John Deere XUV835E, XUV835M, XUV835R Vehicle Repair Manual.pdf

XUV835E, XUV835M and
XUV835R Gator™ Utility
Vehicles
(SN. 010001-)
TECHNICAL MANUAL
XUV835E, XUV835M and XUV835R Gator™ Utility
Vehicles (SN. 010001-)
TM145519 01DEC18 (ENGLISH)
John Deere Horicon Works

Introduction
Foreword Operation and tests sections help you identify the majority of
routine failures quickly.
This manual is written for an experienced technician. Essential Information is organized in groups for the various components
tools required in performing certain service work are identified in requiring service instruction. At the beginning of each group are
this manual and are recommended for use.summarylistingsofallapplicableessentialtools,service
equipment and tools, other materials needed to do the job,
Live with safety: Read the safety messages in the introduction of service parts kits, specifications, wear tolerances, and torque
this manual and the cautions presented throughout the text of the values.
manual.
Technical Manuals are concise guides for specific machines.
They are on-the-job guides containing only the vital information
CAUTION:needed for diagnosis, analysis, testing, and repair.
This is the safety-alert symbol. When you see this symbol on the Fundamental service information is available from other sources
machine or in this manual, be alert to the potential for personal covering basic theory of operation, fundamentals of injury.
troubleshooting, general maintenance, and basic type of failures
and their causes.
Technical manuals are divided in two parts: repair and operation
DX,TMIFC-19-20140415
and tests. Repair sections tell how to repair the components.
TM145519 (01.12.2018) XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Contents
Section 10 - General Information
Section 20 - Engine Repair
Section 30 - Electrical Repair
Section 40 - Power Train Repair
Section 50 - Steering and Brake Repair
Section 60 - Operator ` s Station Repair
Section 70 - Miscellaneous Repair
Section 220 - Engine Operation, Tests and
Adjustments
Section 299 - Service Tools
Section 230 - Electrical Operation, Tests and
Adjustments
Section 240 - Control Unit Operation, Tests
and Adjustments
Section 250 - Power Train Operation, Tests
and Adjustments
Section 260 - Steering and Brake Operation,
Tests and Adjustments
Group 10 - Safety
Group 20 - General Specifications
Group 30 - Fuel and Lubricants
Group 40 - Machine Specifications
Group 10 - Engine
Group 10 - Wiring Harnesses
Group 10 - Transmission
Group 20 - Axles and Driveshaft
Group 30 - Mechanical Four Wheel Drive
Group 10 - Steering
Group 20 - Brakes
Group 10 - Operator ` s Station
Group 10 - Wheels
Group 20 - Hood, Cargo Box, and Bumper
Group 30 - Miscellaneous Repair
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnosis
Group 40 - Tests and Adjustments
Group 5 - General Information
Group 30 - Schematics
Group 40 - Schematics, Kits
Group 50 - Connector Information
Group 20 - Diagnostic Trouble Codes, ICC
Group 30 - Diagnostic Trouble Codes, ECU
Group 40 - Diagnostic Trouble Codes, SCU
Group 10 - Service Tools and Kits

Section 10
General Information
Page
Contents
Page
Group 10 - Safety
Recognize Safety Information...............................10-10-1
Understand Signal Words......................................10-10-1
Follow Safety Instructions......................................10-10-1
Practice Safe Maintenance....................................10-10-2
Use Proper Tools...................................................10-10-2
Handle Fluids Safely - Avoid Fires........................10-10-2
Drain Gasoline When Storing Machine.................10-10-3
Handling Batteries Safely......................................10-10-3
Prepare for Emergencies.......................................10-10-4
Park Machine Safely..............................................10-10-4
Support Machine Properly.....................................10-10-4
Wear Protective Clothing.......................................10-10-4
Work in Clean Area...............................................10-10-5
Service Machines Safely.......................................10-10-5
Work In Ventilated Area.........................................10-10-5
Illuminate Work Area Safely..................................10-10-5
Replace Safety Signs............................................10-10-6
Use Proper Lifting Equipment................................10-10-6
Keep ROPS Installed Properly..............................10-10-6
Follow Tire Recommendations..............................10-10-6
Decommissioning - Proper Recycling and Disposal 10-10-
7
of Fluids and Components.............................
Protect Against High Pressure Spray....................10-10-7
Live With Safety....................................................10-10-7
Group 20 - General Specifications
Service Recommendations for O - Ring Boss 10-20-1
Fittings............................................................
Service Recommendations For Flat Face O - Ring 10-20-2
Seal Fittings...................................................
Metric Cap Screw Torque Values - Grade 7..........10-20-2
Metric Bolt and Screw Torque Values....................10-20-3
Unified Inch Bolt and Screw Torque Values..........10-20-4
Group 30 - Fuel and Lubricants
Gasoline Engine Oil...............................................10-30-1
Oil Filters...............................................................10-30-1
Gasoline Fuel for 4 - Cycle Engines......................10-30-1
Transmission and Hydraulic Oil.............................10-30-2
Grease................................................................... 10-30-2
Mixing of Lubricants..............................................10-30-2
Alternative and Synthetic Lubricants.....................10-30-2
Lubricant Storage..................................................10-30-3
Group 40 - Machine Specifications
Machine Specifications..........................................10-40-1
Product Identification Number Location................10-40-1
10-1

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Group 10
Safety
Understand Signal Words
TS187-19: Signal Words
Follow Safety Instructions
Recognize Safety Information
TS201-UN: Safety Messages
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your
machine or in this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe operating practices.
DX,ALERT-19-19980929
DANGER ; The signal word DANGER indicates a hazardous
situation which, if not avoided, will result in death or serious
injury.
WARNING ; The signal word WARNING indicates a hazardous
situation which, if not avoided, could result in death or
serious
injury.
CAUTION ; The signal word CAUTION indicates a hazardous
situation which, if not avoided, could result in minor or
moderate
injury. CAUTION may also be used to alert against unsafe
practices associated with events which could lead to personal
injury.
A signal word—DANGER, WARNING, or CAUTION—is used
withthesafety-alertsymbol.DANGERidentifiesthemostserious
hazards. DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on CAUTION
safetysigns.CAUTIONalsocallsattentiontosafetymessagesin
this manual.
DX,SIGNAL-19-20161005
Carefully read all safety messages in this manual and on your
machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Be sure new
equipment components and repair parts include the current
safety signs. Replacement safety signs are available from
your
John Deere dealer.
Therecanbeadditionalsafetyinformationcontainedonpartsand
components sourced from suppliers that isnot reproduced in
this
operator′s manual.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
Unauthorized
modifications to the machine may impair the function and/or
safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
DX,READ-19-20090616
Safety
TM145519 (01.12.2018)
Vehicles
10-10-1

