John Deere XUV835E, XUV835M, XUV835R Gator Manual TM145519 - DOWNLOAD 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 routine failures quickly.

Operation and tests sections help you identify the majority of

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 Group 10 - Safety Group 20 - General Specifications Group 30 - Fuel and Lubricants Group 40 - Machine Specifications

Section 20 - Engine Repair Group 10 - Engine

Section 30 - Electrical Repair Group 10 - Wiring Harnesses

Section 40 - Power Train Repair Group 10 - Transmission Group 20 - Axles and Driveshaft Group 30 - Mechanical Four Wheel Drive

Section 230 - Electrical Operation, Tests and Adjustments Group 5 - General Information Group 10 - Component Location Group 20 - Theory of Operation Group 30 - Schematics Group 40 - Schematics, Kits Group 50 - Connector Information Group 60 - Tests and Adjustments

Section 240 - Control Unit Operation, Tests and Adjustments Group 10 - Theory of Operation Group 20 - Diagnostic Trouble Codes, ICC Group 30 - Diagnostic Trouble Codes, ECU Group 40 - Diagnostic Trouble Codes, SCU

Section 50 - Steering and Brake Repair Group 10 - Steering Group 20 - Brakes

Section 60 - Operator ` s Station Repair Group 10 - Operator ` s Station

Section 250 - Power Train Operation, Tests Group 10 - Component Location and Adjustments Group 20 - Theory of Operation Group 30 - Diagnosis Group 40 - Tests and Adjustments

Section 70 - Miscellaneous Repair Group 10 - Wheels Group 20 - Hood, Cargo Box, and Bumper Group 30 - Miscellaneous Repair

Section 220 - Engine Operation, Tests and Adjustments Group 10 - Component Location Group 20 - Theory of Operation Group 30 - Diagnosis Group 40 - Tests and Adjustments

TM145519 (01.12.2018)

Section - Steering Group 10 -260 Component Location and Operation, Tests and Adjustments

Brake

Group 20 - Theory of Operation Group 30 - Diagnosis Group 40 - Tests and Adjustments Group 10 - Service Tools and Kits

Section 299 - Service Tools

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Section 10 Contents

General Information Page

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.............................

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10-1

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

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Safety

Group 10 Safety 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.

Understand Signal Words

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.

TS187-19: Signal Words

DX,SIGNAL-19-20161005

Follow Safety Instructions

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.

TS201-UN: Safety Messages

DX,READ-19-20090616

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Safety

Practice Safe Maintenance

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

Use Proper Tools

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

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

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Safety

Drain Gasoline When Storing Machine

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

Handling Batteries Safely

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:

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.

TS204-UN: Caution

If acid is spilled on skin or in eyes:

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.

If acid is swallowed:

Do not induce vomiting.

Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).

Get medical attention immediately.

Battery posts, terminals, and related accessories WARNING: contain lead and lead compounds, chemicals known to the State of California cause cancer and reproductive harm. Wash hands afterto handling.

DX,WW,BATTERIES-19-20101202

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Safety

Prepare for Emergencies

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

Park Machine Safely

TS230-UN: Remove the Key

Before working on the machine:

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 DX,PARK-19-19900604

Support Machine Properly

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

Wear Protective Clothing

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

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Safety

Work in Clean Area

T6642EJ-UN: Clean Work Area

Before starting a job:

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.

DX,CLEAN-19-19900604

Service Machines Safely

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

Work In Ventilated Area

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

Illuminate Work Area Safely

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

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Safety

Replace Safety Signs

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

Use Proper Lifting Equipment

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

Keep ROPS Installed Properly

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

Follow Tire Recommendations

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

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Safety

Decommissioning—Proper Recycling and Disposal of Fluids and Components

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:

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.

Protect Against High Pressure Spray

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.

DX,DRAIN-19-20150601

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

Live With Safety

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

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General Specifications

Group 20 General Specifications Service Recommendations for O-Ring Boss Fittings Straight Fitting

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.

T6243AE-UN: Straight Fitting

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

1

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.

2 .

Tighten fitting to torque value shown on chart.

3 Angle Fitting .

Thread SizeN·mlb·ft 3/8-24 UNF

8

7/16-20 UNF

12

9

1/2-20 UNF

16

12

9/16-18 UNF

24

18

3/4-16 UNF

46

34

7/8-14 UNF

62

46

1-1/16-12 UN

10

75

1-3/16-12 UN

2

90

1-5/16-12 UN

12

10

1-5/8-12 UN

2

5

1-7/8-12 UN

14

14

2

0

19

16

0

0

NOTE: Torque tolerance is±10%.

