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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

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.


MX37146

3. Check oil level:

• Remove and wipe dipstick (A) clean.

• Install dipstick. Remove and check oil level.

4. When checking oil level:

• Oil level must be between upper and lower fill marks on dipstick.

• If oil level is below lower mark on dipstick, 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.

5. Install dipstick.

6. 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 plug.


MX37149

Picture Note: View from under machine.

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


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6. Remove and discard oil filter (B) at rear facing 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.


MX37146

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 (D). Do not overfill.

• Capacity with oil filter: 2.2 L (2.3 qt)

12. Install dipstick (D) and oil fill cap (C).

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

14. Check oil level, add oil if necessary.

15. 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.)

2. Raise and secure cargo box.


MX30612, MX37148

Picture Note: The air cleaner canister cover is removed for clarity only. Removal of the canister cover or dust unloading valve is not required.

3. Locate dust unloading valve (A) attached to the front of the air cleaner canister cover.

NOTE: If canister cover is removed, install with rubber dust unloading valve (A) pointing downward.

4. Visually check dust unloading valve (A). Replace with new valve if worn, damaged, or missing.

5. 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.


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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.

3. Raise and secure cargo box.


MX37148

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

5. Remove and discard primary filter element. Replace with a new filter element.

6. Install air cleaner canister cover with rubber dust unloading valve pointing downward. Check instruction molded into canister cover for proper installation.

7. Hook the canister cover latches.


MX31119

8. Press reset button at end of air restriction indicator (C).

9. Start engine and run at slow idle.

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

11. 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.


12. 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.


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c. Pull secondary air filter element (D) 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.

13. Lower the cargo box.

Checking Air Intake, Hoses and Clamps

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

2. Raise and secure cargo box.


MX37148

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

4. Check and tighten air intake hose clamps (B) (both ends of hose) as needed.

5. Lower the cargo box.

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


MX37151

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

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

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

3. Remove filter from inside bowl. Discard filter.


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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.


MX37627

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.

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 Frame Screen and Intake Louvers

IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating. Keep air intake screen and other external surfaces of the engine, including cooling fins, clean at all times to allow adequate air intake.



MX33581

1. Check screens (A) and (B) for dirt, grass clippings and debris.


MX37548

2. Check front radiator screen (C) for dirt, grass clippings and debris.

3. Clean screens by washing or with a brush or cloth.

Checking Coolant Level

This vehicle has a dual radiator system. One radiator is front-mounted, below the grille. The other radiator is side-mounted under the operator’s seat. There is a single pressure cap, and a single coolant recovery tank at the front of the vehicle, under the hood.

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

2. Allow engine to cool.

3. Remove hood.


MX37241

4. Check coolant level in recovery tank (A):

• 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.

7. Install recovery tank cap.

8. Install 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

Prepare Vehicle

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

2. Remove hood.

Draining Cooling System

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.

NOTE: Cooling system capacity is approximately 8.4 L (8.9 qt), including reservoir.

1. Make sure engine has cooled completely.

2. Raise and secure cargo box.


MX37552

3. Slowly open pressure cap (A) on de-aeration tank to the first stop to release all pressure.

4. Remove cap after all pressure is released.

5. Place a suitable container under the front radiator.


MX37551


MX37549

6. Disconnect hoses (B) and (C) at the front radiator, and air bleed hose (D) at thermostat housing on engine. Allow coolant to drain fully from front radiator, then lower hoses (B) and (C) to drain as much coolant as possible from side radiator.

7. Raise rear of vehicle as necessary to allow side radiator coolant to fully drain out to the front.

8. Lower vehicle, and replace hoses (B) and (C). Do not connect air bleed hose (D) at this time.

9. Place a suitable container under the engine channel.


MX37636

10. Loosen engine block drain (E) near engine oil filter (F). Allow coolant to fully drain into the container.

11. After all coolant has drained, tighten the engine block drain.

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.


MX37676

3. Remove screws (G) to remove thermostat housing, thermostat, and O-ring. Inspect and replace O-ring if necessary.

4. Fill engine with flushing solution through the thermostat opening. This will save time purging air from the system later.

5. Install O-ring and thermostat housing. Save thermostat, but do not install at this time. Flushing solution should be circulated with thermostat removed. Tighten the thermostat screws to 26 N•m (230 lb-in.).


