SECTION 0B - LUBRICATION AND SERVICING

Maintenance Schedule List

Maintenance Schedule

Extrem e Op erati ng Cond iti ons

Reco mm ende d Fluids and Lubrica nts

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 kilometers;

• to be driven on the correct fuel as specified for the engine type.

Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following

sections.

Techline

Maintenance Schedule

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 - All # RRRRRRRRRRRR

Engine oil filter - All #RRRRRR

Oil leaka ge & cont a mi nati on IIIIIIIIIIIII

Fluid levels: power steering, brake, clutch,

washer, battery IIIIIIIIIIIII

Coolant Level 50% concentration IIIIIIIIIIRI I

Radiator cap and cooling system pressure

test IIIIII

Idle Speed and Acceleration IIIIIIIIIIIII

Timing Belt - C24SE R

Timing belt - 6VE1 Repla ce ev ery 160 ,00 0 km

All hoses and pipes in the engine compart-

ment for leaks and deterioration IIIIIIIIIIIII

Clean front of radiator core and A/C con-

denser IIIIII

Fuel filter - All ** RRRRRR

Air cleaner elem en t # IIIIRI IIRI IIR

Pre-air cleaner #IIIIIIIIIIIII

Access ory -driv e bel t cond itio n IIIIIIIIIIIII

Val v e clearances - 6VE1 Check and adjust if necessary every 100,000kms

Val v e clearances - 4JH1-TC AAAAAAA

Spark plugs - 6VE1 Replace every 100,000kms

Spark plugs - C24SE R R R

Oxygen Sensor- 6 VE1 Replace every 160,000kms

Pow er steering f luid IIIIRI IIRI IIR

Techline

I: Insp ect 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.

Use odometer readings or years, which ever

occurs firs t.

x1000km

** - Pre-wet diesel fuel filter before fitment - fill with clean fuel and soak for 10 minutes before fitting to vehicle.

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 IIIIRI IIRI IIR

Brake fluid IIIIRI IIRI IIR

Manual tran sm is sion oil #IIIIRI IIRI IIR

Automatic transmission fluid #IIIIIIIIIIIII

Transfer case fluid/oil #IIIIIIIIIIIII

Universal joints and splines for wear #IIIIIII

Universal joints and sliding sleeve #LLLLLLLLLLLLL

Dif fere nti al gea r oil #IIIIRI IIRI IIR

Exhau st sy ste m IIIIIIIIIIIII

Disc brake pads and disc / drum wear IIIIIIIIIIII

Wheel nuts TTTTTTTTTTTTT

Front hub bearing grease R R R R

Rear hub bearing grease Replace every 240,000kms or 5 years

Front and rear hubs bearing for looseness IIIIIIIIIIIII

Front axle shaft rubber boots for damage IIIIII

Axle housings - visual inspection for distor-

tion or damage IIIIII

Vehicle ride height AAAAAAAAAAAAA

Tyre pressure and whee ls for dam age IIIIIIIIIIIII

Tyre rotation Rotate a s necessar y

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.

IIIIII

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 IIIIII

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

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

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 holiday 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 treme co nditi ons for a pe riod of one m ont h or 1500km , then the vehic le

would qualify for additional services.

A: Repeated short trips

B: Driving on rough roads

C: Driving on dusty roads

D: Driving in extremely cold weather and/or on salted roads.

E: Caravan or trailer towing .

Change engine oil every 5000km ACDE

Change oil filter every 5000km (exc. 6VE1) ACD

Change oil filter every 10000km - 6VE1 ACD

Change air cleaner element every 5000km C

Inspect steering system for looseness and damage every 5000km B C

Inspect universal joints and sleeve for wear every 5000km B C

Change manual transmission and transfer case oil every 5000km B C E

Change auto trans fluid and strainer every 40000 ABCDE

Inspect exhaust system every 5000 AB D

Change dif ferential oil every 20000km B C E

Inspect brake pads and linings every 5000km ABC E

Recommended Fluids and Lubricants

B00RW003

USAGE FLUID/LUBRICANT

Engine Coolant 50% water and 50% coolant conforming to Holden

Specification HN2217.

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.

Transfer Case SAE 15W-40 Engine Oil

Clutch System

• Pivot points & Clutch fork joint

• Master cylinder

NLGI No.2 Lithium Grease with 10% Molybdenum

Disulphide

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 cylinde rs Powdered Graphite – Do Not Oil

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.

Follow the manufacturer's instructions at all times.

3. Be absolutely sure to remove all lubricants and

moistu re from the co nnec ting sur fa ce s 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

adhe sion wil l resul t.

* RTV: Room Temperature Vulcanizer

Type Brand Name Manufacturer Remarks

RTV*

Sili con Base

Three Bond 1207B

Three Bond 1207C

Three Bond 1215

Three Bond 1280

Three Bond 1281

Three Bond

For Engine Repairs

For Axle Case

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

For Engine Repairs

Anaerobic LOCTITE 515

LOCTITE 518

LOCTITE 17430

Loctite

Loctite All

Recommended Thread Locking Agents

Application Steps

1. Completely remove all lubricant and moisture

fromthe 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.

1. 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.

LOCTITE Type LOCTITE Color

LOCTITE 242 Blue

LOCTITE 262 Red

LOCTITE 271 Red

Maintenance Service Data

APPROXIMATE CAPACITIES (LITRES) C24SE 6VE1 4JH1-TC

Engine Oil Capacity - w/filter 4.5 5.3 6.5 (4x2)

7.3(4x4)

Coolant capacity 6.9 11.2 (Man.)

11.0 (Auto) 9.9

Manual Transmission 2.95 2.95 2.95

Automatic Transmission —8.6 8.7

Transfer Case —1.45 1.45

Manual Steering 0.4 — —

Power Steering —1.0 1.0

Front Axle —1.4 1.4

Rear Axle 1.8 1.8 1.8

Shift On the Fly System —0.12 0.12

Air conditioning system 180cc DH-PRN7 PAG oil

Service Da ta and Specific at ions

C24SE 6VE1 4JH1-TC

Valve Clearance - Inlet (mm)

Valve Clearance - Exhaust (mm) —

—0.28 ± 0.05

0.30 ± 0.05 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 0 ± 2.0mm

Caster 3°35’ ± 45’ 3°10’

Camber 0° ± 30’

Trim Height 105mm 140mm

Wheel nut torque 118 Nm

Tyre Pressure Refer Tyre Placard