recovery tank. Do not allow hose to contact bottom of recovery tank or bend upwards out of the coolant. |
6. Remove recovery tank cap and add coolant mixture to recovery tank until it is approximately half full.
IMPORTANT: Avoid damage! If coolant temperature indicator comes on while engine is running, stop engine and add more coolant mixture to radiator. |
8. Start and run engine at medium speed until upper and lower radiator hoses have become warm (10 - 15 minutes), indicating thermostat has opened and coolant is circulating.
10. Loosen bleed screw and allow air to bubble out until air bubbles are no longer visible at bleed port. Tighten bleed screw completely.
11. Remove radiator cap and add recommended coolant mixture to radiator until coolant runs out of overflow port and into the recovery tank.
13. Run engine until cooling fan starts, indicating the engine and coolant has reached operating temperature.
14. Stop engine and remove key.
15. Allow engine to cool and suction back any needed coolant from overflow recovery tank. Fill recovery tank as needed to lower line.
Flushing Cooling System
2. Prepare a cooling system flushing solution using clean water and John Deere Cooling System Cleaner, John Deere Cooling System Quick Flush, or an equivalent.
3. Fill radiator completely with flushing solution. Install and tighten radiator cap.
4. Start and run engine until it reaches operating temperature.
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c CAUTION: Avoid injury! Engine and coolant will be hot. Use a thick rag or gloves to protect your skin.
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6. Turn radiator cap slowly to the stop to release system pressure. Remove radiator cap.
7. Drain cooling system immediately into a container before rust and dirt settle:
ˇ Disconnect radiator hoses from engine.
ˇ Loosen engine block drain screws.
8. After all solution has drained, connect radiator hoses and tighten engine block drain screws.
9. Remove and clean recovery tank.
10. Install the recovery tank.
11. Fill cooling system with recommended coolant mixture.
Recommended Engine Coolant
The following John Deere coolants are preferred:
ˇ COOL-GARDŽ PRE-DILUTED SUMMER COOLANT (TY16036).
ˇ COOL-GARDŽ CONCENTRATED SUMMER COOLANT (TY16034).
If neither of the recommended coolants is available, use a glycol base coolant that meets the following specification:
Check container label before using to be sure it has the appropriate specifications for your machine. Use coolant with conditioner or add conditioner to coolant before using.
If using concentrate, mix approximately 50 percent antifreeze with 50 percent distilled or deionized water before adding to cooling system. This mixture will provide freeze protection to -37 degrees C (-34 degrees F).
Certain geographical areas may require lower temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations. Never exceed the maximum dilution rate for the coolant you are using. Exceeding the maximum rate will greatly reduce the coolant effectiveness.
Checking Radiator Hoses and Clamps
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
NOTE: Visually inspect hoses for cracks and wear. Squeeze hoses to check for deterioration. Hoses should not be hard and brittle, nor soft or swollen.
6. Check radiator hoses (A) between intermediate tubes and engine for damage or cracking. Replace if necessary.
7. Check hose clamps (B) and tighten or replace as needed.
8. Check radiator hose (C) between intermediate tubes and radiator for damage or cracking. Replace if necessary.
9. Check hose clamps (D) and tighten or replace as needed.
Checking Spark Arrestor
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Allow vehicle to cool completely.
3. Remove screw (A) securing spark arrestor (B) to muffler exhaust pipe. Retain the screw.
5. Make sure deflector screen inside arrestor is not plugged or damaged:
ˇ If plugged, spray with carburetor/choke cleaner and blow dry with low pressure compressed air.