6

21 7 04T,90,K66-19-19990929

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General Specifications

ServiceRecommendationsForFlatFace O-Ring Seal Fittings 1

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.

2 .

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.

3

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 6.35 0.250 9/16-18 16 12

12

9

9.52 0.375 11/16-16 24 18

24

18

12.70 0.500 13/16-16 50 37

46

34

15.88 0.625 1-14 69 51

62

46

19.050.7501 3/16-1210275

10

75

22.220.8751 3/16-1210275

2

75

25.401.0001 7/16-12142105

10

10

31.751.2501 11/16-12190140

2

5

38.10 1.500 2-12 217 160

14

14

*Torque tolerance is +15 -20% unless otherwise specified.

2

0

19 16 Stud End O-ring Seal Torque for Straight and Adjustable Fittings* 0 0 ThreadStraight HexLocknut HexStraight Fitting or Locknut Size Size Size Toque 21 Inch Inch Inch N˙m lb·ft 7 3/8-24 5/8 9/16 12

9

7/16-20 5/8 5/8 21

15

1/2-20 3/4 11/16 26

19

9/16-18 3/4 3/4 34

25

3/4-16 7/8 15/16 73

55

7/8-141 1/161 1/16104

76

1 1/16-121 1/41 3/8176

13

1 3/16-121 3/81 1/2230

0

1 5/16-121 1/21 5/8285

17

*Torque tolerance is +15 -20% unless otherwise specified.

0 21

OUO6092,00010A4-19-20110531

0

Metric Cap Screw Torque Values— Grade 7 NOTE: When bolting aluminum parts, specified in table.

tighten to 80% of torque

Size

N˙m

(lb-ft)

M6

9.5—12.2

(7—9)

M8

20.3—27.1

(15—20)

M1

47.5—54.2

(35—40)

0

81.4—94.9

(60—70)

M1

128.8—146.4

(95—108)

2

210.2—240

(155—177)

M1 4

CED,OUO1085,12-19-20000731

M1 6

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General Specifications

Metric Bolt and Screw Torque Values

TS1670-UN: Metric Bolt and Screw

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

lb.-in.

N˙m lb.-in.

N˙m

lb.-in.

N˙m lb.-in.

M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172 N˙m lb.-ft.

N˙m lb.-ft.

N˙m

lb.-ft.

N˙m lb.-ft.

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.

DX,TORQ2-19-20110112

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General Specifications

Unified Inch Bolt and Screw Torque Values

TS1671-UN: Unified Inch Bolt and Screw

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.

1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-ft.

N˙m

lb.-ft.

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.

DX,TORQ1-19-20110112

TM145519 (01.12.2018)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

For the full PDF version of this manual, Please click on the above download PDF button.

Fuel and Lubricants

Group 30 Fuel and Lubricants Use oil viscosity based on the expected air temperature range during the period between oil changes.

Gasoline Engine Oil

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:

John Deere Plus-4™ John Deere Plus-50™ II one or more of the following: Other oils may be used if they meet 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 A3 ACEA Oil Sequence A1 ACEA Oil Sequence C4 ACEA Oil Sequence C3 ACEA Oil Sequence C2 ACEA Oil Sequence C1 Turf-Gard is a trademark of Deere & Company Plus-4 is a trademark of Deere & Company Plus-50 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

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.

When storing fuel, add John Deere Gasoline Conditioner and IMPORTANT: DO NOT use methanol or fuel blends that contain methanol.

Avoid spilling fuel. Gasoline can damage plastic and painted

CAUTION: surfaces.

Reduce the risk of fire. Handle fuel carefully. DO NOT fill DO NOT mix oil with gasoline. 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.

TM145519 (01.12.2018)

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DX,FUEL2-19-20130515

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Fuel and Lubricants

Transmission and Hydraulic Oil

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 CECL-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

Grease

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

The following greases are also recommended:

John Deere HD Lithium Complex Grease John Deere HD Water Resistant Grease John Deere GREASE-GARD™ Other greases may be used if they meet the following:

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.

GREASE-GARD is a trademark of Deere & Company

DX,GREA1-19-20110414

Mixing different oils can interfere with the proper functioning of

Mixing of and Lubricants these additives 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

Alternative and Synthetic Lubricants

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.

