John Deere XUV825E, XUV825M, XUV825M S4 Vehicle Service Manual TM150019

XUV825E, XUV825M,
XUV825M S4 Gator™
Utility Vehicles
(SN. 010001-)
TECHNICAL MANUAL
XUV825E, XUV825M, XUV825M S4 Gator™ Utility
Vehicles (SN. 010001-)
TM150019 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.
TM150019 (01.12.2018) XUV825E, XUV825M, XUV825M S4 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 - Miscellaneous Repair
Section 70 - Operator ` s Station Repair
Section 220 - Engine Operation, Tests, and
Adjustments
Group 10 - Component Location
Group 20 - Diagnosis
Group 25 - Tests and Adjustments
Section 230 - Electrical Operation, Tests,
and Adjustments
Section 260 - Steering and Brake Operation,
Tests, and Adjustments
Section 270 - Miscellaneous Operation,
Tests, and Adjustments
Section 299 - Service Tools
Section 240 - Control Unit Operation, Tests,
and Adjustments
Section 250 - Power Train Operation, Tests,
and Adjustments
Group 05 - Safety
Group 10 - General Specifications
Group 15 - Fuel and Lubricants
Group 20 - Machine Specifications
Group 10 - Repair
Group 10 - Wiring Harnesses
Group 20 - Wiring Harnesses, Kits
Group 10 - Transmission
Group 15 - Axles and Drive Shaft
Group 20 - Mechanical Four Wheel Drive
Group 10 - Steering
Group 20 - Brakes
Group 10 - Wheels
Group 15 - Hood, Cargo Box, and Bumper
Group 20 - Miscellaneous
Group 05 - General Information
Group 15 - Theory of Operation
Group 30 - Wiring Schematics
Group 55 - 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 05 - Safety
Recognize Safety Information...............................
Understand Signal Words......................................
Replace Safety Signs............................................
Handle Fluids Safely - Avoid Fires........................
Prepare for Emergencies.......................................
Prevent Battery Explosions...................................
Prevent Acid Burns................................................
Wear Protective Clothing.......................................
Avoid High - Pressure Fluids.................................
Avoid Heating Near Pressurized Fluid Lines.........
Service Machines Safely.......................................
Use Proper Tools...................................................
Park Machine Safely..............................................
Support Machine Properly.....................................
Use Proper Lifting Equipment................................
Work in Clean Area...............................................
Protect Against High Pressure Spray....................
Illuminate Work Area Safely..................................
Work In Ventilated Area.........................................
Remove Paint Before Welding or Heating.............
Avoid Harmful Asbestos Dust................................
Service Tires Safely...............................................
Stay Clear of Rotating Drivelines...........................
Service Cooling System Safely.............................
10-05-
1 10-
05-1
10-05-
1 10-
05-2
10-05-
2 10-
05-2
10-05-
3 10-
05-3
10-05-
3 10-
05-4
10-05-
4 10-
05-4
10-05-
4 10-
05-5
10-05-
5 10-
05-5
10-05-
5 10-
05-6
10-05-
6 10-
05-6
10-05-
7 10-
05-7
10-05-
8 10-
05-8
Decommissioning - Proper Recycling and Disposal 10-05-9
of Fluids and Components.............................
Handle Chemical Products Safely.........................10-05-9
Live With Safety....................................................10-05-9
Group 10 - General Specifications
Service Recommendations for O - Ring Boss 10-10-1
Fittings............................................................
Service Recommendations For Flat Face O - Ring 10-10-2
Seal Fittings...................................................
Metric Cap Screw Torque Values - Grade 7..........10-10-2
Metric Bolt and Screw Torque Values....................10-10-3
Unified Inch Bolt and Screw Torque Values..........10-10-4
Group 15 - Fuel and Lubricants
Gasoline Engine Oil...............................................10-15-1
Oil Filters...............................................................10-15-1
Gasoline Fuel for 4 - Cycle Engines......................10-15-1
Transmission and Hydraulic Oil.............................10-15-2
Grease................................................................... 10-15-2
Mixing of Lubricants..............................................10-15-2
Alternative and Synthetic Lubricants.....................10-15-2
Lubricant Storage..................................................10-15-3
Group 20 - Machine Specifications
Machine Specifications..........................................10-20-1
Product Identification Number Location................10-20-1
10-1