Use Proper Tools
Practice Safe Maintenance
Handle Fluids Safely—Avoid Fires TS227-UN: Avoid Fires
When you work around fuel, do not smoke or work near heaters
or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate
or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
DX,FLAME-19-19980929
TS779-UN: Proper Tools
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools.
DO NOT use U.S. measurement tools on metric fasteners. Avoid
bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR-19-19990217
TS218-UN: Keep Area Clean
Understand service procedure before doing work. Keep area
clean and dry.
Never lubricate, service, or adjust machine while it is moving.
Keep hands, feet, and clothing away from power-driven parts.
Disengage all power and operate controls to relieve pressure.
Lower equipment to the ground. Stop the engine. Remove the
key. Allow machine to cool.
Securely support any machine elements that must be raised for
service work.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts. Remove any
buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-
) before making adjustments on electrical systems or welding on
machine.
On towed implements, disconnect wiring harnesses from tractor
before servicing electrical system components or welding on
machine.
Falling while cleaning or working at height can cause serious
injury. Use a ladder or platform to easily reach each location. Use
sturdy and secure footholds and handholds.
DX,SERV-19-20170228
Safety
TM145519 (01.12.2018)
Vehicles
10-10-2

Handling Batteries Safely
Drain Gasoline When Storing Machine
TS204-UN: Caution
DX,WW,BATTERIES-19-20101202
TS227-UN: Storing Gasoline
Gasoline stored in fuel tank can explode.
Never store equipment with gasoline in the tank inside a building
where fumes may reach an open flame or spark.
Always drain gasoline from fuel tank and carburetor bowl when
storing machine. Allow engine to cool before storing.
DX,STORE2-19-19900126
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals known to the State
of California to cause cancer and reproductive harm. Wash
TS203-UN: Caution
Battery gas can explode. Keep sparks and flames away from
batteries. Use a flashlight to check battery electrolyte level.
Never check battery charge by placing a metal object across the
posts. Use a voltmeter or hydrometer.
Always remove grounded (-) battery clamp first and replace
grounded clamp last.
Sulfuric acid in battery electrolyte is poisonous and strong
enough to burn skin, eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid hazards by:
If acid is swallowed:
WARNING:
hands after handling.
If acid is spilled on skin or in eyes:
Filling batteries in a well-ventilated area
Wearing eye protection and rubber gloves
Avoiding use of air pressure to clean batteries
Avoiding breathing fumes when electrolyte is added
Avoiding spilling or dripping electrolyte
Using correct battery booster or charger procedure.
Flush skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush eyes with water for 15—30 minutes. Get
medical attention immediately.
Do not induce vomiting.
Drink large amounts of water or milk, but do not
exceed 2 L (2 qt.).
Get medical attention immediately.
Safety
TM145519 (01.12.2018)
Vehicles
10-10-3

Park Machine Safely
Wear Protective Clothing
Prepare for Emergencies
Support Machine Properly
DX,PARK-19-19900604
TS230-UN: Remove the Key
Before working on the machine:
TS206-UN: Protective Clothing
Wear close fitting clothing and safety equipment appropriate to
the job.
Prolonged exposure to loud noise can cause impairment or loss
of hearing.
Wear a suitable hearing protective device such as earmuffs or
earplugs to protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while operating
machine.
DX,WEAR-19-19900910
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before
youworkonthemachine.Iftheworkrequiresthatthemachineor
attachment be lifted, provide secure support for them. If left in a
raised position, hydraulically supported devices can settle or leak
down.
Do not support the machine on cinder blocks, hollow tiles, or
props that may crumble under continuous load. Do not work
under a machine that is supported solely by a jack. Follow
recommended procedures in this manual.
When implements or attachments are used with a machine,
always follow safety precautions listed in the implement or
attachment operator′s manual.
DX,LOWER-19-20000224
TS291-UN: First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
DX,FIRE2-19-19930303
Lower all equipment to the ground.
Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag
station.
in operator
Safety
TM145519 (01.12.2018)
Vehicles
10-10-4

Work in Clean Area
Work In Ventilated Area
Service Machines Safely
Illuminate Work Area Safely
DX,CLEAN-19-19900604
T6642EJ-UN: Clean Work Area
Before starting a job:
TS223-UN: Work Area Safely
Illuminate your work area adequately but safely. Use a portable
safety light for working inside or under the machine. Make sure
the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
DX,LIGHT-19-19900604
TS220-UN: Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove the
exhaust fumes from the area with an exhaust pipe extension.
Ifyoudonothaveanexhaustpipeextension,openthedoorsand
get outside air into the area.
DX,AIR-19-19990217
TS228-UN: Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf,
loose clothing, or necklace when you work near machine tools
or moving parts. If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent electrical shorts and
entanglement in moving parts.
DX,LOOSE-19-19900604
Clean work area and machine.
Make sure you have all necessary tools to do your
job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
Safety
TM145519 (01.12.2018)
Vehicles
10-10-5

Replace Safety Signs
Keep ROPS Installed Properly
Follow Tire Recommendations
Use Proper Lifting Equipment
TS201-UN: Safety Signs
Replace missing or damaged safety signs. See the machine
operator’s manual for correct safety sign placement.
DX,SIGNS1-19-19900604
TS212-UN: Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over
protective structure (ROPS) is loosened or removed for any
reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is
subjected to structural damage, is involved in an overturn
incident, or is in any way altered by welding, bending, drilling, or
cutting. A damaged ROPS should be replaced, not reused.
The seat is part of the ROPS safety zone. Replace only with John
Deere seat approved for your tractor.
Any alteration of the ROPS must be approved by the
manufacturer.
DX,ROPS3-19-20111012
H111235-UN: Read OM
Keep your machine in proper working order.
Use only prescribed tire sizes with correct ratings and inflate to
the pressure specified in this manual.
Use of other than prescribed tires may decrease stability, affect
steering, result in premature tire failure, or cause other durability
or safety issues.
DX,TIRE,INFO-19-20140519
TS226-UN: Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or
machine damage.
Follow recommended procedure for removal and installation of
components in the manual.
DX,LIFT-19-19900604
Safety
TM145519 (01.12.2018)
Vehicles
10-10-6

Live With Safety
Protect Against High Pressure Spray
Decommissioning—Proper Recycling
and Disposal of Fluids and Components
DX,DRAIN-19-20150601
TS1133-UN: Recycle Waste
Safety and environmental stewardship measures must be taken
into account when decommissioning a machine and/or
component. These measures include the following:
TS1343-UN: High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and
cause serious injury. Keep spray from contacting hands or body.
If an accident occurs, see a doctor immediately. Any high
pressure spray injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors unfamiliar
withthistypeofinjuryshouldreferenceaknowledgeablemedical
source. Such information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
DX,SPRAY-19-19920416
TS231-19: Safety Systems
Before returning machine to customer, make sure machine is
functioning properly, especially the safety systems. Install all
guards and shields.
DX,LIVE-19-19920925
Use appropriate tools and personal protective
equipment such as clothing, gloves, face shields or
glasses, during the removal or handling of objects
and materials.
Follow instructions for specialized components.
Release stored energy by lowering suspended
machine elements, relaxing springs, disconnecting
the battery or other electrical power, and releasing
pressure in hydraulic components, accumulators,
and other similar systems.
Minimize exposure to components which may have
residue from agricultural chemicals, such as
fertilizers and pesticides. Handle and dispose of
these components appropriately.
Carefully drain engines, fuel tanks, radiators,
hydraulic cylinders, reservoirs, and lines before
recycling components. Use leak-proof containers
when draining fluids. Do not use food or beverage
containers.
Do not pour waste fluids onto the ground, down a
drain, or into any water source.
Observe all national, state, and local laws,
regulations, or ordinances governing the handling or
disposal of waste fluids (example: oil, fuel, coolant,
brake fluid); filters; batteries; and, other substances
or parts. Burning of flammable fluids or components
inotherthanspeciallydesignedincineratorsmaybe
prohibited by law and could result in exposure to
harmful fumes or ashes.
Service and dispose of air conditioning systems
appropriately. Government regulations may require
a certified service center to recover and recycle air
conditioning refrigerants which could damage the
atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic,
glass, rubber, and electronic components which
may be recyclable, in part or completely.
Contact your local environmental or recycling
center, or your John Deere dealer for information on
the proper way to recycle or dispose of waste.
Safety
TM145519 (01.12.2018)
Vehicles
10-10-7