TM145519 (01.12.2018)

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Fuel and Lubricants Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

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

TM145519 (01.12.2018)

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DX,ALTER-19-20110411

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 BS62576,0001E69-19-20180215

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Machine Specifications

Group 40 Machine Specifications Machine Specifications

Type12 volt StarterSolenoid Shift BatteryBCI Group U1

NOTE:

Cold Cranking Amps @-18° C (0° F)480 amps Charging System (@ Output at 1900 rpm)36 amps

Specifications and design subject to change without notice. Charging System (Rated Output at 6000 rpm)75 amps Charging System Static Draw5 mA XUV835

Power Train: Drive Belt Width (Nominal)31.75 mm (1.25 in.)

Ground Speed: Forward HI

72 km/h (45 mph)

Forward LO

47 km/h (29 mph)

Reverse

53 km/h (33 mph)

Continuously Variable Transmission (CVT) with Clutch Drivetrain Enclosure Clutch Engagement1350 rpm Clutch Disengagement1250 rpm

Engine:

Transmission OilHy-Gard™ J20C or J20D (Cold Weather)

Make

Chery

Type

Gas

Model

SQR372 FI

Low Idle Speed

950±50 rpm

Rev Limiter Speed

6150 rpm

Cylinders

3

Displacement

812 cm3(49.5 in.3)

Spark Plug

NGK BKR6 EGP

Spark Plug Gap

0.9—1.05 mm (0.035—0.041 in.)

Bore

72 mm (2.835 in.)

Stroke

66.5 mm (2.618 in.)

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.)

John Deere Plus-4™ or John Deere TURFGARD™

Oil Oil Filter Cooling System (including recovery tank) Air Cleaner Engine Shut Off Fuel Fuel System: System Pressure

Spin On

Dimensions: Width (overall)1.62 m (63.7 in.)

Length (with bumper)3.36 m (132.2 in.)

5.0 L (5.2 qt.)

Dry Replaceable Single Element with Remote Intake Key Switch

Height (with Protective 1.98 m (78.25 in.)

Structure) Ground Clearance28.4 cm (11.2 in.)

Plus-4 is a trademark of Deere & Company TURF-GARD is a trademark of Deere & Company Hy-Gard is a trademark of Deere & Company

315—345 kPa (45.6—50.4 psi)

BS62576,0001E5D-19-20180216

Electrical System:

Product Identification Number Location

MXT021762-UN: Engine Serial Number Location

Engine identification number (B) is on the timing belt cover.

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.

TM145519 (01.12.2018)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Machine Specifications 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)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Section 20

Engine Repair Contents

Page

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...................

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

Recondition Cylinder Head.................................... 20-10-24 Remove and Install Oil Pan and Strainer.............. 20-10-28 Remove and Install Oil Pump................................ 20-10-29 Remove and Install Crankshaft Front Oil Seal...... 20-10-34 Remove and Install Camshafts.............................. 20-10-35 Check Crankshaft Main Bearing Clearance.......... 20-10-40 20-10-41 Check Connecting Rod Bearing Clearance...........

TM145519 (01.12.2018)

20-1

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

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

Group 10 Engine 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

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

Essential or Recommended Tools NOTE: Order tools from the SERVICEGARD™ Catalog.

ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from the SERVICEGARD™ Catalog.

BS62576,0001E69-19-20180215

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.

RECOMMENDED TOOLS, as noted, are suggested to perform thejobcorrectly.SometoolsmaybeavailablefromlocalSERVICEGARD is a trademark of Deere & Company suppliers or may be fabricated.

MX52301,0001D83-19-20180214

Service Equipment and Tools NOTE: Order tools according to information given in the SERVICEGARD™ Catalog. Some tools may be available from a local supplier.

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.

SERVICEGARD is a trademark of Deere & Company

MX52301,0001D84-19-20180214

Other Material

Number

Number Name Use 587 Applied to mating surfaces of oil pan and Form-in-Place Gasket Loctite®(LOCTITE®)engine block

N/A (U.S.)

TY12130 (U.S.)

J20D (U.S.) Applied to mating surfaces of cylinder

TY15130 (U.S.)Form-in-Place Gasket head.

545 Loctite®(U.S.)Thread LockerApplytothreadsofcamshaftsprocketbolt.

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

Loctite is a trademark of Henkel Corporation Plastigage is a trademark of Perfect Circle Corporation

MX52301,0001D85-19-20180215

N/A (U.S.)Plastigage®Used to measure bearing clearance.

