All Manuals Close Window

Service Engine


Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

• Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

• Allow fresh outside air into the work area to clear the exhaust fumes out.

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:

• Torq-Gard Supreme™

• PLUS- 50™

Other oils may be used if above John Deere oils are not available, provided they meet the following specification:

• API Service Classification CD or higher

Checking Engine Oil Level

IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is out of the operating range:

• Check oil level before operating.

• Check oil level when the engine is cold and not running.

• Keep oil level between the dipstick marks.

• Shut off engine before adding oil.


1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Raise and secure cargo box.


MX35809

3. Remove dipstick (A) and wipe it clean.

4. Install dipstick.

5. Remove dipstick.

6. Check oil level:

• 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.

7. Install dipstick.

8. Lower the cargo box.

Changing Engine Oil and Filter

IMPORTANT: Avoid damage! Change the oil more often if the vehicle is used in extreme conditions:

• Extremely dusty conditions.

• Frequent slow or low-speed operation.

• Frequent short trips.


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.


MX35812

5. Remove drain plug (A). Allow oil to drain completely.


MX35809

6. Remove and discard oil filter (B) on transaxle side of engine. Wipe off filter base on engine.

7. Put a light coat of clean engine oil on gasket of new oil filter.

8. Install new filter until rubber gasket contacts filter base. Tighten filter an additional one-half turn.

9. Install drain plug.


MX35813

10. Remove oil fill cap (C) 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.


11. Add oil no higher than upper mark on dipstick. Use approximately 2.2 L (2.3 qt) of oil. Do not overfill.

12. Install oil fill cap.

13. Start and run engine at idle to check for leaks. Stop engine. Fix any leaks before operating.

14. Stop engine.

15. Check oil level; add oil if necessary.

16. Lower the cargo box.

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.)


MX30612, MX32404

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.

Checking Air Restriction Indicator

IMPORTANT: Avoid damage! Never check air cleaner until restriction indicator is red or at 6.2 kPa (25 in. H2O) vacuum. This keeps contamination of the intake system to a minimum.

Check air restriction indicator more frequently if operating in dusty conditions.


1. Lock park brake.

2. Place transmission in N (neutral).

3. Start the engine.


MX31119

4. Check, the color at sight window (A) and vacuum reading at scale (B).

5. Stop the engine and wait for all moving parts to stop.

6. Service air cleaner element if sight window shows red or reading is at 6.2 kPa (25 in. H2O) vacuum.

Servicing Air Cleaner Element

IMPORTANT: Avoid damage! Dirt and debris can enter engine when air cleaner canister is opened. Do not open canister unless required for scheduled service. This will keep contamination of the intake system to a minimum.

Check filter element more frequently if operating in dusty conditions.


1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.


MX32404

3. Release latches (A) and remove air cleaner canister cover (B).


MX32405

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.


MX31119

7. Press reset button at end of air restriction indicator (D).

8. Start engine and run at slow idle.

9. Check reading on air restriction indicator with engine running.

10. Shut off engine and wait for all moving parts to stop.

IMPORTANT: Avoid damage! Do not service secondary air filter element unless air restriction indicator rises above 2.5 kPa (10 in. of H2O) after primary element was replaced.


11. If air restriction indicator went above 2.5 kPa (10 in. of H2O), change secondary air filter element:

a. Remove air cleaner canister cover.

b. Remove primary air filter element.


W02268

c. Pull secondary air filter element (E) from canister. Discard the filter element.

d. Install new secondary air filter element.

e. Install primary air filter element.

f. Install canister cover.

g. Push reset button on air restriction indicator.

12. Lower the cargo box.

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.


MX35809


MX35814

4. Check intake hose (A) for damage or cracking. Replace if necessary.

5. Check and tighten air intake hose clamps (B) as needed.

6. Lower the cargo box.

7. Tip seat back.

Servicing Sediment Bowl

c CAUTION: Avoid injury! Fuel vapors are explosive and flammable:

• Do not smoke while handling fuel.

• Keep fuel away from flames or sparks.

• Shut off engine before servicing.

• Cool engine before servicing.

• Work in a well-ventilated area.

• Clean up spilled fuel immediately.

1. Park the vehicle safely. (See Park Safely in the SAFETY section.)

2. Allow engine to cool.

3. Raise and secure cargo box.

Checking


MX35815

1. Check for water in sediment bowl (A):

• Red ring will float on top of the water.

2. If necessary, clean bowl and replace filter.

Cleaning


MX35815

1. Close fuel shut-off valve (B).

2. Turn collar (C) to remove bowl (A).

3. Remove filter from inside bowl. Discard filter.


W02278

4. Remove and retain O-ring (D), float ring (E), and spring (F) from bowl. Clean bowl and allow drying.

5. Install O-ring, float ring, spring, and new filter into bowl.

6. Install bowl to filter head and tighten collar to secure.

7. Open fuel shut-off valve.

8. Lower the cargo box.

9. Bleed fuel system.

Bleeding Fuel System

IMPORTANT: Avoid damage! Modification or alteration of injection pump, pump timing, or fuel injectors in a manner not recommended by the manufacturers will terminate the warranty obligation to the purchaser.


DO NOT attempt to service injection pump or fuel injectors yourself. Special training and special tools are required. See your John Deere dealer.

Bleed air from fuel system:

• After you, service fuel system.

• If you run out of fuel.

1. Make sure there is fuel in the tank.

2. Open fuel shut-off valve on filter.

NOTE: If fuel filter has been cleaned or changed, fuel will be heard immediately returning to tank when primer lever is operated. Continue operating lever until you can hear the return flow stop and then start again.