Group 20
General Specifications
Service Recommendations for O-Ring
Boss Fittings
Angle Fitting
Straight Fitting
T6243AE-UN: Straight Fitting
04T,90,K66-19-19990929
1
.
2
.
3
.
Inspect O-ring boss seat for dirt or defects.
Lubricate O-ring with petroleum jelly. Place electrical tape
over threads to protect O-ring. Slide O-ring over tape and
into O-ring groove of fitting. Remove tape.
Tighten fitting to torque value shown on chart.
T6520AB-UN: Angle Fitting
LEGEND:
A-Lock Nut
B-Backup Washer
C-Head End
1. Back off lock nut (A) and backup washer (B) completely to
head end (C) of fitting.
2. Turn fitting into threaded boss until backup washer contacts
face of boss.
3. Turn fitting head end counterclockwise to proper index
(maximum of one turn).
4. NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head end with a wrench and tighten locknut and
backup washer to proper torque value.
NOTE:
Torque tolerance is±10%.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread SizeN·mlb·ft
3/8-24 UNF
7/16-20 UNF
1/2-20 UNF
9/16-18 UNF
3/4-16 UNF
7/8-14 UNF
1-1/16-12 UN
1-3/16-12 UN
1-5/16-12 UN
1-5/8-12 UN
1-7/8-12 UN
8
12
16
24
46
62
10
2
12
2
14
2
19
0
21
7
6
9
12
18
34
46
75
90
10
5
14
0
16
0
TM145519 (01.12.2018)
Vehicles
10-20-1

Metric Cap Screw Torque Values—
Grade 7
ServiceRecommendationsForFlatFace
O-Ring Seal Fittings
1
.
2
.
3
.
Inspect the fitting sealing surfaces and O-ring. They must be
free of dirt or defects.
Lubricate O-rings and install into grove using petroleum jelly
to hold in place.
Index angle fittings and tighten by hand pressing joint
together to insure O-ring remains in place.
4. Tighten fitting or nut to torque value shown on the chart. Do
not allow hoses to twist when tightening fittings, use backup
wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if
indexing is necessary or if fitting is attached to an
actuating device.
Tighten fittings to 50% of listed torque value if used in
aluminum housing.
FLAT FACE O-RING SEAL FITTING TORQUE*
Nomial Tube O.D.Thread SizeSwivel NutBulkhead Nut mm in. in.
N˙m lb·ft N˙m lb·ft
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
ThreadStraight HexLocknut HexStraight Fitting or Locknut
Size Size Size Toque
Inch Inch Inch N˙m lb·ft
M6
M8
M1
0
M1
2
M1
4
M1
6
9.5—12.2
20.3—27.1
47.5—54.2
81.4—94.9
128.8—146.4
210.2—240
6.35 0.250 9/16-18 16 12
9.52 0.375 11/16-16 24 18
12.70 0.500 13/16-16 50 37
15.88 0.625 1-14 69 51
19.050.7501 3/16-1210275
22.220.8751 3/16-1210275
25.401.0001 7/16-12142105
31.751.2501 11/16-12190140
38.10 1.500 2-12 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
3/8-24 5/8 9/16 12
7/16-20 5/8 5/8 21
1/2-20 3/4 11/16 26
9/16-18 3/4 3/4 34
3/4-16 7/8 15/16 73
7/8-141 1/161 1/16104
1 1/16-121 1/41 3/8176
1 3/16-121 3/81 1/2230
1 5/16-121 1/21 5/8285
*Torque tolerance is +15 -20% unless otherwise specified.
12
24
46
62
10
2
10
2
14
2
19
0
21
7
(7—9)
(15—20)
(35—40)
(60—70)
(95—108)
(155—177)
9
15
19
25
55
76
13
0
17
0
21
0
9
18
34
46
75
75
10
5
14
0
16
0
CED,OUO1085,12-19-20000731
OUO6092,00010A4-19-20110531
NOTE:
When bolting aluminum parts,
specified in table.
tighten to 80% of torque
Size N˙m (lb-ft)
TM145519 (01.12.2018)
Vehicles
10-20-2

Metric Bolt and Screw Torque Values
TS1670-UN: Metric Bolt and Screw
DX,TORQ2-19-20110112
Class 4.8Class 8.8 or 9.8Class 10.9Class 12.9
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
[‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means
Boltcoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinc
orsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated without
Screwfasteners withanyfasteners withanyfasteners withanyfasteners withany
Sizephosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, or
coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18
larger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners with
JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,
zinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13H
zinc flakezinc flakezinc flakezinc flake
coating.] coating.] coating.] coating.]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m
N˙m
lb.-in.
lb.-ft.
N˙m
N˙m
lb.-in.
lb.-ft.
N˙m
N˙m
lb.-in.
lb.-ft.
N˙m
N˙m
lb.-in.
lb.-ft.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N˙m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of the bolt or
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with
screw. DO NOT use these values if a different torque value or tightening
identical property class. Replace fasteners with the same or higher property class. If higher
procedure is given for a specific application. For stainless steel fasteners or for
property class fasteners are used, tighten these to the strength of the original. Make sure
nuts on U-bolts, see the tightening instructions for the specific application. Tighten
fastener threads are clean and that you properly start thread engagement. When possible,
plastic insert or crimped steel type lock nuts by turning the nut to the dry torque
lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts,
shown in the chart, unless different instructions are given for the specific
unless different instructions are given for the specific application.
application.
TM145519 (01.12.2018)
Vehicles
10-20-3