TM145519 (01.12.2018)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine Item

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 0.8—1.2 mm Exhaust Valve Face MarginThickness 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 4.95—4.97 mm Exhaust Valve StemDiameter 5.00—5.018 mm Intake Valve GuideID 5.00—5.018 mm Exhaust Valve GuideID Intake Valve Guide-to-Valve StemClearance Exhaust Valve Guide-to-Valve StemClearance 37 mm Valve Spring Free Length (Nominal)Free Length (1.457 in) 1.2 mm Maximum Spring InclinationDistance TM145519 (01.12.2018) (0.047 in) 6 N·m

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

(0.195—0.196 in)

Top Ring Wear Limit

0.03—0.06 mm

Piston Pin Clearance

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)

Piston Pin-to-Bore

0.25—0.40 mm

Second Ring Second Ring Wear Limit Oil Control Ring

Piston Pin-to-Bore Wear Limit Cylinder Bore (Max)

(0.197—0.198 in) (0.197—0.198 in) 0.030—0.060 mm (0.001—0.002 in) 0.030—0.068 mm (0.001—0.003 in)

20-10-2

0.020—0.044 mm

Top Ring

Oil Control Ring Wear Limit

(0.195—0.196 in)

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)

(0.0008—0.002 in) 0.07 mm Clearance (0.003 in) 36.984—37 mm OD (1.456—1.457 in)

Piston Ring End Gap

(0.031—0.047 in)

6±1 N·m

Clearance

Second Piston Ring (Max)

(0.031—0.047 in)

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)

Piston-to-Cylinder (Max) Main Bearing Cap Screws First Pass

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

XUV835E, XUV835M and XUV835R Gator™ Utility in) Vehicles 0.015 mm

Engine Item Second Pass Final Pass Crankshaft Crankshaft Connecting Rod Journal Crankshaft Main Bearing Journal

TM145519 (01.12.2018)

MeasurementSpecification 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)

20-10-3

Item Crankshaft Main Bearing Crankshaft Main Bearing Wear Limit Oil Seal Case Cap Screws Flywheel Mounting Cap Screw

MeasurementSpecification 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 (62OUMX068,000141F-19-20180216 lb·ft)

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

Remove and Install Engine Removal

8.

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

MXT022226-UN: Remove Belt Cover

LEGEND:

A-Bolts (2 Used) B-Belt Cover

Disconnect coolant hoses (G) and (H).

Machines equipped with HVAC: Remove hose connected to

9.

CAUTION: T-fitting.

Avoid Injury! USE CAUTION AROUND MOVING PARTS. Remove two bolts and nuts (I) securing the oxygen sensor STOP the engine and remove the ignition key. Wait for all 10. shield and exhaust pipe to the exhaust manifold. moving parts to STOP. 11. Mark and disconnect connectors to ignition coils (J).

1.

Park machine safely on a hard level surface. (See the‘Safety 12. Disconnect coolant temperature sensor (K).

Section”.)

2. Remove cargo box. (SeeRemove and Install Cargo Box.) 3. Remove two bolts (A) and remove belt cover (B).

4. Drain coolant from the engine.13.

5.

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.

MXT022227-UN: Driveshaft Coupling

LEGEND:

C-Screw D-Coupling E-Bolts (2 Used) F-Bearing

6 .

7

MXT022229-UN: Fuel Hose Connector

Remove screw (C) and slide coupling (D) away from the transmission output shaft.

LEGEND:

Remove bolts (E) from the driveshaft bearing (F).

Disconnect fuel hose connector (L) at the injector rail. Plug end of the fuel hose.

Machines equipped with HVAC: Remove air conditioner compressor. (See Remove Air Conditioner Compressor.)14.

L-Fuel Hose Connector M-Hose

Disconnect hose (M) from valve cover.

.

TM145519 (01.12.2018)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

15. MXT022230-UN: Fuel Injector Connectors24. LEGEND:

MXT022232-UN: Intake Hose and Clutch Cover

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).

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 .)

16.

17.

25.

MXT022231-UN: Throttle Cable and Harness Connectors

LEGEND:

P-Clip Q-Nut R-Intake Manifold Temperature Sensor S-Knock Sensor T-Exciter Wire U-Spring Locking Pin

and

Pressure

Remove drive belt (X).

.

Disconnect the intake manifold temperature and pressure sensor (R).

Disconnect the knock sensor (S).

19

Disconnect positive (+) battery cable (T) and exciter wire from the starting motor solenoid.

.

20 .

21

LEGEND:

X-Drive Belt Y-Clutch Retaining Bolt Z-Fan

Remove clip (P) from the throttle cable end. Loosen nut (Q) and disconnect throttle cable and move aside.