MX35815

3. Access fuel pump primer lever (A) through opening at rear of vehicle. Move lever up and down. Continue operating lever until:

• Fuel filter bowl is full of fuel.

• You can hear fuel returning to tank through return hose.

Servicing Fuel Injection Pump

IMPORTANT: Avoid damage! Fuel injection pump is calibrated by the engine manufacturer and should not be adjusted.

Do not clean a warm fuel injection pump with steam or water.


Changing injection pump in any way not approved by the manufacturer will end warranty. See your John Deere warranty on this machine.

Do not service injection pump. See your John Deere dealer for service.

If engine is difficult to start, lacks power, or runs rough, check the TROUBLESHOOTING section of this manual. If your engine is still not performing correctly, contact your John Deere dealer.

Servicing Fuel Injection Nozzles

IMPORTANT: Avoid damage! Do not service or remove fuel injection nozzles. Service life of injection nozzles may be shortened by overheating, improper operation, poor fuel quality, or excessive idling.


Incorrectly functioning, or dirty injection nozzles, will cause the engine to run poorly. See your John Deere dealer for service.

Cleaning Engine Compartment

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

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.

• Clear work area of bystanders.

• Wear eye protection when using compressed air for cleaning purposes.

• Reduce compressed air pressure to 210 kPa (30 psi).

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.)

2. Open hood.

3. Remove storage tray.

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).

Turn engine off before cleaning radiator screen and fins.



MX35816

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.

5. Install storage tray.

6. Close hood.

Checking Coolant Level

1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Open hood.


MX31022

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 (E) to touch bottom of bottle or bend upwards out of coolant.


7. Install and tighten recovery tank cap.

8. Close hood.

Service Cooling System Safely


TS281

c CAUTION: Avoid injury! The radiator will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed:

• Shut off the engine and allow to cool.

• Do not remove the cap unless the radiator and the engine are cool enough to touch with bare hands.

• Slowly loosen the cap to the first stop to release all pressure. Then remove the cap.

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.)

2. Raise cargo box.

3. Tip seats forward.

4. Open hood.

5. Remove storage tray.

6. When the coolant system service is completed:

• Install storage tray.

• Close hood.

• Tip seats back.

• Lower cargo box.

Draining Cooling System

1. Make sure engine has cooled completely.

2. Place drain pan under engine.


MX35816

3. Slowly open radiator cap (A) to the first stop to release all pressure.

4. Remove cap after all pressure is released.


MX31120

5. Disconnect radiator hoses (B).

6. Route radiator hoses over the drain pan and allow coolant to drain into drain pan.


MX31121

7. Loosen engine block drain (C) near engine oil filter. Allow coolant to drain into a container.

8. After all coolant has drained, connect radiator hoses and tighten the engine block drain screw.


MX31022

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).

IMPORTANT: Avoid damage! Install overflow hose properly to ensure proper function of the cooling system. Position hose slightly above bottom of reservoir. Do not allow hose to contact bottom of reservoir or bend upwards out of the coolant.


14. Install overflow hose (D) and cap (F).

15. Fill and bleed cooling system.

Filling and Bleeding Cooling System

IMPORTANT: Avoid damage! Using incorrect coolant mixture can damage the radiator:

• DO not operate engine with plain water.

• Use antifreeze approved for use in aluminum engines.

• DO not exceed a 50% antifreeze mixture for the coolant.

• DO not pour coolant or water into the radiator when the engine is hot.


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.


MX35817

1. Remove bleed screw (A) located on the thermostat housing.

2. Remove radiator cap and add recommended coolant mixture to radiator until coolant runs out of bleed port.

3. Install and tighten bleed screw.

4. Add additional coolant mixture to radiator until coolant runs out of overflow port and into the recovery tank.

5. Install radiator cap.

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.

7. Install recovery tank cap.

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.

9. Allow engine to cool.

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.

12. Install radiator cap.

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

1. Drain 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.

5. Stop engine.

c CAUTION: Avoid injury! The radiator will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed:

• Slowly loosen the cap to the first stop to release all pressure. Then remove the drain plug.

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.

• 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

IMPORTANT: Avoid damage! Using incorrect coolant mixture can damage the radiator:

• Do not operate engine with plain water.

• Use ethylene-glycol based antifreeze approved for use in aluminum radiators or aluminum engines.

• Do not exceed a 50% mixture of coolant and water.

• Do not pour coolant or water into the radiator when the engine is hot.


The following John Deere coolants are preferred:

• COOL-GARD® PRE-DILUTED SUMMER COOLANT (TY16036).

• COOL-GARD® CONCENTRATED SUMMER COOLANT (TY16034).

If neither of the recommended coolants is available, use a glycol base coolant that meets the following specification:

• ASTM D4985 (JDM H24A2).

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.)

2. Raise cargo box.

3. Tip seats forward.

4. Open hood.

5. Remove storage tray.

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.


MX35818


MX31120

6. Check radiator hoses (A) connected to the engine for damage or cracking. Replace if necessary.

7. Check hose clamps (B) and tighten or replace as needed.


MX35819

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.

10. Install storage tray.

11. Close hood.

12. Tip seats back.

13. Lower cargo box.

Checking Spark Arrestor

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Allow vehicle to cool completely.


MX31026

3. Remove screw (A) securing spark arrestor (B) to muffler exhaust pipe. Retain the screw.

4. Remove spark arrestor.

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 with original hardware.