Unified Inch Bolt and Screw Torque Values
TS1671-UN: Unified Inch Bolt and Screw
DX,TORQ1-19-20110112
SAE Grade 2 [Grade 2 applies for hex
cap screws (not hex bolts) up to 6 in.
(152 mm) long. Grade 1 applies for
SAE Grade 1SAE Grade 5, 5.1 or 5.2SAE Grade 8 or 8.2
hex cap screws over 6 in. (152 mm)
long, and for all other types of bolts
and screws of any length.]
Bolt Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
or [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means
Screwcoated with a lubricantplain or zinccoated with aplain or zinccoated with aplain or zinccoated with a lubricantplain or zinc
Sizesuch as engine oil,plated withoutlubricant such asplated withoutlubricant such asplated withoutsuch as engine oil,plated without
fasteners withanyengine oil, fastenersanyengine oil, fastenersanyfasteners withany
phosphate and oillubrication, orwith phosphate andlubrication, orwith phosphate andlubrication, orphosphate and oillubrication, or
coatings, or 7/8 in. and1/4 to 3/4 in.oil coatings, or 7/8 in.1/4 to 3/4 in.oil coatings, or 7/8 in.1/4 to 3/4 in.coatings, or 7/8 in. and1/4 to 3/4 in.
larger fasteners withfasteners withand larger fastenersfasteners withand larger fastenersfasteners withlarger fasteners withfasteners with
JDM F13C, F13F or F13JJDM F13B,with JDM F13C, F13FJDM F13B,with JDM F13C, F13FJDM F13B,JDM F13C, F13F or F13JJDM F13B,
zinc flake coating.]F13E or F13Hor F13J zinc flakeF13E or F13Hor F13J zinc flakeF13E or F13Hzinc flake coating.]F13E or F13H
zinc flakecoating.]zinc flakecoating.]zinc flakezinc flake
coating.] coating.] coating.] coating.]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m
N˙m
lb.-in.
lb.-ft.
N˙m
N˙m
lb.-in.
lb.-ft.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N˙m lb.-ft. N˙mlb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N˙m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt or screw.
Replace fasteners with the same or higher grade. If higher grade fasteners are
DO NOT use these values if a different torque value or tightening procedure is given for a
used, tighten these to the strength of the original. Make sure fastener threads are
specific application. For plastic insert or crimped steel type lock nuts, for stainless steel
clean and that you properly start thread engagement. When possible, lubricate plain
fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application.
or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts
different instructions are given for the specific application.
with identical grade.
TM145519 (01.12.2018)
Vehicles
10-20-4

Group 30
Fuel and Lubricants
Gasoline Engine Oil
DX,FUEL2-19-20130515
Turf-Gard is a trademark of Deere & Company
Plus-4 is a trademark of Deere & Company
TS1734-UN: Oil Viscosities for Air Temperature Ranges DX,ENOIL2-19-20150720
Oil FiltersAlways change filters regularly as specified in this manual.
Use filters meeting John Deere performance specifications.
Filtration of oils is critical to proper operation and lubrication.DX,FILT-19-19960318
Gasoline Fuel for 4-Cycle EnginesRefueloutdoors.DONOTsmokewhileyoufillthefueltank
or service the fuel system. Store fuel in properly identified
Useunleadedgasolinewithaminimumoctaneratingof87AKIpolyethylene containers.
(anti-knock index) or 90 RON (research octane number).
Gasoline fuels specified to EN 228 or ASTM D4814 are
When storing fuel, add John Deere Gasoline Conditioner and
recommended.
Stabilizer (or equivalent) at the specified concentration.
Fuel blends of unleaded gasoline with a maximum 10% ethanol
or 15% MTBE (methyl tertiary-butyl ether) are also acceptable.
Use oil viscosity based on the expected air temperature range
during the period between oil changes.
Using single viscosity grade oils such as SAE 30 or SAE 40 can
reduce oil consumption in air cooled engines.
John Deere Turf-Gard™ is preferred.
The following oils are also recommended:
Other oils may be used if they meet one or more of the following:
CAUTION:
Reduce the risk of fire. Handle fuel carefully. DO NOT fill
the fuel tank when the engine is running or hot. Stop
engine and allow it to cool for several minutes before filling
fuel tank. Fill fuel tank only to the bottom of the filler neck.
John Deere Plus-4™
John Deere Plus-50™ II
ILSAC GF-5
API Service Category SN
API Service Category SM
API Service Category SL
API Service Category SJ
ACEA Oil Sequence A5
ACEA Oil Sequence C4
IMPORTANT:
DO NOT use methanol or fuel blends that contain methanol.
Avoid spilling fuel. Gasoline can damage plastic and painted
surfaces.
DO NOT mix oil with gasoline.
Fuel and Lubricants
TM145519 (01.12.2018)
Vehicles
10-30-1

Grease
Transmission and Hydraulic Oil
Mixing of Lubricants
Alternative and Synthetic Lubricants
DX,GREA1-19-20110414
GREASE-GARD is a trademark of Deere & Company
Other greases may be used if they meet the following:
TS1673-UN: Greases for Air Temperature Ranges
Use grease based on NLGI consistency numbers and
expected air temperature range during the service interval.
John Deere SD Polyurea Grease is preferred.
The following greases are also recommended:
the
TS1739-UN: Oils for Air Temperature Ranges
Use oil viscosity based on the expected air temperature range
during the period between oil changes.
The following oils are preferred:
John Deere Hy-Gard™
John Deere Low Viscosity Hy-Gard™
Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use John Deere Bio Hy-Gard™ II oil when a biodegradable
fluid is required. [Bio Hy-Gard II meets or exceeds the minimum
biodegradability of 80% within 21 days according to CEC-
L-33-T-82 test method. Bio Hy-Gard II should not be mixed with
mineral oils, because this reduces the biodegradability and
makes proper oil recycling impossible.]
Hy-Gard is a trademark of Deere & Company
Bio Hy-Gard is a trademark of Deere & Company
DX,ANTI-19-20160825
Mixing different oils can interfere with the proper functioning of
these additives and degrade lubricant performance.
In general, avoid mixing different brands or types of oil. Oil ConsultyourJohnDeeredealertoobtainspecificinformationand
manufacturers blend additives in their oils to meet certain recommendations.
specifications and performance requirements.DX,LUBMIX-19-19960318
Consult your John Deere dealer to obtain information and
recommendations.
Conditions in certain geographical areas may require lubricant Synthetic lubricants may be used if they meet the performance
recommendations different from those printed in this manual.requirements as shown in this manual.
Some John Deere brand coolants and lubricants may not be Thetemperaturelimitsandserviceintervalsshowninthismanual
available in your location.apply to both conventional and synthetic lubricants.
John Deere HD Lithium Complex Grease
John Deere HD Water Resistant Grease
John Deere GREASE-GARD™
NLGI Performance Classification GC-LB
IMPORTANT:
Some types of grease thickeners are not compatible with
others. Consult your grease supplier before mixing
different types of grease.
Fuel and Lubricants
TM145519 (01.12.2018)
Vehicles
10-30-2

Re-refined base stock products may be used if
lubricant meets the performance requirements.
the finished
BS62576,0001E69-19-20180215
DX,ALTER-19-20110411
Summary of References
Remove and Install Engine
Remove and Install Valve Cover
Remove and Install Timing Belt
Remove and Install Water Pump
Remove and Install Cylinder Head
Remove and Install Intake Manifold
Remove and Install Exhaust Manifold
Recondition Cylinder Head
Remove and Install Oil Pan and Strainer
Remove and Install Oil Pump
Remove and Install Crankshaft Front Oil Seal
Remove and Install Camshafts
Check Crankshaft Main Bearing Clearance
Check Connecting Rod Bearing Clearance
Check Connecting Rod Side Play
Remove and Install Piston and Connecting Rod
Disassemble and Assemble Piston and Connecting
Rod
Inspect Piston and Connecting Rod
Bore Cylinder
Remove and Install Crankshaft and Main Bearings
Inspect Crankshaft
Remove and Install Crankshaft Rear Oil Seal
Remove and Install Alternator
Remove and Install Starting Motor
Replace Fuel Injector
Replace Exhaust Gas Oxygen Sensor
Replace Knock Sensor
Replace Camshaft Position Sensor
Replace Crankshaft Position Sensor
Replace Intake Manifold Pressure and Temperature
Sensor
Replace Throttle Body
Fuel and Lubricants
TM145519 (01.12.2018)
Vehicles
10-30-3