18

LVAL22465-UN: Fan and Clutch Retaining Bolt

26.

Remove clutch retaining bolt (Y) and fan (Z).

Remove spring locking pin (U) and drilled pin from the shift cable yoke.

Disconnect the throttle position sensor.

Disconnect the idle air control actuator.

.

22 .

23 .

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Engine 29. NOTE:

Keep track of different bolt lengths and locations for reassembly purposes.

27.

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.

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.

31. 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.

30.

28.

LVAL22467-UN: Driven Clutch Retaining Bolt

LEGEND:

ab-Driven Clutch Retaining Bolt

Remove driven clutch retaining bolt (ab) and slide clutch off shaft.

32.

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.

34. Remove brace being careful to keep pin (ag) with brace.

33.

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Engine

35.

LVAL22470-UN: Clutch Stub Shaft

38.

LEGEND:

ah-Bolt (4 Used)

Removefourcapscrews(al)andremovebackingplatefrom the engine.

39.

LVAL22471-UN: Crankshaft Position Sensor

LEGEND:

LEGEND:

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.

41

Remove the clamp securing the engine wiring harness to the cylinder head.

Remove two bolts (ai) securing crankshaft position sensor 40 (aj) and remove the sensor.

Remove bolts (ak) and remove the flywheel.

MXT022235-UN: Shift Cable Bracket

am-Bolt, M8 (4 Used)

ai-Bolt (2 Used) aj-Crankshaft Position Sensor ak-Bolt (6 Used)

37.

LEGEND:

al-Cap Screw (4 Used)

Remove four bolts (ah) from the clutch stub shaft and remove the shaft.

36.

LVAL22472-UN: Backing Plate

.

42 .

43 .

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.

44 .

45 .

46 .

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Engine

47.

50.

MXT022236-UN: Rear Skid Plate

LEGEND:

MXT022238-UN: Viewed from under the rear of the machine.

an-Rear Skid Plate

Remove rear skid plate (an).

MXT022239-UN: Components hidden for a better view.

LEGEND:

aq-Bolt and Washer ar-Bolt, M10 (4 Used) as-Bolt, M8

Remove bolt and washer (aq) from the rear engine isolator.

48.

MXT022237-UN: Components hidden for a better view.

LEGEND: engine mount to the engine block.

51. Remove four M10 bolts (ar) and M8 bolt (as) securing rear

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.

49.

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.

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)

2. Install bolt and washer into the rear engine isolator. Tighten to specification.

Item Measurement Specification 170 RearN·m Engine (125 lb·ft) Mounting Isolator to Carrier BoltTorque

3.

Install front engine isolator bolt and nut. Tighten to specification.

Item Measurement Specification 108 N·m Front Engine Mounting Isolator to Carrier NutTorque (80 lb·ft)

Machines equipped with HVAC: Install air conditioner 4. compressor. (See Install Air Conditioner Compressor.)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine 5. Install shift cable bracket to transmission and right-hand 15. Clean exhaust pipe and exhaust manifold flanges of any old brace. Tighten bolts and flange nut to specification. gasket material. Install a new manifold gasket.

Installexhaustpipeandoxygensensorshieldtotheexhaust 16. manifold with two bolts and nuts. Tighten nuts to specifications.

Item Measurement Specification

6 .

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)

Item Measurement Specification 73 N·m Exhaust Pipe to Manifold NutTorque (54 lb·ft)

Install backing plate to the engine.

Connect all engine wiring connectors.

7

Install crankshaft position sensor.

.

Install left-hand brace to backing plate and transmission.

8 .

17. Attach throttle cable to throttle lever and adjust cable. (See Throttle Cable Adjustment.)

18. Connect coolant hoses. Check condition of hoses and Make sure that the brace locating pin is seated in the backing replace as necessary. plate. Tighten bolts and flange nuts to specification.

19.

Attach ground wire to the engine bracket.

Item Measurement Specification 37 N·m Left-Hand Brace to Transmission BoltTorque (27 lb·ft)

Attach battery positive (+) cable and solenoid exciter wire to 73 N·m20. starting motor solenoid.

Left-Hand lb·ft) Brace to Engine Backing Plate NutTorque 9. (54 21. Connect fuel line.

Use a medium strength thread locker on flywheel bolts and install the flywheel. Tighten bolts to specifications.22.

NOTE:

Item Measurement Specification

10

Flywheel BoltsTorque (60 lb·ft)

.

Install inner clutch enclosure.

11

Install primary and secondary clutches and tighten to specification.