Group 05
Safety
TS187-19: Signal Words
Replace Safety Signs
Understand Signal Words
Recognize Safety Information 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
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
Safety
TM150019 (01.12.2018)
Vehicles
10-05-1

Prepare for Emergencies
Prevent Battery Explosions
Handle Fluids Safely—Avoid Fires
TS204-UN: Battery Explosions
Keep sparks, lighted matches, and open flame away from the top
of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the
posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to
16°C (60°F).
DX,SPARKS-19-19930303
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
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
Safety
TM150019 (01.12.2018)
Vehicles
10-05-2

Prevent Acid Burns
Wear Protective Clothing
Avoid High-Pressure Fluids
DX,POISON-19-19930421
X9811-UN: High Pressure
Inspect hydraulic hoses periodically–at least once per year–for
leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.
If acid is swallowed:
If you spill acid on yourself:
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
Replace worn or damaged hose assemblies immediately with
John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing
serious injury.
Avoid the hazard by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and
body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected
into the skin must be surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with this type of injury
should reference a knowledgeable medical source. Such
information is available in English from Deere & Company
Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.
DX,FLUID-19-20111012
TS203-UN: Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush your 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 quarts).
Get medical attention immediately.
Safety
TM150019 (01.12.2018)
Vehicles
10-05-3

Use Proper Tools
Park Machine Safely
Service Machines Safely
Avoid Heating Near Pressurized Fluid
Lines
DX,PARK-19-19900604
TS230-UN: Remove the Key
Before working on the machine:
TS953-UN: Flammable Spray
Flammable spray can be generated by heating near pressurized
fluid lines, resulting in severe burns to yourself and bystanders.
Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials. Pressurized
lines can accidentally burst when heat goes beyond the
immediate flame area.
DX,TORCH-19-20041210
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
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
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
TM150019 (01.12.2018)
Vehicles
10-05-4

Work in Clean Area
Support Machine Properly
Use Proper Lifting Equipment
Protect Against High Pressure Spray
DX,CLEAN-19-19900604
T6642EJ-UN: Clean Work Area
Before starting a job:
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
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
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
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
TM150019 (01.12.2018)
Vehicles
10-05-5

Remove
Heating
Paint
Work In Ventilated Area
Illuminate Work Area Safely
Before Welding or
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
welding, soldering, or using a torch.
is heated by
Remove paint before heating:
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
Do not use a chlorinated solvent in areas where welding will take
place.
Do all work in an area that is well ventilated to carry toxic fumes
and dust away.
Dispose of paint and solvent properly.
DX,PAINT-19-20020724
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
Remove paint a minimum of 100 mm (4 in.) from
area to be affected by heating. If paint cannot be
removed, wear an approved respirator before
heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or
heating.
Safety
TM150019 (01.12.2018)
Vehicles
10-05-6

TS220-UN: Asbestos Dust
Service Tires Safely
Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling
components containing asbestos fibers. Inhaled asbestos fibers
may cause lung cancer.
Components in products that may contain asbestos fibers are
brakepads, brakebandandlining assemblies, clutch plates, and
somegaskets.Theasbestosusedinthesecomponentsisusually
found in a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing asbestos is not
generated.
Avoid creating dust. Never use compressed air for cleaning.
Avoid brushing or grinding material containing asbestos. When
servicing, wear an approved respirator. A special vacuum cleaner
is recommended to clean asbestos. If not available, apply a mist
of oil or water on the material containing asbestos.
Keep bystanders away from the area.
DX,DUST-19-19910315
TS211-UN: Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious
injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires
above the recommended pressure. Never weld or heat a wheel
and tire assembly. The heat can cause an increase in air pressure
resulting in a tire explosion. Welding can structurally weaken or
deform the wheel.
Wheninflatingtires,useaclip-onchuckandextensionhoselong
enough to allow you to stand to one side and NOT in front of or
over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or
missing lug bolts and nuts.
DX,RIM-19-19900824
Safety
TM150019 (01.12.2018)
Vehicles
10-05-7