Group 40
Machine Specifications
Product Identification Number Location
NOTE:
Specifications and design subject to change without notice.
XUV835
Ground Speed:
Fuel System:
Electrical System:
Forward HI
Forward LO
Reverse
Engine:
Make
Type
Model
Low Idle Speed
Rev Limiter Speed
Cylinders
Displacement
Spark Plug
Spark Plug Gap
Bore
Stroke
Oil
Oil Filter
Cooling System (including recovery
tank)
Air Cleaner
Engine Shut Off
Fuel System Pressure
72 km/h (45 mph)
47 km/h (29 mph)
53 km/h (33 mph)
Chery
Gas
SQR372 FI
950±50 rpm
6150 rpm
3
812 cm3(49.5 in.3)
NGK BKR6 EGP
0.9—1.05 mm (0.035—0.041 in.)
72 mm (2.835 in.)
66.5 mm (2.618 in.)
John Deere Plus-4™ or John Deere TURF-
GARD™
Spin On
5.0 L (5.2 qt.)
Dry Replaceable Single Element with Remote
Intake
Key Switch
315—345 kPa (45.6—50.4 psi)
Type12 volt
StarterSolenoid Shift
BatteryBCI Group U1
Cold Cranking Amps @-18° C (0° F)480 amps
Charging System (@ Output at 1900 rpm)36 amps
Charging System (Rated Output at 6000 rpm)75 amps
Charging System Static Draw5 mA
Power Train:
Drive Belt Width (Nominal)31.75 mm (1.25 in.)
Continuously Variable Transmission (CVT) with Clutch
Drivetrain
Enclosure
Clutch Engagement1350 rpm
Clutch Disengagement1250 rpm
Transmission OilHy-Gard™ J20C or J20D (Cold Weather)
EMFWD OilLow Viscosity Hy-Gard™ J20C
Steering:
TypeRack and Pinion
Brakes:
TypeAll Wheel Hydraulic Disc
Capacities:
Fuel Tank42.2 L (11.2 gal.)
Crankcase (with Filter)2.2 L (2.3 qt.)
Transmission3.8 L (4.0 qt.)
EMFWD Front Differential590 mL (19.6 oz.)
Dimensions:
Width (overall)1.62 m (63.7 in.)
Length (with bumper)3.36 m (132.2 in.)
Height (with Protective
1.98 m (78.25 in.)
Structure)
Ground Clearance28.4 cm (11.2 in.)
MXT021761-UN: Machine Product Identification Number Location
Product identification number (A), also called serial number or
chassis number, is on the frame behind the right front wheel.
TURF-GARD is a trademark of Deere & Company
Hy-Gard is a trademark of Deere & Company
MXT021762-UN: Engine Serial Number Location
Engine identification number (B) is on the timing belt cover.
BS62576,0001E5D-19-20180216
TM145519 (01.12.2018)
Vehicles
10-40-1

MXT021763-UN: EPAS Serial Number Location
Electric Power Assisted Steering (EPAS) identification number
(C) is on the module where shown.
BS62576,0001E5E-19-20180109
TM145519 (01.12.2018)
Vehicles
10-40-2

Section 20
Engine Repair
Page
Contents
Page
Group 10 - Engine
Summary of References........................................
Essential or Recommended Tools.........................
Service Equipment and Tools................................
Other Material........................................................
Specifications........................................................
Remove and Install Engine....................................
Remove and Install Valve Cover...........................
Remove and Install Timing Belt.............................
Remove and Install Water Pump...........................
Remove and Install Cylinder Head........................
Remove and Install Intake Manifold......................
Remove and Install Exhaust Manifold...................
Recondition Cylinder Head....................................
Remove and Install Oil Pan and Strainer..............
Remove and Install Oil Pump................................
Remove and Install Crankshaft Front Oil Seal......
Remove and Install Camshafts..............................
Check Crankshaft Main Bearing Clearance..........
Check Connecting Rod Bearing Clearance...........
20-10-1
20-10-1
20-10-1
20-10-1
20-10-2
20-10-4
20-10-10
20-10-11
20-10-16
20-10-17
20-10-22
20-10-23
20-10-24
20-10-28
20-10-29
20-10-34
20-10-35
20-10-40
20-10-41
Check Connecting Rod Side Play.........................20-10-41
Remove and Install Piston and Connecting Rod...20-10-42
DisassembleandAssemblePistonandConnecting 20-10-44
Rod.................................................................
Inspect Piston and Connecting Rod......................20-10-46
Bore Cylinder.........................................................20-10-48
Remove and Install Crankshaft and Main 20-10-49
Bearings.........................................................
Inspect Crankshaft................................................20-10-52
Remove and Install Crankshaft Rear Oil Seal.......20-10-53
Remove and Install Alternator...............................20-10-55
Remove and Install Starting Motor........................20-10-57
Replace Fuel Injector............................................20-10-60
Replace Exhaust Gas Oxygen Sensor..................20-10-60
Replace Knock Sensor..........................................20-10-61
Replace Camshaft Position Sensor.......................20-10-61
Replace Crankshaft Position Sensor.....................20-10-61
Replace Intake Manifold Pressure and 20-10-62
Temperature Sensor.......................................
Replace Throttle Body...........................................20-10-63
20-1