.

12

Item Measurement Specification 67.8 N·mClutch Mounting BoltTorque Primary (50 lb·ft) 109 N·m Secondary Clutch Mounting BoltTorque (80 lb·ft)

80 N·m23. 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.

Fill engine to proper level with oil of correct specifications.

Check clutch alignment. (SeeClutch Sheave Alignment.)

.

Install drive belt.

13

Install outer clutch enclosure.

24.

25.

Fill coolant to the correct level. (See Fill and Bleed Coolant System.)

Attach negative (-) cable to battery.

OUMX068,00013FB-19-20180216

.

14 .

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Engine 4. Remove six bolts (D) and remove valve cover.

Remove and Install Valve Cover

LVAL22478-UN: Valve Cover Gasket and Seals 5.

MXT022240-UN: Crankcase Breather Hoses and Spark Plug Cover

LEGEND:

LEGEND:

E-Gasket F-Seals (3 Used)

A-Crankcase Breather Hoses B-Screw (6 Used)

1.Disconnect crankcase breather hoses (A) from valve cover.

2. Remove oil fill cap and six screws (B) securing spark plug cover to valve cover.

Replace gasket (E) and seals (F).

Assembly Assemble in the reverse order of disassembly.

Tighten valve cover bolts to specifications.

Item

Measuremen

Valve Cover Bolt

t Torque

Specificatio n 6 N·m (53 lb·in) OUMX068,00013FC-19-20180215

3.

LVAL22477-UN: Valve Cover

LEGEND:

C-Spark Plug Wires D-Bolt (6 Used)

Disconnect spark plug wires (C).

TM145519 (01.12.2018)

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

Remove and Install Timing Belt Removal

8.

MXT022241-UN: Belt Cover

LVAL22481-UN: Crankshaft Pulley

LEGEND: F-Bolt G-Bolt

LEGEND:

A-Bolt (2 Used) B-Belt Cover

Remove bolt (F) holding dipstick tube and remove dipstick tube.

NOTE: Timing belt can be replaced with the engine in the machine. Some photos in this section are shown with engine out for clarity of photo.

9.

Remove bolt (G) securing crankshaft pulley and remove the pulley. Use a puller if necessary.

1. Park machine safely on a hard level surface. (See the‘Safety Section”.)

2. Remove two bolts (A) and remove belt cover (B).

10.

3.

MXT022242-UN: Water Pump Pulley

Remove the upper (H) and lower (I) timing belt covers.

Remove bolt (C) and slide coupler forward onto driveshaft.

Remove bolts (D) and move the driveshaft aside.

5

Machines equipped with HVAC: Remove the belt from the air conditioner compressor. (See Remove Air Conditioner Compressor.)

.

Loosen alternator bolts and remove alternator belt.

.

6

LEGEND:

H-Upper Timing Belt Cover I-Lower Timing Belt Cover

LEGEND:

C-Bolt D-Bolt (2 Used) E-Water Pump Pulley

4

LVAL22482-UN: Upper and Lower Timing Belt Covers

Remove four bolts from the water pump pulley (E) and remove pulley.

.

7 .

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Engine 12. NOTE:

If timing belt is broken turn camshaft sprocket bolt with a wrench until marks (L) and (M) align, then turn crankshaft until marks (K) align.

Do not pry on the belt with a screwdriver or sharp tool if you plan on reusing the belt. Belt damage results.

11.

LVAL22483-UN: Belt Guide

LEGEND:

J-Belt Guide

Remove belt guide (J).

LVAL22484-UN: Timing Marks.

LVAL22485-UN: Timing Marks

LEGEND:

K-Timing Marks L-Camshaft Sprocket Mark M-Timing Mark

Align timing marks (K) on the crankshaft sprocket and oil pump housing.

13. With crankshaft timing marks aligned as in previous step, camshaft sprocket mark (L) must be either straight up and aligned with the timing mark (M) or down at the six o’clock position. If it is in the six o’clock position turn crankshaft one revolution and line up all marks.

TM145519 (01.12.2018)

20-10-12

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

14.

4.

LVAL22486-UN: Belt Tensioner and Timing Belt

LEGEND:

LVAL22487-UN: Timing Marks

LEGEND:

K-Timing Marks

N-Belt Tensioner

Before installing the belt, align timing marks (K) on crankshaft sprocket and oil pump housing.

Remove belt tensioner (N) and remove belt.

Installation 1. NOTE:

If the belt meets the following conditions, it can be reused.

•Belt has low hours on it.