H96219-UN: Drivelines
Service Cooling System Safely
Stay Clear of Rotating Drivelines
TS1644-UN: Rotating Drivelines
DX,PTO-19-20170228
TS281-UN: Cooling System
Explosive release of fluids from pressurized cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when cool enough to
touch with bare hands. Slowly loosen cap to first stop to relieve
pressure before removing completely.
DX,RCAP-19-19900604
Entanglement in rotating driveline can cause serious injury or
death.
Keep tractor master shield and driveline shields in place at all
times. Make sure rotating shields turn freely.
Only use power take-off driveshafts with adequate guards and
shields.
Wear close fitting clothing. Stop the engine and be sure that PTO
driveline is stopped before making adjustments, connections, or
cleaning out PTO driven equipment.
Do not install any adapter device between the tractor and the
primary implement PTO driveshaft that will allow a 1000 rpm
tractorshafttopowera540rpmimplementatspeedshigherthan
540 rpm.
Do not install any adapter device that results in a portion of
the rotating implement shaft, tractor shaft, or the adapter to be
unguarded. The tractor master shield shall overlap the end of the
splined shaft and the added adaptor device as outlined in the
table.
The angle at which the primary implement PTO driveshaft can be
inclined may be reduced depending on the shape and size of the
tractor master shield and the shape and size of the guard of the
primary implement PTO driveshaft.
Do not raise implements high enough to damage the tractor
master shield or guard of primary implement PTO driveshaft.
Detach the PTO driveline shaft if it is necessary to increase
implement height. (See Attching/Detaching PTO Driveline)
When using Type 3/4 PTO, inclination and turning angles may be
reduced depending on type of PTO master shield and coupling
rails.
PTO Type Diameter Splines n±5 mm (0.20 in.)
1
2
3
4
35 mm (1.378 in.)
35 mm (1.378 in.)
45 mm (1.772 in.)
57.5 mm (2.264
in.)
6
2
1
2
0
2
2
85 mm (3.35 in.)
85 mm (3.35 in.)
100 mm (4.00
in.) 100 mm
(4.00 in.)
Safety
TM150019 (01.12.2018)
Vehicles
10-05-8

Live With Safety
Handle Chemical Products Safely
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:
TS1132-UN: Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury.
Potentially hazardous chemicals used with John Deere
equipmentincludesuchitemsaslubricants,coolants,paints,and
adhesives.
A Material Safety Data Sheet (MSDS) provides specific details
on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous
chemical. That way you will know exactly what the risks are
and how to do the job safely. Then follow procedures and
recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products
used with John Deere equipment.)
DX,MSDS,NA-19-19930303
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
TM150019 (01.12.2018)
Vehicles
10-05-9

Group 10
General Specifications
Service Recommendations for O-Ring
Boss Fittings
Angle Fitting
Straight Fitting
TCT008638-UN: Angle Fitting
OUMX258,00000F8-19-20160120
TCT008637-UN: Straight Fitting
LEGEND:
A-Straight Boss Fitting
B-Straight Stud and Tube Nut
1.Inspect O-ring boss seat for dirt or defects.
2. 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.
3.Tighten fitting to torque value shown on chart.
LEGEND:
A-Locknut
B-Washer
C-Head-End of Fitting
1.Inspect O-ring boss seat for dirt or defects.
2. 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.
3. Back-off locknut (A) and back-up washer (B) completely to
head-end (C) of fitting.
4. Turn fitting into threaded boss until back-up washer contacts
face of boss.
5. Turn fitting head-end counterclockwise to proper index
(maximum of one turn).
6. NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head-end with a wrench and tighten locknut and
back-up washer to proper torque value.
STUD END O-RING SEAL TORQUE FOR STRAIGHT AND ADJUSTABLE
FITTINGS*
Thread SizeStraight Hex SizeLocknut Hex SizeStraight Fitting or
Locknut Toque
Inch Inch Inch N·m lb-ft
3/8-24 5/8 9/16
7/16-20 5/8 5/8
1/2-20 3/4 11/16
9/16-18 3/4 3/4
3/4-16 7/8 15/16
7/8-141 1/161 1/16
1 1/16-121 1/41 3/8
1 3/16-121 3/81 1/2
1 5/16-121 1/21 5/8
*Torque tolerance is +15 -20% unless otherwise specified.
18
24
30
37
75
10
4
17
6
23
0
27
0
13
18
22
27
55
76
13
0
17
0
19
9
TM150019 (01.12.2018)
Vehicles
10-10-1

