SECTION 0B - LUBRICATION AND SERVICING
Maintenance Schedule List
Maintenance Schedule
Extreme Operating Conditions
Recommended Fluids and Lubricants
Recommended Liquid Gasket
Recommended Thread Locking Agents
Maintenance Service Data
MAINTENANCE SCHEDULE LIST
Normal Vehicle Use
The maintenance instructions in this Maintenance Schedule are based on the assumption that the vehicle will be used
as designed:
• to carry passengers and cargo within the limitations specified on the Tyre placard located on the inside of the glove
compartment door;
• to be driven on reasonable road surfaces within legal operating limits;
• to be driven on a daily basis, as a general rule, for at least several miles/kilometers;
• to be driven on unleaded fuel
Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following
sections.
Techline
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MAINTENANCE SCHEDULE
I: Inspect and correct or replace as necessary
R: Replace or change
T: Tighten to specified torque
L: Lubricate
A: Adjust
Use odometer readings or years, which ever
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or years .25 .5 11.522.533.544.555.56
UNDERBONNET
Engine oil RRRRRRRRRRRR
Engine oil filter RRRRRR
Oil cont aminati on IIIIIIIIIIIII
Fluid levels: power steering, brake, clutch,
washer, battery IIIIIIIIIIIII
Coolant Level IIIIIIIIIIIII
Radiator cap and cooling system pressure
test I I I I I I
Timi ng belt Replace every 160,000 km or 8 years
All hoses and pipes in the engine compart-
ment for leaks and deterioration IIIIIIIIIIIII
Clean front of radiator core and A/C con-
denser I I I I I I
Fuel filt er RRRRRR
Air cleaner elem en t I I I I R I I
Pre-air cleaner
Access ory -driv e bel t cond itio n IIIIIIIIIIIII
Val v e clea ranc es A
Spark plugs R
Oxygen Sensors Replace every 150,000 km or 7.5 years
Pow er ste ering flui d RRR
MAINTENANCE SCHEDULE
I: Inspect and correct or replace as necessary
R: Replace or change
T: Tighten to specified torque
L: Lubricate
A: Adjust
Use odometer readings or years, which ever
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or years .25 .5 11.522.533.544.555.56
UNDER VEHICLE
Clutch fluid RRR
Brake fluid RRR
Manual tran sm is sion oil IIIIRI IIRI IIR
Automatic transmission fluid IIIIIIIIRI III
Transfer case fluid/oil IIIIIIIIRI III
Universal joints and splines for wear IIIIIIIIIIIII
Universal joints and sliding sleeve LLLLLLLLLLLLL
Differential gear oil (front and rear) IIIIRI IIRI IIR
Disc brake p ad s and dis c wear IIIIIIIIIIII
Wheel nuts TTTTTTTTTTTTT
Front wheel bearing and locking hubs -
grease RRRR
Front and rear hubs bearing for looseness I I I I I I
Vehicle ride height IIIIIIIIIIIII
Tyre pressure and whee ls for dam age IIIIIIIIIIIII
Tyre rotation Rotate as necessary
General underbody check: steering and
suspension components (inc. shock
absorbers, rubber bushes and boots, ball
joints and connections) park brake cables,
fuel sytem, exhaust system, brake system,
bolts, nuts, hoses, pipes and check for
leaks.
I I I I I I
I: Inspect and correct or replace as necessary
R: Replace or change
T: Tighten to specified torque
L: Lubricate
A: Adjust
The owner will be charged for all lubricants and materials plus labour at the times recommended above.
Use odometer readings or years, which ever
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or years .25 .5 11.522.533.544.555.56
INSIDE VEHICLE
Clutch pedal and free travel IIIIIIIIIIIII
Steering wheel play IIIIIIIIIIIII
Brake pedal and free travel IIIIIIIIIIIII
Park brake lever travel IIIIIII
Park brake ratchet for wear or damage I I I I I I
ROAD TEST
Check vehicle on the road for braking,
steering, engine response,and transmis-
sion operation. Check cruise control, park
pawl operation, A/C performance and neu-
tral start switch.
IIIIIIIIIIIII
SERVICE TIMES
Hours -1.21.4 1.9 2.1 1.2 2.2 1.2 2.1 1.9 61.22.8
- add for automatic transmission 0.2
- add for manual transmission 0.4 0.4 0.4
EXTREME OPERATING CONDITIONS
If the vehicle operates under any of the extreme conditions listed below, it is recommended that some items be
serviced more frequently than the intervals specified in the maintenance plan.
The extra services listed below need only be carried out if the vehicle operates continuosly under the conditions
specified.
If the vehicle is operated under any of these conditions on a one-off basis, e.g. a ho liday trip, then the extra service
should only be applied for that period of time.