•Belt has not been contaminated with coolant or oil.

•Belt has no cracks or evident wear.

•Belt has no cracked or missing teeth.

If there is any doubt about the condition of the belt, replace it.

5.

LEGEND:

L-Cam Sprocket Timing Mark M-Timing Mark

Inspect belt sprockets for wear or damage. Replace sprockets if worn or damaged.

2. Inspect belt tensioner for wear or damage. Tensioner must turn smoothly and quietly. Outside diameter of the tensioner wheel must be smooth and clean. If any defects are found, 3. replace the tensioner.

Inspect camshaft and crankshaft oil seals for any sign of leakage. Inspect water pump for leakage. Any leaks must be repaired before installing a new belt.

LVAL22488-UN: Timing Marks

Align the timing mark (L) on the cam sprocket with the timing mark (M) on front cam bearing cover.

6. NOTE:

Once timing belt has been installed, engine must be turned only in a clockwise direction as viewed from the front (timing belt) side of engine.

Install timing belt. Make sure that all marks are still aligned and right side of belt has little or no slack.

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Engine

7.

LVAL22489-UN: Check Timing Belt Tension

Install tensioner and push tensioner arm in direction of arrow until the gap between the belt tensioner and the bottom of the water pump housing meets specifications.

Item Measurement Specification 5 mm Belt Tensioner to Water Pump HousingGap Timing (0.2 in)

8 .

9

Tighten tensioner bolt snug.

Rotate crankshaft clockwise two turns and line up all timing marks again.12.

LVAL22491-UN: Upper and Lower Timing Belt Covers

LEGEND:

H-Upper Timing Belt Cover I-Lower Timing Belt Cover

.

Install the upper (H) and lower (I) timing belt covers.

13.

10.

LVAL22490-UN: Check Belt Deflection

LEGEND:

F-Dipstick Tube and Bolt G-Crankshaft Pulley Bolt

LEGEND:

N-Tensioner Arm O-Tensioner Bolt P-Belt Guide

Install dipstick tube and bolt (F).

Apply specified finger pressure to belt about halfway 14. between cam and crank sprockets (arrow). The belt must deflect the specified distance with specified finger pressure applied. If it does not, loosen tensioner bolt (O) and move tensioner arm (N) right for more tension or left for less tension. When proper tension is obtained tighten tensioner bolt to specifications.

Item MeasurementSpecification 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)

LVAL22492-UN: Crankshaft Pulley

Install crankshaft pulley and specification.

tighten the bolt

Item

Measuremen

Crankshaft Pulley Bolt

t Torque

(G) to

Specificatio n 98 N·m (72 lb·ft)

FingerPressureAppliedtoBeltatMid-

11. Install the belt guide (P) with the curved edge out.

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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine 19. Install bolts (D) into the front driveshaft bearing and tighten to specifications.

15.

Item

Measuremen

Driveshaft Bearing Bolts

t Torque

Specificatio n 73 N·m (54 lb·ft)

MXT022243-UN: Water Pump Pulley

LEGEND:

C-Bolt D-Bolt (2 Used) E-Water Pump Pulley

Install water pump pulley (E).

16. Install alternator belt over pulleys. Adjust belt tension and 20. tighten alternator mounting bolts.

17. Machines equipped with HVAC: Install the belt onto the air 18.

conditioner compressor. (See Install Air Conditioner Compressor.)

LEGEND:

A-Bolt (2 Used) B-Belt Cover

Install belt cover (B) with two bolts (A).

Slide coupler onto the output shaft splines and install bolt (C).

TM145519 (01.12.2018)

MXT022244-UN: Belt Cover

20-10-15

OUMX068,00013FD-19-20180215

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

Remove and Install Water Pump

5. NOTE:

Keep track of locations of different proper reassembly.

length bolts for

Remove six bolts (C) and remove water pump.

Installation

MXT008756-UN: Timing Belt and Water Pump

LEGEND:

A-Idler B-Timing Belt C-Bolts

NOTE: It is possible to replace the water pump with the engine in machine. Some photos are from a removed engine for clarity of photos.

1. Park machine safely on a hard level surface. (See the‘Safety Section”.).

2. Drain coolant from radiator and engine block.

3. Remove timing belt cover. (See Remove and Install Timing Belt .)

4. Remove timing belt idler (A) and timing belt (B).

MXT008757-UN: Water Pump Components

LEGEND:

A-Gasket B-O-ring C-Dust Seals

1.Clean all gasket material from mating surfaces.

2.Install new gasket (A) on dowel pins.