Metric Cap Screw Torque Values—
Grade 7
ServiceRecommendationsForFlatFace O-
Ring Seal Fittings
CED,OUO1085,12-19-20000731
OUMX258,00000F9-19-20140812
TCT008639-UN: Flat Face Fittings
LEGEND:
A-O-ring
B-Nut
1. Inspect the fitting sealing surfaces and O-ring. They must be
free of dirt or defects.
2. Lubricate O-ring (A) and install into groove using petroleum
jelly to hold in place.
3.
4.
Index angle fittings and tighten by hand pressing joint
together to insure O-ring remains in place.
Unlessspecifiedotherwise,tightenfittingornut(B)totorque
value shown on the chart. Do not allow hoses to twist when
tightening fittings, use backup wrench on straight hose
couplings.
FLAT FACE O-RING SEAL FITTING TORQUE*
Nominal Tube O.D.Thread SizeSwivel NutBulkhead Nut
mm in in N·m lb-ft 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 24 18
9.52 0.375 11/16-16 37 27
12.70 0.500 13/16-16 63 46
15.88 0.625 1-14 103 76
19.050.7501 3/16-12152112
22.220.8751 3/16-12152112
25.401.0001 7/16-12214158
31.751.2501 11/16-12286211
38.10 1.500 2-12 326 240
*Torque tolerance is +15 -20% unless otherwise specified.
32
42
93
11
8
17
5
17
5
24
7
32
8
37
4
(7—9)
(15—20)
(35—40)
(60—70)
(95—108)
(155—177)
24
31
69
87
12
9
12
9
18
2
24
2
27
6
NOTE:
When bolting aluminum parts,
specified in table.
tighten to 80% of torque
Size N˙m (lb-ft)
TM150019 (01.12.2018)
Vehicles
10-10-2

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.
TM150019 (01.12.2018)
Vehicles
10-10-3

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.
TM150019 (01.12.2018)
Vehicles
10-10-4

Group 15
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
TM150019 (01.12.2018)
Vehicles
10-15-1

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
TM150019 (01.12.2018)
Vehicles
10-15-2

Re-refined base stock products may be used if
lubricant meets the performance requirements.
the finished
OUMX068,000141B-19-20180213
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
TM150019 (01.12.2018)
Vehicles
10-15-3

Group 20
Machine Specifications
Product Identification Number Location
NOTE:
Specifications and design subject to change without notice.
XUV825
Ground Speed:
Forward HI
Forward LO
Reverse
Engine:
Make
Type
Model
Slow 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:
Fuel System Pressure
Electrical System:
Type
71 km/h (44 mph)
43 km/h (27 mph)
48 km/h (30 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)
12 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
31.75 mm (1.25 in.)
(Nominal)
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 Tank20.1 L (5.3 gal)
Crankcase (with Filter)2.2L (2.3 qt.)
Transmission4.3 L (4.5 qt.)
EMFWD Front
660 mL (22 oz.)
Differential
Dimensions:
2 Passenger4 Passenger
Width (overall)1.5 m (59.3 in.)
Length (with bumper)2.87 m (113.0 in.)
Height (with OPS)1.89 m (74.4 in.)
Ground Clearance26.7 cm (11.0 in.)
MXT005497-UN: Machine Product Identification Number Location
The product identification number (A) is located on the right-hand
side frame.
TURF-GARD is a trademark of Deere & Company
Hy-Gard is a trademark of Deere & Company
MXT005498-UN: Engine Serial Number Location
The engine identification number (B) is located on the right-hand
side of the engine.
BS62576,0002120-19-20170928
BS62576,0002121-19-20170928
TM150019 (01.12.2018)
Vehicles
10-20-1