Group 10
Engine
Other Material
Summary of References
Service Equipment and Tools
Essential or Recommended Tools
NOTE:
Order tools from the SERVICEGARD™ Catalog.
Remove and Install Valve Cover
Remove and Install Timing Belt
Remove and Install Water Pump
Remove and Install Cylinder Head
Remove and Install Intake Manifold
Remove and Install Exhaust Manifold
Recondition Cylinder Head
Remove and Install Oil Pan and Strainer
Remove and Install Oil Pump
Remove and Install Crankshaft Front Oil Seal
Remove and Install Camshafts
Check Crankshaft Main Bearing Clearance
Check Connecting Rod Bearing Clearance
Check Connecting Rod Side Play
Remove and Install Piston and Connecting Rod
NOTE:
Order tools according to information given in the
SERVICEGARD™ Catalog. Some tools may be available
from a local supplier.
Disassemble and Assemble Piston and Connecting
Rod
Inspect Piston and Connecting Rod
Bore Cylinder
Remove and Install Crankshaft and Main Bearings
Inspect Crankshaft
Remove and Install Crankshaft Rear Oil Seal
Remove and Install Alternator
Remove and Install Starting Motor
Replace Fuel Injector
Replace Exhaust Gas Oxygen Sensor
Replace Knock Sensor
Replace Camshaft Position Sensor
Replace Crankshaft Position Sensor
Replace Intake Manifold Pressure and Temperature
Sensor
Replace Throttle Body
MX52301,0001D84-19-20180214
BS62576,0001E69-19-20180215
MX52301,0001D83-19-20180214
MX52301,0001D85-19-20180215
SERVICEGARD is a trademark of Deere & Company
ESSENTIAL TOOLS listed are required to perform the job
correctly and are obtainable only from the SERVICEGARD™
Catalog.
RECOMMENDED TOOLS, as noted, are suggested to perform
thejobcorrectly.SometoolsmaybeavailablefromlocalSERVICEGARD is a trademark of Deere & Company
suppliers or may be fabricated.
Loctite is a trademark of Henkel Corporation
Plastigage is a trademark of Perfect Circle Corporation
Ridge Reamer.......JT07277
Use to remove carbon from liner bore prior to piston removal.
Socket.......JDG10982
Use to aid in the removal & installation of the oxygen sensor.
Number Name Use
587 Applied to mating surfaces of oil pan and
Form-in-Place Gasket
Loctite®(LOCTITE®)engine block
Applied to mating surfaces of cylinder
TY15130 (U.S.)Form-in-Place Gasket
head.
545 Loctite®(U.S.)Thread LockerApplytothreadsofcamshaftsprocketbolt.
N/A (U.S.)Plastigage®Used to measure bearing clearance.
Number
TY12130 (U.S.)
N/A (U.S.)
J20D (U.S.)
Name Use
Form-in-Place GasketApplytomatingsurfaceofengineblockfor
Sealeroil seal case
Form-in-Place Gasket
Apply to transmission flange
Sealant
Hy-GardUse to fill park brake assembly
Clutch Removal Tool.......JDG11200
Use to remove Clutch from Tapered Shaft by screwing tool into drive clutch.
Valve Spring Compressor.......JDG10981
Use to remove intake & exhaust valves from the cylinder head. Tool compresses the
valve spring to allow removal of the valve spring retainers from the valve stem.
Valve Stem Seal Protector.......JDG10984
Use to install valves into guides/seals without damaging the seals. Tool is bullet shaped
& fits over the valve stem.
Intake Valve Seal Installer.......JDG10979
Used to install intake valve guide to specified depth & to install the valve guide seal
once the guide is in place.
Exhaust Valve Seal Installer.......JDG10980
Used to install exhaust valve guide to specified depth and to install the valve guide
once the guide is in place.
Oil Seal Protector.......JDG10978
Used to install front engine seal with crankshaft in the engine. Two piece tool that
includes a seal protector that fits over the end of the crankshaft & a seal installer to
press the seal in place.
Engine
TM145519 (01.12.2018)
Vehicles
20-10-1

Specifications
Item MeasurementSpecification
73 N·m
Front Engine Mount to Engine Block M10 BoltTorque
(54 lb·ft)
73 N·m
Rear Engine Mount to Engine Block M10 BoltTorque
(54 lb·ft)
37 N·m
Rear Engine Mount to Engine Block M8 BoltTorque
(27 lb·ft)
170 N·m
Rear Engine Mounting Isolator to Carrier BoltTorque
(125 lb·ft)
108 N·m
Front Engine Mounting Isolator to Carrier NutTorque
(80 lb·ft)
37 N·m
Shift Cable Bracket to Transmission BoltTorque
(27 lb·ft)
73 N·m
Shift Cable Bracket to Right-Hand Brace NutTorque
(54 lb·ft)
37 N·m
Left-Hand Brace to Transmission BoltTorque
(27 lb·ft)
73 N·m
Left-Hand Brace to Engine Backing Plate NutTorque
(54 lb·ft)
80 N·m
Flywheel BoltsTorque
(60 lb·ft)
67.8 N·m
Primary Clutch Mounting BoltTorque
(50 lb·ft)
109 N·m
Secondary Clutch Mounting BoltTorque
(80 lb·ft)
73 N·m
Exhaust Pipe to Manifold NutTorque
(54 lb·ft)
6 N·m
Valve Cover BoltTorque
(53 lb·in)
5 mm
Timing Belt Tensioner to Water Pump HousingGap
(0.2 in)
FingerPressureAppliedtoBeltatMid-PointBetween20—30 N
Pressure
Cam and Crank Sprockets(4—6 lb)
5 mm
Timing BeltDeflection
(0.2 in)
25 N·m
Timing Belt Tensioner BoltTorque
(18 lb·ft)
98 N·m
Crankshaft Pulley BoltTorque
(72 lb·ft)
73 N·m
Driveshaft Bearing BoltsTorque
(54 lb·ft)
20 N·m
Water Pump BoltTorque
(177 lb·in)
Cylinder Head Bolts
30 N·m
Initial PassTorque
(22 lb·ft)
50 N·m
Second PassTorque
(37 lb·ft)
70 N·m
Final PassTorque
(51 lb·ft)
6 N·m
Intake Manifold Mounting NutsTorque
(53 lb·in)
15 N·m
Exhaust Manifold to Cylinder Head NutTorque
(133 lb·in)
0.08 mm
Cylinder Head FlatnessOut-of-Flat
(0.003 in)
0.8—1.2 mm
Intake Valve Face MarginThickness
(0.031—0.047 in)
0.8—1.2 mm
Exhaust Valve Face MarginThickness
(0.031—0.047 in)
0.75 mm
Valve Face Margin Wear LimitThickness
(0.030 in)
Intake Valve FaceAngle45°
Exhaust Valve FaceAngle45°
4.96—4.98 mm
Intake Valve StemDiameter
(0.195—0.196 in)
4.95—4.97 mm
Exhaust Valve StemDiameter
(0.195—0.196 in)
5.00—5.018 mm
Intake Valve GuideID
(0.197—0.198 in)
5.00—5.018 mm
Exhaust Valve GuideID
(0.197—0.198 in)
0.030—0.060 mm
Intake Valve Guide-to-Valve StemClearance
(0.001—0.002 in)
0.030—0.068 mm
Exhaust Valve Guide-to-Valve StemClearance
(0.001—0.003 in)
37 mm
Valve Spring Free Length (Nominal)Free Length
(1.457 in)
1.2 mm
Maximum Spring InclinationDistance
(0.047 in)
6 N·m
Item
Outer Rotor-to-Pump Body Wear Limit
Inner Rotor-to-Outer Rotor
Inner Rotor-to-Outer Rotor Wear Limit
Crankshaft Pulley Cap Screw
Timing Belt Tensioner Cap Screw
Intake Camshaft
Exhaust Camshaft
Camshaft End Play (Max)
Camshaft Bearing Cap Screw
Exhaust Camshaft
Coupling Flange Cap Screw
Hub Lock Nut
Intake Cam Front Journal
Intake Cam 2, 3 & 4th Journals
Exhaust Cam Front Journal
Exhaust Cam 2, 3 & 4th Journals
Main Bearing Cap Screw
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Connecting Rod Cap Screw
Connecting Rod Bearing Oil
Connecting Rod Bearing Wear Limit
Connecting Rod Side Play
Connecting Rod Side Play Wear Limit
Connecting Rod Nut
Connecting Rod Bearing Clearance
Connecting Rod Bearing
Connecting Rod Bearing Wear Limit
Crankshaft Connecting Rod Journal
Piston Ring Groove Side Clearance
Top Piston Ring
Top Piston Ring (Max)
Second Piston Ring
Second Piston Ring (Max)
Piston Ring End Gap
Top Ring
Top Ring Wear Limit
Second Ring
Second Ring Wear Limit
Oil Control Ring
Oil Control Ring Wear Limit
Piston Pin Clearance
Piston Pin-to-Bore
Piston Pin-to-Bore Wear Limit
Cylinder Bore (Max)
Piston-to-Cylinder (Max)
Main Bearing Cap Screws
First Pass
MeasurementSpecification
0.25 mm
Clearance
(0.010 in)
0.05—0.18 mm
Clearance
(0.002—0.007 in)
0.35 mm
Clearance
(0.014 in)
98 N·m
Torque
(72 lb·ft)
25 N·m
Torque
(18 lb·ft)
0.1—0.17 mm
End Play
(0.004—0.007 in)
0.1—0.173 mm
End Play
(0.004—0.007 in)
0.18 mm
End Play
(0.007 in)
9±1 N·m
Final Torque
(80±9 lb·in)
6±1 N·m
Torque
(53±17 lb·in)
100±5 N·m
Torque
(73±7 lb·ft)
25.97 mm
OD
(1.022 in)
22.97 mm
OD
(0.904 in)
29.967 mm
OD
(1.18 in)
22.97 mm
OD
(0.904 in)
78 N·m
Torque
(58 lb·ft)
0.020—0.072 mm
Clearance (0.0008—0.0028
in)
0.15 mm
Clearance
(0.006 in)
40 N·m
Torque
(30 lb·ft)
0.020—0.044 mm
Clearance
(0.001—0.002 in)
0.07 mm
Clearance
(0.003 in)
0.15—0.24 mm
End Play
(0.006—0.009 in)
0.30 mm
End Play
(0.012 in)
40 N·m
Torque
(30 lb·ft)
0.020—0.044 mm
Clearance
(0.0008—0.002 in)
0.07 mm
Clearance
(0.003 in)
36.984—37 mm
OD
(1.456—1.457 in)
0.03—0.06 mm
Clearance
(0.001—0.002 in)
0.12 mm
Clearance
(0.005 in)
0.03—0.06 mm
Clearance
(0.001—0.002 in)
0.11 mm
Clearance
(0.004 in)
0.25—0.40 mm
Gap
(0.010—0.016 in)
0.65 mm
Gap
(0.026 in)
0.35—0.50 mm
Gap
(0.014—0.020 in)
0.65 mm
Gap
(0.026 in)
0.20—0.070 mm
Gap
(0.008—0.028 in)
1.00 mm
Gap
(0.075 in)
0.004—0.009 mm
Clearance (0.00015—0.00035
in)
0.015 mm
Engine
TM145519 (01.12.2018)
Vehicles
20-10-2

