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 customer’s 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
Use oil viscosity based on the expected air temperature range during the period between oil changes.
The following John Deere oils are preferred:
Other oils may be used if above John Deere oils are not available, provided they meet the following specification:
• 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.
• Oil level must be between fill marks on dipstick.
• If oil level is low, add oil to bring oil level no higher than upper mark on dipstick.
• 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. Remove three bolts (A) and closeout panel (B) from machine.
5. Place drain pan under engine drain plug (C) and oil filter drain hole (D) in frame.
6. Pull off oil fill cap (E) from filler opening.
7. Remove drain plug (C) and drain oil into oil drain pan. Allow oil to drain completely. Place oil fill cap (E) back on filler opening.
8. Remove and discard oil filter (F) 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. Install drain plug. Tighten to 50 N•m (37 lb-ft).
12. Pull off oil fill cap (E) from filler opening.
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 recommended fluid no higher than upper mark on dipstick (G). 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.
17. Install closeout panel with three bolts.
Cleaning 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.)
3. Squeeze dust unloading valve (A) to clean. Remove and replace if damaged.
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 hoses (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.
• 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):
• See SPECIFICATIONS for gap distance.
9. Install and tighten spark plug(s). Tighten to 25 N•m (18 lb-ft).
10. Install spark plug wire(s).
Replacing Fuel Filter
Relieve Fuel Line Pressure
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Raise bucket seat, or remove bench seat base.
3. Disconnect wiring connector (A) for fuel pump.
4. Start and run engine until engine quits.
Remove Old Filter
1. Raise and secure cargo box.
c CAUTION: Avoid injury! Cover connections with a cloth while disconnecting fuel line to avoid fuel spray from residual pressure in system.
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2. Locate the fuel filter (B) at the right front of the engine compartment.
3. Place a drain pan or cloth under fuel lines to catch any fuel left in lines.
4. Press on release mechanism to disconnect fuel line couplers (C) from filter.
5. Remove push fasteners on top (D) and bottom holding fuel filter to frame.
Install New Filter
1. Install new filter making sure filter arrow (E) is pointed in the direction of fuel flow (towards the engine). Secure filter with push fasteners onto frame.
2. Connect fuel line couplers to new filter, making sure couplers are securely connected.
3. Connect wiring connector for fuel pump.
4. Turn ignition key to the run position for several seconds, and turn key off. Check for leaks.
Cleaning Engine Compartment
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Raise and secure cargo box.
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c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.
• Clear work area of bystanders. • Wear eye protection when using compressed air for cleaning purposes. |
IMPORTANT: Avoid damage! High-pressure water can damage seals, gaskets, and force water into electrical connectors. Use water from a hose or pressure washer with pressures less than 420 kPa (60 psi). |
3. Remove any debris in engine compartment, especially around exhaust components.
• Keep closeout panel holes (A) and slots (B) clear of any debris.
• Keep engine intake manifold (C) and the top of engine compartment closeout panel (D) clear of any debris.
• Keep front and rear of entire muffler and muffler shield (E) clear of any debris.
5. Check and remove any obstructions around the control cables and linkages.
Cleaning Radiator Cooling Fins
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c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.
• Clear work area of bystanders. • 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 (B) and fan shroud (C) 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:
• If engine is warm, coolant level should be between the FULL line (B) and the LOW line (C).
• 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 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. Slowly open radiator cap (A) to the first stop to release all pressure.
3. Remove cap after all pressure is released.
4. Remove three bolts (B) and closeout panel (C) from machine.
5. Place a coolant drain pan under area where closeout panel was removed.
Picture Note: View from under left (driver) side.
6. Loosen hose clamps (D), and disconnect radiator hoses (E) from intermediate tubes.
7. Route radiator hoses over the drain pan and allow coolant to drain into drain pan.
8. Remove two bolts (F) and belt cover (G) from machine.
9. Place a coolant drain pan under engine. Remove plug (H) from water pump to drain coolant from engine.
10. Raise front of vehicle to ensure complete drainage of coolant.
11. After all coolant has drained, lower front of vehicle, connect radiator hoses (E), and install and tighten plug (H).
12. Remove overflow hose (I) from recovery tank.
13. Remove the screw (J) and lift recovery tank out of machine.
14. Remove cap (K) and empty recovery tank into drain pan.
15. Check condition of all hoses. Replace as needed. Check all hose clamps and tighten as needed.
16. Install recovery tank in machine and secure with screw (J).
17. Install overflow hose (I) and cap (K).
18. Install closeout panel with three bolts.
19. Install belt cover with two bolts.
20. 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.
1. Loosen bleed valve screw (L) located in T-fitting connecting hoses (M).
2. Remove radiator cap and add recommended coolant mixture to radiator until coolant runs out of bleed port.
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 valve screw and allow air to bubble out until air bubbles are no longer visible at bleed port. Tighten bleed valve 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.
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:
• Disconnect radiator hoses from engine.
• Remove plug from engine water pump.