As a guide , if oper ating u nder any o f these ex trem e conditi ons for a pe riod o f one mont h or 150 0km, the n the veh icle
would qualify for additional services.
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Drving in extremely cold weather and/or on salted roads.
Change engine oil every 5,000 kms or 3 months
Replace engine oil filter every 10,000km
Inspect exhaust system and mountings every 5000km
Replace aircleaner element every 20,000km
Inspect steering system for looseness or damage every 5,000km
Inspect universal joints and sleeves for wear and lubricate every 5,000km
Change manual transmission oil every 20000km, after an initial 10,000km change
Change transfer case fluid/oil every 20,000km
Change differential oil every 20,000km after an initial 10,000km change.
Inspect front brake pads and discs.
ACD
ACD
AB D
C
B
B C
B
B
B
ABC
RECOMMENDED FLUIDS AND LUBRICANTS
B00RW003
USAGE FLUID/LUBRICANT
Engine Oil
Normal use
Prolonged use in snow areas
API SG or SH Engine oil with a viscosity of 20W/50 for
normal use or 15W/40 for prolonged use in snow areas
Engine Coolant 50% water and 50% coolant conforming to Holden
Speci ficati on HN22 17.
Brake System Heavy Duty Brake Fluid DOT-3, SAE Spec J1703.
Power Steering System DEXRON® -III Automatic transmission fluid.
Automatic Transmission DEXRON® -III Automatic transmission fluid.
MUA T ype Manual transmission & Transfer case
(W/O TOD system) Same oil as engine or 5W/30 synthetic engine oil
Torque On Demand (TOD) Transfer case DEXRON® -III Automatic transmission fluid.
Front Axle API-GL5 80W/90 Gear Oil
Shift On the Fly (SOF) System API-GL5 80W/90 Gear Oil
Rear Axle - Standard Differential
Rear Axle - Limited Slip Differential API-GL5 80W/90 Gear Oil
API-GL5 80W/90 LSD Gear Oil
Clut ch System
• Pivot points & Clutch fork joint NLGI No.2 Lithium Grease with 10% Molydenum
Disulphide
• Master cylinder Heavy Duty Brake Fluid DOT-3, SAE Spec J1703.
Parking brake cables Multipurpose grease
Door hinge pins, check straps, fuel door & hood hinges,
hood catch, seat adjusters NLGI No.2 Lithium Grease with 9% Zinc Oxide
Windshield Washer Washer fluid & water
Door and ignition key lock cylinders Powdered Graphite - Do Not Oil
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RECOMMENDED LIQUID GASKET
NOTE:
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacturer's instructions at all times.
3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
* RTV: Room Temperature Vulcanizer
RECOMMENDED THREAD LOCKING
AGENTS
Application Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
3. Tighten the bolts to the specified torque.
After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
Type Brand Name Manufacturer Remarks
RTV*
Silicon Base
Three Bond 1207B
Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
For Engine Repairs
For Axle Case
Repairs T/M
Repairs T/M
Water Base Three Bond 1141E Three Bond For Engine Repairs
Solvent
Three Bond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518
LOCTITE 17430
Loctite
Loctite
Loctite All
LOCTITE Type LOCTITE Color
LOCTIT E 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
MAINTENANCE SERVICE DATA
Service Data and Specifications
* Unless otherwise specified on Tyre information label on the vehicle.
Approximate C apacities
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
ENGINE Valve clearance (cold) Intake 0.28 ±0.05 mm
Exhaust 0.3 ±0.05 mm
Spark plug type K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap 1.05 mm
CLUTCH Clutch pedal free play 5-15 mm
BRAKE Brake pedal free play 8-11 mm
Parking brake travel 6-8 notches
WHEEL ALIGNMENT Toe-in (Front) 0 to +2 mm
Toe-in (Rear) 0 to +2 mm
Camber (Front) 0°±30'
Camber (Rear) 0°±1°
Caster (Front) 2° 30'±1°
Toe–Axis (Rear) ±1°
PROPELLER SHAFT Flange torque HEX BOLT 63 N·m
INNER HEX BOLT 43 N·m
WHEEL AND TyreS Size P235/75R15
Wheel nut torque 118 N·m
* Tyre inflation pressure (Front) 200 kpa
* Tyre inflation pressure (Rear) 200 kpa
Items Litres
Fuel tank 80
* Crankcase (V6–3.2L ENGINE) Oil Change with Filter 4.5
Oil Change without Filter 4.0
Coolant M/T (V6–3.2L ENG) 11.0
A/T 11.1
Transmiss io n Manu al (V6– 3.2L ENG) 2.95
Automatic 8.6
Transfer Normal Type 1.45
TOD 1.35
Axle Rear 1.77
Front 1.25
Shift on the fly system 0.12
Air conditioning (R-134a) 0.7