Item
Second Pass
Final Pass
Crankshaft
Crankshaft Connecting Rod Journal
Crankshaft Main Bearing Journal
48 N·m
Torque
(36 lb·ft)
70.5 N·m
Torque
(52 lb·ft)
Radial0.03 mm
Runout(0.001 in)
36.984—37 mm
Diameter
(1.456—1.457 in)
41.984—42 mm
Diameter
(1.653—1.654 in)
Item
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Oil Seal Case Cap Screws
Flywheel Mounting Cap Screw
0.025—0.069 mm
Clearance
(0.001—0.003 in)
0.10 mm
Clearance
(0.004 in)
25 N·m
Torque
(221 lb·in)
83.4 N·m
Torque
(62 lb·ft)
OUMX068,000141F-19-20180216
Engine
TM145519 (01.12.2018)
Vehicles
20-10-3

Removal
MXT022226-UN: Remove Belt Cover
1.
2.
3.
4.
5.
6
.
7
.
LEGEND:
MXT022227-UN: Driveshaft Coupling
LEGEND:
C-Screw
D-Coupling
E-Bolts (2 Used)
F-Bearing
Remove screw (C) and slide coupling (D) away from the
transmission output shaft.
Remove bolts (E) from the driveshaft bearing (F).
Machines equipped with HVAC: Remove air conditioner
compressor. (See Remove Air Conditioner Compressor.)14.
8.
9.
10.
11.
Park machine safely on a hard level surface. (See the‘Safety 12.
Section”.)
Remove cargo box. (SeeRemove and Install Cargo Box.)
Remove two bolts (A) and remove belt cover (B).
Drain coolant from the engine.13.
MXT022229-UN: Fuel Hose Connector
LEGEND:
L-Fuel Hose Connector
M-Hose
Disconnect fuel hose connector (L) at the injector rail. Plug
end of the fuel hose.
Disconnect hose (M) from valve cover.
MXT022228-UN: Remove Coolant Hoses from Engine
LEGEND:
G-Coolant Hose
H-Coolant Hose
I-Bolt and Nut (2 Used)
J-Ignition Coil (3 Used)
K-Coolant Temperature Sensor
Disconnect coolant hoses (G) and (H).
Machines equipped with HVAC: Remove hose connected to
T-fitting.
Remove two bolts and nuts (I) securing the oxygen sensor
shield and exhaust pipe to the exhaust manifold.
Mark and disconnect connectors to ignition coils (J).
Disconnect coolant temperature sensor (K).
A-Bolts (2 Used)
B-Belt Cover
CAUTION:
Avoid Injury! USE CAUTION AROUND MOVING PARTS.
STOP the engine and remove the ignition key. Wait for all
moving parts to STOP.
CAUTION:
Avoid Injury! Gasoline is flammable. DO NOT SMOKE.
Always work in a well-ventilated area away from open
flame or spark-producing equipment, including
equipment that utilizes pilot lights.
Engine
TM145519 (01.12.2018)
Vehicles
20-10-4

15.
16.
17.
18
.
19
.
20
.
21
.
22
.
23
.
LEGEND:
MXT022230-UN: Fuel Injector Connectors24. LEGEND:
N-Fuel Injector Connectors
O-Camshaft Position Sensor
Mark fuel injector connectors (N) to correspond with the cylinder
number to aid in reassembly and disconnect the fuel injectors.
Disconnect the camshaft position sensor (O).
25.
26.
Remove clip (P) from the throttle cable end. Loosen nut (Q)
and disconnect throttle cable and move aside.
Disconnect the intake manifold temperature and pressure
sensor (R).
Disconnect the knock sensor (S).
Disconnect positive (+) battery cable (T) and exciter wire
from the starting motor solenoid.
Remove spring locking pin (U) and drilled pin from the shift
cable yoke.
Disconnect the throttle position sensor.
Disconnect the idle air control actuator.
LVAL22465-UN: Fan and Clutch Retaining Bolt
LEGEND:
X-Drive Belt
Y-Clutch Retaining Bolt
Z-Fan
Remove drive belt (X).
Remove clutch retaining bolt (Y) and fan (Z).
MXT022232-UN: Intake Hose and Clutch Cover
LEGEND:
V-Intake Hose
W-Clutch Cover
Remove intake hose (V) and clutch cover (W). Refer to Clutch
Housing Removal. (See Remove and Install Clutch Housing .)
MXT022231-UN: Throttle Cable and Harness Connectors
P-Clip
Q-Nut
R-Intake Manifold Temperature and Pressure
Sensor S-Knock Sensor
T-Exciter Wire
U-Spring Locking Pin
Engine
TM145519 (01.12.2018)
Vehicles
20-10-5