Section 20
Engine Repair
Page
Contents
Page
Group 10 - Repair
Summary of References........................................
Specifications........................................................
Essential or Recommended Tools.........................
Service Equipment and Tools................................
Other Material........................................................
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
20-10-2
20-10-3
20-10-3
20-10-3
20-10-4
20-10-9
20-10-10
20-10-15
20-10-16
20-10-21
20-10-21
20-10-23
20-10-27
20-10-28
20-10-33
20-10-34
20-10-39
20-10-40
Check Connecting Rod Side Play.........................20-10-40
Remove and Install Piston and Connecting Rod...20-10-41
DisassembleandAssemblePistonandConnecting 20-10-43
Rod.................................................................
Inspect Piston and Connecting Rod......................20-10-45
Bore Cylinder.........................................................20-10-47
Remove and Install Crankshaft and Main 20-10-48
Bearings.........................................................
Inspect Crankshaft................................................20-10-51
Remove and Install Crankshaft Rear Oil Seal.......20-10-52
Remove and Install Alternator...............................20-10-54
Remove and Install Starting Motor........................20-10-56
Replace Fuel Injector............................................20-10-59
Replace Exhaust Gas Oxygen Sensor..................20-10-59
Replace Knock Sensor..........................................20-10-60
Replace Camshaft Position Sensor.......................20-10-60
Replace Crankshaft Position Sensor.....................20-10-60
Replace Intake Manifold Pressure and 20-10-61
Temperature Sensor.......................................
Replace Throttle Body...........................................20-10-62
20-1

Group 10
Repair
Summary of References
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
OUMX068,000141B-19-20180213
Repair
TM150019 (01.12.2018)
Vehicles
20-10-1

Specifications
Item MeasurementSpecification
Specifications:
Make Chery
ModelSQR372 FI
Type4-cycle gas/Liquid Cooled
Cylinders 3
Bore72 mm (2.835 in.)
Stroke66.5 mm (2.618 in.)
Displacement812 cm3 (49.5 cu-in.)
Spark PlugNGK BKR6 EGP
0.9—1.05 mm
Spark Plug Gap
(0.035—0.041 in.)
Crankcase (approximate with filter)2.2 L (2.3 qt)
Engine Oil (see temperature chart in spec John Deere PLUS-4 or
section, 5W - 30 Preferred)John Deere TURF-GARD
Cooling system (Including recovery tank)5.0 L (5.2 qt)
EngineMounttoEngineBlockM10Cap73 N·m
Torque
Screw(54 lb.-ft.)
RearEngineMounttoEngineBlockM8Cap37 N·m
Torque
Screw(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
Left Hand Engine Strut to Transmission BoltsTorque
(27 lb.-ft.)
LeftHandEngineStruttoEngineBacking73 N·m
Torque
Plate Nuts(54 lb.-ft.)
80 N·m
Flywheel BoltsTorque
(60 lb.-ft.)
67.8 N·m
Primary Clutch Mounting Cap ScrewTorque
(50 lb.-ft.)
109 N·m
Secondary Clutch Mounting Cap ScrewTorque
(80 lb.-ft.)
73 N·m
Exhaust Pipe to Manifold Nut TorqueTorque
(54 lb.-ft.)
6 N·m
Valve Cover BoltTorque
(53 lb.-in.)
TimingBeltTensionertoWaterPump5 mm
Gap
Housing(0.2 in.)
FingerPressureAppliedtoBeltatMid-Point20—30 N
Pressure
Between 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.)
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 Cap ScrewTorque
(53 lb.-in.)
15 N·m
Exhaust Manifold to Cylinder Head NutsTorque
(133 lb.-in.)
73 N·m
Exhaust Manifold to Exhaust Pipe NutsTorque
(54 lb.-ft.)
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.)
Item
Oil Pan Cap Screw
Oil Pan
Oil Pump Mounting Cap Screws
Oil Pickup Tube Cap Screw
Outer Rotor-to-Pump Body
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
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)
MeasurementSpecification
6 N·m
Torque
(53 lb.-in.)
2.2 L
Capacity
(2.3 qt.)
20 N·m
Torque
(177 lb.-in.)
6.1 N·m
Torque
(53 lb.-in.)
0.10—0.181 mm
Clearance
(0.004—0.007 in.)
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
Torque
(80±9 lb.-in.)
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
Repair
TM150019 (01.12.2018)
Vehicles
20-10-2