MX37675

6. Add flushing solution to de-aeration tank (H) until full. Do not install pressure cap at this time.


MX37549

7. Connect air bleed hose (D) at thermostat housing on engine.

8. Disconnect hose from recovery tank so that flushing solution does not enter the tank.

9. Start engine.

10. Monitor flushing solution level and add solution as air is purged from system:

a. Place a small container near the air bleed hose (D) at the engine thermostat housing. With engine running, remove hose and hold over container to check for solution flow through hose. While air is being purged from system, flow through hose will be intermittent. When flow is steady, purging of air is complete.

b. Alternate between checking solution level in de-aeration tank, adding solution as necessary, and pulling off air bleed hose (D) to check solution flow from the hose.

c. When air is purged from system, connect air bleed hose (D) and clamp, top off solution level at de-aeration tank, and replace pressure cap.

11. Run engine until it reaches operating temperature.

12. Stop engine.

13. Connect hose to recovery tank.

c CAUTION: Avoid injury! Engine and coolant will be hot. Turn radiator cap using a thick rag or glove to protect your hand.

14. Follow instructions for draining and filling cooling system. Thermostat housing will have to be removed, and thermostat installed before filling system after flushing.

Filling Cooling System

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

• Do not operate engine without coolant or 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 radiator when 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 8.4L (8.9qt.) including reservoir.


MX37676

1. Remove screws (G) to remove thermostat housing, thermostat, and O-ring. Inspect and replace O-ring if necessary.

2. Fill engine with coolant through the thermostat opening. This will save time purging air from the system later.

3. Install thermostat, O-ring and thermostat housing. Tighten the thermostat screws to 26 N•m (230 lb-in.).


MX37675

4. Add coolant to de-aeration tank (H) until full. Do not install pressure cap at this time.


MX37549

5. Connect air bleed hose (D) at thermostat housing on engine.

6. Check coolant level in recovery tank, and ensure that level is at or above the low mark. Add coolant if necessary.

7. Start engine and run until engine is at operating temperature and thermostat is open.

8. Monitor coolant level and add coolant as air is purged from system:

a. Place a small container near the air bleed hose (D) at the engine thermostat housing. With engine running, remove hose and hold over container to check for coolant flow through hose. While air is being purged from system, flow through hose will be intermittent. When flow is steady, purging of air is complete.

b. Alternate between checking coolant level in de-aeration tank, adding coolant as necessary, and pulling off air bleed hose (D) to check coolant flow from the hose. Check coolant temperature warning light during this process as a precaution.

c. When air is purged from system, connect air bleed hose (D) and clamp, top off coolant level at de-aeration tank, and replace pressure cap.

9. Turn off engine.

10. Install hood and lower cargo box.

Recommended Engine Coolant

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

• Do not operate engine with plain water.

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

• Aluminum engine blocks and radiators require approved ethylene-glycol based antifreeze.


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. Remove service access panel under passenger seat.

5. Open hood.

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.


MX37549

6. Check radiator hoses and air bleed hose connected to the engine for damage or cracking. Replace if necessary.

• Hose (A) goes from engine to intermediate tube.

• Hose (B) goes from engine to side radiator.

• Air bleed hose (C) goes from engine to de-aeration tank.

7. Check hose clamps (D) and (E), and tighten or replace as needed.

NOTE: Removal of service access panel will allow visual inspection of side radiator connections. For most repairs, seat base panel will need to be removed.


MX37550

Picture Note: Shown with service access panel and seat base panel removed.

8. Check radiator hoses and air bleed hose at side radiator (F) and intermediate tube (G) for damage or cracking. Replace if necessary.

• Hose (A) comes from engine to intermediate tube.

• Hose (B) comes from engine to side radiator.

• Hose (H) goes from side radiator to front radiator.

• Hose (I) goes from intermediate tube to front radiator.

• Air bleed hose (J) goes from side radiator to de-aeration tank.

9. Check hose clamps (D) and (E), and tighten or replace as needed.


MX37551

10. Check radiator hoses at front radiator for damage or cracking. Replace if necessary.

• Hose (I) comes from intermediate tube.

• Hose (H) comes from side radiator.

• Air bleed hose (K) goes to de-aeration tank (L).

• Check hose clamps (D), and tighten or replace as needed.


MX37552

11. Check air bleed hoses (C) and (K), and recovery tank hose (M) for damage or cracking. Replace if necessary.

12. Check hose clamps (E) and replace as necessary.

13. Close hood.

14. Replace service access panel under passenger seat.

15. Tip seats back.

16. 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.

NOTE: Spark arrestor is optional equipment and may not appear on your machine.

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

2. Allow vehicle to cool completely.


W02281

Picture Note: Cargo box shown raised for clarity. Raising cargo box is not necessary.

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

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.