SECTION 0B - LUBRICATION AND SERVICING
Maintenance Schedule List
Maintenance Schedule
Extreme Operating Conditions
Recomm ended Fluids and Lubricants
Recomm ended Liq uid Gask et
Recomm ended Th read Loc king Ag ents
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 designe d:
1. to carry passengers and cargo wit hin the limitations specified on the tyre placard located on the inside of the glove
compartment doo r;
2. to be driven on reasonable road surfaces wit hin legal operating limit s;
3. to be driven on a daily basis, as a general rule, for at leas t several kilometers;
4. to be driven on unleaded fuel
Unusual or severe operating conditions wi ll require more frequent vehicle maintenance, as specified in the following
sections.
Techline
Techline
Techline
MAINTENANCE SCHEDULE
Use odome ter readings or years, whi c h 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 - 6VD1, C22NE #RRRRRRRRRRRRR
Engine oil filter - 6VD1 #RRRRRR
Engine oil filter - C22NE #RRRRRRRRRRRRR
Engine oil - 4JB1T, 4JH1-TC #RRRRRRRRRRRRR
Engine oil filter - 4JB1T, 4JH1-TC #RRRRRR
Oil l eakage & contamin ati on IIIIIIIIIIIII
Flui d level s: power steeri ng, brak e, clutch,
washer, battery IIIIIIIIIIIII
Coolant Level IIIIIIIIIIRI I
Radiator cap and cooling system pressure
test I I I I I I
Timing Belt - C22NE R
Timing belt - 6VD1 Replace every 160, 000 km or 8 years
All hoses and pipes in t he engine compart-
ment for leaks and deterioration IIIIIIIIIIIII
Clean front of ra diator core and A/C con-
denser I I I I I I
Fuel filter RRRRRR
Air cleaner element # IIIIRI IIRI IIR
Pre-air cleaner #IIIIIIIIIIIII
Accessory-drive belt condition IIIIIIIIIIIII
Valve clearances - 6VD1 A
Valve clearances - 4JB1T, 4JH1- TC AAAAAAA
Spark plugs - 6VD1 R
Spark plugs - C22NE R R R
Oxygen Sensors Replace ever y 150,000 km or 7. 5 years
I: Inspect and correct or replace as necessary
R: Replace or change
T: Tighten to specified torque
L: Lubricate
A: Adjust
# : Under extreme conditions, more frequent maintenance is required. Refer to ‘Extreme Operating Conditions” in this Section.
Power steering fluid IIIIRI IIRI IIR
Use odome ter readi ngs or years, whi c h ev er
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or year s .25 .5 11.522.533.544.555.56
UNDER VEHICLE
Clut ch fl uid I R R R
Brake fluid I R R R
Manua l transmission oil #I I R I R I R
Automati c transmission fluid #IIIIIII
Transfer case fluid/oil #I I I I R I I
Universal j oints and spli nes for wear #IIIIIII
Universal j oints and sliding sleeve #LLLLLLLLLLLLL
Diffe r en t ia l gea r oil - fron t #I I I I R I I
Differential gear oil - rear I I R I R I R
Disc brake p ads and disc / dr um wear I I I I I I
Wheel nuts TTTTTTTTTTTTT
Front wheel bearing and locking hubs -
grease #R R
Front and rear hubs bearing for looseness IIIIIII
Vehicle ride height AAAAAAAAAAAAA
Tyre pressure and wheels for damage I I I I I I I I I I I I I
Tyre rotation Rotate as necessary
Use odome ter readi ngs or years, whi c h ev er
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or year s .25 .5 11.522.533.544.555.56
UNDERBONNET
Techline
I: Inspect and correct or replace as necessary
R: Replace or change
T: Tighten to specified torque
L: Lubricate
A: Adjust
# : Under extreme conditions, more frequent maintenance is required. Refer to ‘Extreme Operating Conditions” in this Section.
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
Use odome ter readi ngs or years, whi c h ev er
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or year s .25 .5 11.522.533.544.555.56
INSIDE VEHICLE
Clutch pedal and fr ee trave l IIIIIIIIIIIII
Steering wheel play IIIIIIIIIIIII
Brake pedal and f ree travel IIIIIIIIIIIII
Park brake lever t ravel IIIIIII
Park brake ratchet for wear or dam age 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 star t swi tch.
IIIIIIIIIIIII
Use odome ter readi ngs or years, whi c h ev er
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or year s .25 .5 11.522.533.544.555.56
Use odome ter readi ngs or years, whi c h ev er
occurs first.
x1000km 51020 30 40 50 60 70 80 90 100 110 120
or year s .25 .5 11.522.533.544.555.56
UNDER VEHICLE
SERVICE TI MES
Hours -1.91.7 1.0 2.2 1.0 1.7 1.9 2.2 1.0 3.3 1.0 2.2
- add for 4wd 0.4 0.4 0.2
- add for C22NE 0.5 0.7 0.5 0.7 0.7
- add for 4JB1T, 4JH1TC 0.5 0.7 0.5 0.5 0.7 0.4 0.7
- add for 6VD1 3.4
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 un der any of these conditions on a one-off basis, e.g. a holiday trip, then the extra service
should only be applied for that period of time.
As a guide, if operating under any of these extreme conditions for a period of one month or 1500k m, then the vehicle
would qualify for additional services.
A: Repeated short trips
B: Driving on rough roads
C: Driving on dust y roads
D: Driving in extremely cold weather and/or on salted roads.