Item
Main Bearing Cap Screws
First Pass
Second Pass
Final Pass
Crankshaft
Crankshaft Connecting Rod Journal
Ridge Reamer.......JT07277
Removes ridge from top of cylinder bore.
Valve Spring Compressor.......JDG10981
Used to compress valve springs.
Number Name
PM38609 (U.S.) (U.S.)
Form-in-Place
PM37469 (Canada) (U.S.)
Gasket
7649 ( Loctite®) (U.S.)
Form-in-Place
TY15130 (U.S.)
Gasket
545 ( Loctite®) (U.S.)
Red 0.050—0.15 mmPlastigage
(0.002-0.006 in.) (U.S.)Plastigage®
Form-in-Place
TY12130 (U.S.)
Gasket Sealer
J20D (U.S.)Hy-Gard
24 N·m
Torque
(18 lb.-ft.)
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.)
Use
Applied to mating surfaces of oil pan
and engine block.
Applied to mating surfaces of
cylinder head.
Apply to threads of camshaft
sprocket bolt.
Used to check main bearing
clearances.
Used to measure main bearing
clearance.
Apply to mating surface of engine
block for oil seal case
Apply to transmission flange
Use to fill park brake assembly
Item
Crankshaft Main Bearing Journal
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Oil Seal Case Cap Screws
Flywheel Mounting Cap Screw
Clutch Removal Tool.......JDG11200
Separates Primary Clutch from Engine Crankshaft
Oil Seal Protector.......JDG10978
Used to protect oil seal.
Intake Valve Seal Installer.......JDG10979
Use to install intake valve stem oil seals.
Exhaust Valve Seal Installer.......JDG10980
Used to install exhaust valve stem oil seals.
Socket.......JDG10982
Used to remove and install exhaust gas oxygen sensor.
Valve Stem Seal Protector.......JDG10984
Used to protect valve stem seals when installing on valve.
41.984—42 mm
Diameter
(1.653—1.654 in.)
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.)
OUMX068,0000088-19-20131118
OUMX068,0000089-19-20141112
OUMX068,0000087-19-20131028
OUMX068,0000206-19-20141112
Other Material
Service Equipment and Tools
Essential or Recommended Tools
NOTE:
Order tools from the SERVICEGARD™ Catalog.
NOTE:
Order tools according to information given in the
SERVICEGARD™ Catalog. Some tools may be available
from a local supplier.
SERVICEGARD is a trademark of Deere & Company
Loctite is a trademark of Henkel Corporation
Plastigage is a trademark of Perfect Circle Corporation
ESSENTIAL TOOLS listed are required to perform the job
correctly and are obtainable only from the SERVICEGARD™
Catalog.
SERVICEGARD is a trademark of Deere & Company
RECOMMENDED TOOLS, as noted, are suggested to perform the
job correctly. Some tools may be available from local suppliers or
may be fabricated.
Repair
TM150019 (01.12.2018)
Vehicles
20-10-3