3.Lubricate and install O-ring (B).

4.Install seals (C).

5. Install water pump and tighten bolts in a cross pattern to specification.

Item

Measuremen

Water Pump Bolt

t Torque

Specificatio n 20 N·m (177 lb·in) OUMX068,00013FE-19-20180215

TM145519 (01.12.2018)

20-10-16

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

Remove and Install Cylinder Head Removal

8.

MXT022247-UN: Driveshaft, Alternator, and Water Pump Pulley

LEGEND:

G-Bolt H-Bolt (2 Used) I-Alternator Bolts (2 Used) J-Water Pump Pulley Bolts (4 Used)

Remove bolt (G) and slide coupler forward onto driveshaft.

MXT022245-UN: Remove Coolant Hoses

LEGEND:

A-Coolant Hose B-Coolant Tube C-Bolt and Nut (2 Used) D-Coolant Temperature Sensor

9.

1. Park machine safely on a hard level surface. (See the‘Safety Section”.).

2. Allow engine to cool and cooling system pressure to return to zero. Drain coolant from engine.12.

Remove bolts (H) from bearing support and move driveshaft aside.

10. Machines equipped with HVAC: Remove the belt from the air conditioner compressor. (See Remove Air Conditioner Compressor.)

11. Loosen alternator bolts (I) and remove alternator belt.

Remove four bolts from the water pump pulley (J) and remove pulley.

3. NOTE:

Cylinder head can be removed and installed with the engine in machine. Some photos are from an engine that has been removed for unobstructed views.

Disconnect coolant hose (A) from the thermostat housing and coolant tube (B) under the intake manifold.

4 .

5

Machines equipped with HVAC: Remove hose connected to T-fitting.

Remove two bolts and nuts (C) securing the oxygen sensor shield and exhaust pipe to the exhaust manifold.

Disconnect coolant temperature sensor (D).

.

6 .

13.

LVAL22498-UN: Crankshaft Pulley

LEGEND:

K-Dipstick Tube and Bolt L-Crankshaft Pulley Bolt

Remove bolt (K) holding dipstick tube and remove the dipstick tube.

14.

7.

Remove bolt (L) securing crankshaft pulley and remove pulley. Use a puller if necessary.

MXT022246-UN: Belt Cover

LEGEND:

E-Bolt (2 Used) F-Belt Cover

Remove two bolts (E) and belt cover (F).

TM145519 (01.12.2018)

20-10-17

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

15.

LVAL22499-UN: Coil Pack and Valve Cover

LEGEND:

18.

M-Bolt (2 used)

Remove two bolts (M) securing the coil pack to the cylinder head. Remove the coil pack.

16.

LVAL22501-UN: Belt Guide

LEGEND:

P-Belt Guide

Remove belt guide (P).

Remove valve cover. (See Remove and Install Valve Cover .)

IMPORTANT: 19. Avoid Damage! Do not use a screwdriver or any sharp edged tool to pry belt off sprockets.

LVAL22502-UN: Timing Belt

LEGEND: 17.

F-Belt Tensioner

LVAL22500-UN: Timing Belt Covers

Remove belt tensioner (F). Remove the timing belt.

LEGEND:

N-Upper Timing Belt Cover O-Lower Timing Belt Cover

Remove the upper (N) and lower (O) timing belt covers.

TM145519 (01.12.2018)

20-10-18

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

Engine

22.

LVAL22505-UN: Slave Gears

LEGEND:

K-5 mm x 80 Bolt

InstallanM5x80bolt(K)intotheholenexttothepinnedhole on the intake camshaft to hold master and slave gears in position.

20.

LVAL22503-UN: Cam Sprocket

LEGEND:

G-Sprocket Bolt and Washer H-Cam Sprocket

Remove camshaft sprocket bolt and washer (G) and cam sprocket (H).

23.

21.

LVAL22506-UN: Camshaft Bearing Cap Bolts

Loosen the bolts on the camshaft bearing caps in the sequence shown.

24. NOTE: LVAL22504-UN: Front Cam Housing

LEGEND:

The cam bearing caps are numbered two, three, and four and have an arrow pointing toward the gear end of camshaft. Caps must be installed in the same position and direction as when removed.

I-Bolt (5 Used) J-Front Cam Housing

Remove five bolts (I) and the front cam housing (J).

LVAL22507-UN: Cam Bearing Caps

LEGEND:

L-Cam Bearing Caps

Remove the cam bearing caps (L).

TM145519 (01.12.2018)

20-10-19

XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles

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