8. After all solution has drained, connect radiator hoses and install engine water pump plug.
9. Remove and clean recovery tank.
10. Install the recovery tank.
11. Fill cooling system with recommended coolant mixture.
Recommended Engine Coolant
The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37 degrees C (-34 degrees F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.
The following coolants are preferred:
• John Deere COOL-GARD II™ Premix
• John Deere COOL-GARD PG Premix
John Deere COOL-GARD II Premix and John Deere COOL-GARD Premix are available in a concentration of 50% propylene glycol.
John Deere COOL-GARD PG Premix is available in a concentration of 55% propylene glycol.
Additional recommended coolants:
• John Deere COOL-GARD II Concentrate in a 40% to 60% mixture of concentrate with water.
• John Deere COOL-GARD Concentrate in a 40% to 60% mixture of concentrate with water.
If the recommended coolants are unavailable, use an ethylene glycol or propylene glycol base coolant that meets the following specification:
• ASTM D3306 prediluted (50%) coolant.
• ASTM D3306 coolant concentrate in a 40% to 60% mixture of concentrate with water.
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.
Water Quality
• Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended with ethylene glycol base engine coolant concentrate.
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.
5. Check radiator hoses (A) between intermediate tubes and engine for damage or cracking. Replace if necessary.
6. Check hose clamps (B) and tighten or replace as needed.
7. Check radiator hose (C) between intermediate tubes and radiator for damage or cracking. Replace if necessary.
8. Check hose clamps (D) and tighten or replace as needed.
Inspecting Timing Belt
Inspecting Belt
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Disconnect negative (-) battery cable.
3. Remove two bolts (A) and belt cover (B) from machine.
4. Remove bolt (C) and slide coupler forward onto driveshaft (D).
5. Remove two bolts (E) and remove driveshaft.
6. Loosen bolt (F) and bolt (G).
7. Rotate alternator (H) and remove belt (I) from alternator pulley, water pump pulley (J), and crankshaft pulley (K).
8. Remove four bolts and water pump pulley (J).
Picture Note: Engine shown removed from machine for better view.
9. Remove bolt (L) and dipstick tube (M).
10. Remove bolt (N) securing crankshaft pulley (K) and remove pulley. Use a puller if necessary.
11. Remove seven bolts (O) and timing belt cover (P).
12. Inspect timing belt (Q) for cracks, fraying, wear or damage. If timing belt needs to be replaced, see the technical manual for your machine or see your John Deere Dealer.
13. Inspect tensioner pulley before reinstalling components (see steps below).
Inspecting Tensioner Pulley
IMPORTANT: Avoid damage! Do not rotate belt or engine pulleys from the current position. There are timing marks on bottom and top of engine that align critical internal engine components. |
1. Loosen bolt (R) on tensioner pulley (S). Push tensioner arm (T) inward slightly to release tensioner pulley tension from timing belt. Rotate tensioner pulley (S) and check for any noise or if it is loose. If it is loose, tighten bolt on tensioner pulley to 25 N•m (18 lb-ft).
2. If tensioner pulley is noisy, remove bolt (R) and remove tensioner pulley (S).
3. Install tensioner and push tensioner arm in direction of arrow (U) until the gap between the tensioner pulley (S) and the bottom of the water pump housing is approximately 5 mm (0.2 in.) (V) as shown.
4. Tighten tensioner bolt (R) to 25 N•m (18 lb-ft).
5. Reverse inspecting belt steps to install all components in reverse order of removal.
6. Connect negative (-) battery cable.
Inspecting Alternator Belt
Inspect Belt
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Disconnect negative (-) battery cable.
3. Remove two bolts (A) and belt cover (B) from machine.
4. Inspect belt (C) for wear or damage. Replace if worn or damaged. (See “Replace Belt” for procedure.)
5. Test belt tension at location (D) (half way between alternator and engine pulley). Deflection should be 5 mm (13/64 in.) with 89 N (20 lb) force.
• To adjust belt tension, loosen bolt (E) and bolt (F). Rotate alternator (G) to obtain 5 mm (13/64 in.) deflection with 89 N (20 lb) force at location (D), and tighten bolt (F). Tighten bolt (E).
6. Install belt cover with bolts.
7. Connect negative (-) battery cable.
Replace Belt
2. Loosen bolt (A) and bolt (B).
3. Rotate alternator (C) and remove belt (D) from alternator pulley, water pump pulley (E), and crankshaft pulley (F).
4. Install new belt around all three pulleys. Rotate alternator (C) to obtain 5 mm (13/64 in.) deflection with 89 N (20 lb) force at location (H), and tighten bolt (B). Tighten bolt (A).
5. Install belt cover with bolts.
Checking Spark Arrestor
1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)
2. Allow vehicle to cool completely.
3. Loosen nut (A) on clamp securing spark arrestor (B) on muffler exhaust pipe.
4. Remove spark arrestor, making note of direction of arrestor inside of exhaust pipe.
5. Make sure deflector screen inside arrestor is not plugged or damaged:
• If plugged, spray with carburetor/choke cleaner and blow dry with low pressure compressed air.
• If damaged, replace spark arrestor.
6. Install spark arrestor and tighten nut on clamp to secure.