27.
28. LVAL22467-UN: Driven Clutch Retaining Bolt
LEGEND:
ab-Driven Clutch Retaining Bolt
Remove driven clutch retaining bolt (ab) and slide clutch off
shaft.
LVAL22466-UN: Clutch
LEGEND:
aa-JDG11200 Clutch Removal Tool
Install JDG11200 Clutch Removal Tool(aa). Hold clutch and
tighten tool until clutch pops off tapered shaft.
29.
30.
31.
32.
33.
34.
MXT022234-UN: Backing Plate to Transmission Brace
LEGEND:
ad-Bolt, M8 (3 Used)
ae-Brace
af-Bolt, M10 (2 Used)
ag-Pin
Remove three M8 bolts (ad) securing brace (ae) to
transmission.
Remove two M10 bolts (af) and flange nuts securing brace
to the engine backing plate.
Remove brace being careful to keep pin (ag) with brace.
MXT022233-UN: Components hidden for a better view.
LEGEND:
ac-Crankshaft Position Sensor
Disconnect crankshaft position sensor (ac).
Remove throttle cable from the tab on top of the inner clutch
enclosure.
Mark location of the bolts (arrows) for the inner clutch
enclosure to aid in reassembly. Bolts are not all the same
length. Remove all bolts securing inner clutch enclosure to
engine and transmission.
NOTE:
Keep track of different bolt lengths and locations for
reassembly purposes.
Engine
TM145519 (01.12.2018)
Vehicles
20-10-6

35.
36.
37.
LVAL22470-UN: Clutch Stub Shaft
LEGEND:
ah-Bolt (4 Used)
Remove four bolts (ah)
remove the shaft.
LVAL22471-UN: Crankshaft Position Sensor
LEGEND:
ai-Bolt (2 Used)
aj-Crankshaft Position Sensor
ak-Bolt (6 Used)
Remove two bolts (ai) securing crankshaft position sensor
(aj) and remove the sensor.
Remove bolts (ak) and remove the flywheel.
38.
from the clutch stub shaft and
39.
40
.
41
.
42
.
43
.
44
.
45
.
46
.
LVAL22472-UN: Backing Plate
LEGEND:
al-Cap Screw (4 Used)
Removefourcapscrews(al)andremovebackingplatefrom the
engine.
MXT022235-UN: Shift Cable Bracket
LEGEND:
am-Bolt, M8 (4 Used)
Remove four M8 bolts (am) securing the shift cable bracket
to the transmission.
Remove M10 bolt and lock nut securing the bracket to the
engine brace and move bracket aside.
Disconnect alternator wiring.
Remove the clamp securing the engine wiring harness to the
cylinder head.
Disconnect the oil pressure switch.
Disconnect the oxygen sensor.
Maneuver the engine wiring harness clear of the engine and
set aside.
Attach engine hoist to engine lifting brackets and raise hoist
enoughtosupportenginewhenenginemountsareremoved.
Engine
TM145519 (01.12.2018)
Vehicles
20-10-7

47.
48.
49.
MXT022236-UN: Rear Skid Plate
LEGEND:
an-Rear Skid Plate
Remove rear skid plate (an).
50.
2.
3.
4.
Install bolt and washer into the rear engine isolator. Tighten
to specification.
Item Measurement Specification
170 N·m
Rear Engine Mounting Isolator to Carrier BoltTorque
(125 lb·ft)
Install front engine isolator bolt and nut. Tighten to
specification.
108 N·m
Front Engine Mounting Isolator to Carrier NutTorque
(80 lb·ft)
Machines equipped with HVAC: Install air conditioner
compressor. (See Install Air Conditioner Compressor.)
LEGEND:
aq-Bolt and Washer
ar-Bolt, M10 (4 Used)
as-Bolt, M8
Remove bolt and washer (aq) from the rear engine isolator.
51. Remove four M10 bolts (ar) and M8 bolt (as) securing rear
LEGEND:
engine mount to the engine block.
ao-Nut and Bolt
ap-Bolt, M10 (6 Used)52.Carefully raise engine from the machine.
Remove nut and bolt (ao) from the front engine isolator.
Remove six M10 bolts (ap) securing front engine mount to Installation
the engine block.
Installation is the reverse of removal.
1. Carefully lower engine into machine. Tighten engine
mounting bolts to specifications.
MXT022238-UN: Viewed from under the rear of the machine.
Item
Front Engine Mount to Engine Block M10 Bolt
Rear Engine Mount to Engine Block M10 Bolt
Rear Engine Mount to Engine Block M8 Bolt
Measurement Specification
73 N·m
Torque
(54 lb·ft)
73 N·m
Torque
(54 lb·ft)
37 N·m
Torque
(27 lb·ft)
Engine
TM145519 (01.12.2018)
Vehicles
20-10-8

12
.
13
.
14
.
5.
6
.
7
.
8
.
9.
10
.
11
.
Check clutch alignment. (SeeClutch Sheave Alignment.)
Install drive belt.
Install outer clutch enclosure.
Install shift cable bracket to transmission and right-hand 15.
brace. Tighten bolts and flange nut to specification.
16.
37 N·m
Shift Cable Bracket to Transmission BoltTorque
(27 lb·ft)
73 N·m
Shift Cable Bracket to Right-Hand Brace NutTorque
(54 lb·ft)
Install backing plate to the engine.
Install crankshaft position sensor.
17.
Install left-hand brace to backing plate and transmission.
18.
Make sure that the brace locating pin is seated in the backing
plate. Tighten bolts and flange nuts to specification.
19.
37 N·m
Left-Hand Brace to Transmission BoltTorque
(27 lb·ft)
73 N·m20.
Left-Hand Brace to Engine Backing Plate NutTorque
(54 lb·ft)
21.
Use a medium strength thread locker on flywheel bolts and
install the flywheel. Tighten bolts to specifications.22.
80 N·m23.
Flywheel BoltsTorque
(60 lb·ft)
Install inner clutch enclosure.
Install primary and secondary clutches and tighten to
specification.
67.8 N·m
Primary Clutch Mounting BoltTorque
(50 lb·ft)
109 N·m
Secondary Clutch Mounting BoltTorque
(80 lb·ft)
24.
25.
Fill engine to proper level with oil of correct specifications.
Fill coolant to the correct level. (See Fill and Bleed Coolant
System.)
Attach negative (-) cable to battery.
Clean exhaust pipe and exhaust manifold flanges of any old
gasket material. Install a new manifold gasket.
Installexhaustpipeandoxygensensorshieldtotheexhaust
manifold with two bolts and nuts. Tighten nuts to
specifications.
73 N·m
Exhaust Pipe to Manifold NutTorque
(54 lb·ft)
Connect all engine wiring connectors.
Attach throttle cable to throttle lever and adjust cable. (See
Throttle Cable Adjustment.)
Connect coolant hoses. Check condition of hoses and
replace as necessary.
Attach ground wire to the engine bracket.
Attach battery positive (+) cable and solenoid exciter wire to
starting motor solenoid.
Connect fuel line.
NOTE:
Oil level must be at the full mark with the cap screwed
tight while the engine is cold. To make sure that level
is correct, start engine and run at 4500 rpm for one
minute. Stop engine and check oil level.
OUMX068,00013FB-19-20180216
Engine
TM145519 (01.12.2018)
Vehicles
20-10-9

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