Removal
LVAL22458-UN: Alternator and Water Pump Belt Cover
1
.
2
.
3
.
4
.
5.
6.
LEGEND:
LVAL22459-UN: Coolant Drain Plug
LEGEND:
C-Drain Plug
D-Cap Screw
E-Coupling
F-Bolts (2 Used)
Place a coolant drain pan under engine. Loosen radiator cap
and remove plug (C) from water pump to drain coolant from
engine. 13.
Remove drive shaft retaining cap screw (D) and slide
coupling (E) forward to disconnect from transmission.
7.
8.
9.
10.
11.
Park vehicle safely.
Remove cargo box.
Disconnect negative (—)cable from the battery.12.
Remove two bolts (A). Remove alternator and water pump
belt cover (B).
Remove bolts (F) from driveshaft bearing.
LVAL22460-UN: Connections at Front of Engine
LEGEND:
G-Coolant Hose
H-Coolant Hose
I-Bolt and Nut (2 Used)
J-Ignition Coil (3 Used)
K-Coolant temperature Sensor
Disconnect two coolant hoses (G) and (H).
Remove two bolts and nuts (I) securing the exhaust pipe to
the exhaust manifold.
Mark and disconnect connectors to ignition coils (J).
Disconnect coolant temperature sensor (K).
LVAL22461-UN: Hoses
LEGEND:
L-Fuel Hose Connector
M-Hose
Disconnectfuelhoseatconnector(L).Plugendoffuelhose.
Disconnect hose (M) from valve cover.
A-Bolts (2 Used)
B-Alternator and Water Pump Belt Cover
CAUTION:
Avoid Injury! USE CAUTION AROUND MOVING PARTS.
STOP engine. Remove 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.
Repair
TM150019 (01.12.2018)
Vehicles
20-10-4

14.
15.
16.
17.
18.
19.
20.
LEGEND:
Remove clip (P) from throttle cable end and loosen nut (Q).
Disconnect throttle cable and move aside.
Disconnect wire from intake manifold temperature and
pressure sensor (R).
Disconnect wire from knock sensor (S).
Disconnect positive (+) battery cable and exciter wire (T)
from starting motor solenoid.
Remove spring cotter and pin (U) from transmission shift
cable yoke.
21.
LVAL22462-UN: Fuel Injector Connectors.
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 fuel
injector wiring.
Disconnect camshaft position sensor (O).
22.
23.
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).
LVAL22464-UN: Snorkel Tube and Clutch Cover
LEGEND:
V-Snorkel Tube
W-Clutch Cover
Remove snorkel tube (V) and clutch cover (W).
LVAL22463-UN: Connections at Side of Engine
P-Clip
Q-Jam Nut
R-Intake Manifold Temperature and Pressure Sensor
S-Knock Sensor
T-Exciter Wire
U-Spring Cotter and Pin
Repair
TM150019 (01.12.2018)
Vehicles
20-10-5

24.
25. 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.
26.
27.
28.
LVAL22468-UN: Inner Clutch Enclosure
LEGEND:
ac-Crankshaft Position Sensor
Disconnect crankshaft position sensor (ac).
Mark location of inner clutch enclosure bolts (arrows) to aid
in reassembly. Bolts are not all the same length. Remove
all bolts securing inner clutch enclosure to engine and
transmission.
LVAL22469-UN: Transmission Mount
LEGEND:
ad-Bolt (3 Used)
ae-Transmission Mount
af-Bolt (2 Used)
ag-Mount
Remove three bolts (ad) around transmission mount (ae)
and two bolts (af) securing mount (ag) to engine backplate.
Remove mount.
NOTE:
Keep track of different bolt lengths and locations for
reassembly purposes.
Repair
TM150019 (01.12.2018)
Vehicles
20-10-6

29.
30.
31.
LVAL22470-UN: Clutch Stub Shaft
LEGEND:
ah-Bolt (4 Used)
Remove four bolts (ah)
remove 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 sensor.
Remove bolts (ak) and remove flywheel.
32.
from the clutch stub shaft and
33.
34
.
35
.
36
.
LVAL22472-UN: Backplate
LEGEND:
al-Cap Screw (4 Used)
Remove four cap screws (al) and remove backplate from
engine.
LVAL22473-UN: Shift Cable Bracket
LEGEND:
am-Bolt (3 Used)
Remove three bolts (am) from shift cable bracket and move
bracket aside.
Disconnect alternator wiring.
Maneuver the electrical harness clear of the engine and set
aside.
Attach engine hoist to engine lifting brackets and raise hoist
enoughtosupportenginewhenenginemountsareremoved.
Repair
TM150019 (01.12.2018)
Vehicles
20-10-7