Change engine oil every 5000km ACD
Change oil filter every 5000k m (exc. 6VD1) ACD
Change oil filter every 10000km - 6VD1 ACD
Change air cleaner element every 5000km C
Inspect air cleaner element every 2500km (Diesel) CD
Inspect pre-cleaner weekly C
Inspect steering system f or looseness and damage every 5000km B C
Inspect universal joints and sleeve for wear every 5000km B C
Change manua l transm ission and transfer case oil every 5000km B C
Change auto trans fluid and strainer every 40000 ABCD
Replace front wheel bearing and locking hub grease every 10000km B C
Change diff erential oil ev ery 20000km B C
Inspect brake pads and linings every 10000km ABC
RECOMMENDED FLUIDS AND LUBRICANTS
B00RW003
USAGE FLUID/LUBRICANT
Engine Oil - C22NE, 6VD1
Normal use
Prolonge d use in snow areas API SG or SH Engine oil with a viscosity of 20W/50
API SG or SH Engine oil with a viscosity of 15W/40
Engine Oil - 4JB1T, 4JH1-TC API Minimum CG-4 rating (ACEA B1 or B3), with a
viscocity of 10W/30 or 15W/ 40
Engine Coolant 50% water and 50% coolant conforming to Holden
Sp ecific ati on HN2217 .
Brake System Heavy Duty Brake Fluid DOT-3, SAE Spe c J1703.
Power S teering System DEXRON® -III Automatic trans mission fluid.
Automatic Transmission DEXRON® -III Automatic transmission fluid.
MUA5C Type Manual Transmission - (6VD1, 4JB1T,
4JH1-TC) Same oil as engine or 5W/30 synthetic engine oil or gear
oil 75W/85
MUA5 S Type Ma nual Transmission (C22NE) Same oil as engine or 5W/30 synthetic engine oil
T ransfer case Same oil as engine or 5W/30 synthetic engine oil or gear
oil 75W/85
Front Axle API-GL5 85W/140 Gear Oil
Shift On the Fly (SO F) System API-GL5 85W/140 Gear Oil
Rear Axle - Standard Differential
Rear Axle - Limited Slip Differential API-GL5 85W/140 Gear Oil
API-GL5 85W/140 LSD Gear Oil + one bottle additive
pa rt number 1052358
Clutch System
Pivot points & Clutc h fork joint NLGI No.2 Lithium Grease wit h 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 Washe r fluid & water
Door and ignition key lock cylinders Powdered Graphite - Do Not Oil
Techline
Techline
Techline
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.
3. Follow the manufacturer's ins tructions at all times.
4. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
5. The connecti ng surfaces must be perfectly dry.
6. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 bet ween two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhes ion will r e s ult .
* RTV: Room Temperature Vulcanizer
RECOMMENDED THREAD LOCKING
AGENTS
Ap pl icatio n Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
2. The surfaces must be perfectly dry.
3. A pply LOCT ITE to the bolts.
4. Tighten the bolts to t he specified torque.
5. After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
Type B rand Nam e Manufacturer Remark s
RTV*
Silicon Base Three B ond 1207B
Three B ond 1207C
Three B ond 1215
Three B ond 1280
Three B ond 1281
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
For Engine Repairs
For A x le Case
Repairs T/M
Repairs T/M
Water Base Three B ond 1141E Three Bond For Engine Repairs
Solvent Three B ond 1104
Belc o Bond 4
Belc o Bond 401
Belc o Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobi c LOCTI TE 515
LOCTITE 518
LOCTITE 17430
Loctite
Loctite
Loctite
All
LOCTITE Type LOC TITE Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
MAINTENANCE SERVICE DATA
.
APPROXIMATE CAPACITIES (LITRES) C22NE 6VD1 4JB1T 4JH1-TC
Engine Oil Capacity - w/filter 4.5 5.3 6.5 6.5 (4x2)
7.3(4x4)
Coolant capacity 6.9 11.2 (Man.)
11.0 (Auto) 9.5 9.9
Manual Transmission 2.95 2.95 2.95 2.95
Automatic Transmission —8.6 —8.7
Transfer Case —1.45 1.45 1.45
Manual Steering 0.4 —0.4 —
Power S teeri ng —1.0 1.0 1.0
Front Axle —1.4 1.4 1.4
Rear Axle 1.8 1.8 1.8 1.8
Shift On the Fly System —0.12 0.12 0.12
Air con ditioning syst e m 150cc Zexel -1 00PG oil
Service Data and Specifications C22NE 6VD1 4JB1T 4JH1-TC
Valve Clearance - Inlet (mm)
Valve Clearance - Exhaust (mm) —
—0.28 ± 0.05
0.30 ± 0.05 0.40
0.40 0.40
0.40
Spark Plug Gap (mm) 1.0- 1.1 1.0 - 1.1 — —
Clutch Pedal Free-play 5 - 15mm
Brake Pedal Free-play 6 - 10mm
Park Brake Lever Free-travel 7 - 10 notches
Toe-in 2.0 ± 2.0m m
Caster 30’ ± 60’
Camber 1° 50’ ± 45’(2WD)
2° 10’ ± 45’(4WD)
T ri m Height 56mm (2WD exc. 6VD 1)
130mm (4WD inc. all 6VD1)
Wheel nut torque 118 Nm
Tyre Pressure Refer Tyre Placard