37.
2.
LVAL22474-UN: Rear Skidplate
LEGEND:
am-Rear Skidplate
Remove rear skid plate (an).
22.
23.
3.
4
.
5
.
6
.
7.
8
.
9
.
10.
11.
12.
13.
14.
38.LVAL22475-UN: Engine Mounts
LEGEND:
ao-Nut and Bolt
ap-Bolt (4 Used)
Remove front engine isolator nut and bolt (ao).
15.
39.Remove rear engine isolator bolt.16.
40. Remove bolts (ap) securing engine mounts to the front and
rear of engine block.17.
41.Carefully raise engine from machine.
18.
Installation 19.
Installation is the reverse of removal.20.
1. Carefully lower engine into machine. Tighten engine 21.
mounting cap screws to specifications.
Use medium strength thread locker on flywheel bolts and
install flywheel. Tighten bolts to specifications.
Item Measurement Specification
80 N·m
Flywheel BoltsTorque
(60 lb.-ft.)
Install inner clutch enclosure.
Install primary and secondary clutches and tighten to
specifications.
Install front engine isolator bolt and nut. Tighten to
specification.
108 N·m
Front Engine Mounting Isolator to Carrier NutTorque
(80 lb.-ft.)
Install backplate to engine.
Install crankshaft position sensor.
Install transmission mount and bolt to backplate and
transmission.
Fill engine to proper level with oil of correct specifications.
Fill coolant to correct level. (SeeFill and Bleed Coolant
System.)
Attach negative (—)cable to battery.
Check clutch alignment. (SeeClutch Sheave Alignment.)
Install drive belt.
Install outer clutch enclosure.
Clean exhaust pipe and exhaust manifold flanges of any old
gasket material. Install a new manifold gasket.
Install exhaust manifold flange bolts and nuts and tighten to
specifications.
73 N·m
Exhaust Pipe to Manifold Nut TorqueTorque
(54 lb.-ft.)
Connect all engine wiring harness connectors.
Attach throttle cable to throttle lever and adjust cable.
(SeeAdjust Throttle Cable.)
Connect coolant hoses. Check condition of hoses and
replace as necessary.
Attach ground wire to engine bracket.
Attach battery positive (+) cable and solenoid exciter wire to
starting motor solenoid.
Connect fuel line.
OUMX068,0000068-19-20141112
73 N·m
Engine Mount to Engine Block M10 Cap ScrewTorque
(54 lb.-ft.)
37 N·m
Rear Engine Mount to Engine Block M8 Cap ScrewTorque
(27 lb.-ft.)
Install rear engine isolator bolt. Tighten to specification.
170 N·m
Rear Engine Mounting Isolator to Carrier BoltTorque
(125 lb.-ft.)
Item
Primary Clutch Mounting Cap Screw
Secondary Clutch Mounting Cap Screw
Measuremen
t Torque
Torque
Specificatio
n 67.8 N·m
(50 lb.-ft.)
109 N·m
(80 lb.-ft.)
37 N·m
Left Hand Engine Strut to Transmission BoltsTorque
(27 lb.-ft.)
73 N·m
Left Hand Engine Strut to Engine Backing Plate NutsTorque
(54 lb.-ft.)
NOTE:
Oil level should be at full mark with the cap screwed
tight while the engine is cold. To make sure level is
correct, start engine and run at 4500 rpm for one
minute. Stop engine and check oil level.
Repair
TM150019 (01.12.2018)
Vehicles
20-10-8

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John Deere XUV825E, XUV825M, XUV825M S4 Vehicle Service Manual TM150019

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John Deere XUV825E, XUV825M, XUV825M S4 Vehicle Service Manual TM150019