Major / comprehensive service - light vehicle, van, ute (petrol and diesel)
Estimated duration: 3 - 5 hours • Frequency: every 100,000 km (or per manufacturer schedule)
Vehicle Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine | ||||
| 1 | Drain and replace engine oil (5W-30 or manufacturer spec) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Replace air filter element | REPLACE | ☐ | |
| 4 | Check coolant level and condition | CHECK | ☐ | |
| 5 | Inspect drive belts for wear and cracking | INSPECT | ☐ | |
| 6 | Inspect radiator hoses for leaks, swelling or damage | INSPECT | ☐ | |
| 7 | Inspect/replace spark plugs (petrol, typically every 60-100k km) | REPLACE | ☐ | |
| 8 | Inspect timing belt/chain (replace if due per manufacturer, typically 100-150k km) | INSPECT | ☐ | |
| 9 | Inspect exhaust manifold gaskets | INSPECT | ☐ | |
| 10 | Clean fuel injectors or send for service | CLEAN | ☐ | |
| 11 | Inspect engine mounts for wear or cracking | INSPECT | ☐ | |
| Transmission | ||||
| 12 | Drain and replace transmission fluid (ATF or manual gearbox oil) | DRAIN/FILL | ☐ | |
| 13 | Drain and replace differential oil (if applicable) | DRAIN/FILL | ☐ | |
| 14 | Inspect CV joints/boots (FWD) or universal joints (RWD/4WD) | INSPECT | ☐ | |
| 15 | Inspect clutch operation (manual transmission) | INSPECT | ☐ | |
| Cooling | ||||
| 16 | Drain, flush and replace coolant (full system) | FLUSH/FILL | ☐ | |
| 17 | Pressure test cooling system | CHECK | ☐ | |
| 18 | Inspect water pump for leaks or play | INSPECT | ☐ | |
| 19 | Inspect thermostat operation | INSPECT | ☐ | |
| Brakes | ||||
| 20 | Measure front brake pad thickness (mm) | INSPECT | ☐ | |
| 21 | Measure rear brake pad/shoe thickness (mm) | INSPECT | ☐ | |
| 22 | Flush and replace brake fluid (DOT 3/4) | FLUSH/FILL | ☐ | |
| 23 | Inspect brake lines and hoses for leaks or damage | INSPECT | ☐ | |
| 24 | Inspect brake callipers for leaks or binding | INSPECT | ☐ | |
| 25 | Inspect brake rotors/drums (measure thickness and runout) | INSPECT | ☐ | |
| 26 | Inspect handbrake cable and adjustment | INSPECT | ☐ | |
| Suspension and Steering | ||||
| 27 | Inspect shock absorbers for leaks | INSPECT | ☐ | |
| 28 | Inspect control arm bushes | INSPECT | ☐ | |
| 29 | Inspect ball joints | INSPECT | ☐ | |
| 30 | Inspect tie rod ends and rack boots | INSPECT | ☐ | |
| 31 | Inspect steering rack for play or leaks | INSPECT | ☐ | |
| 32 | Inspect wheel bearings (noise and play) | INSPECT | ☐ | |
| 33 | 4-wheel alignment check | CHECK | ☐ | |
| Tyres and Wheels | ||||
| 34 | Check tyre pressures (all 4 + spare) | CHECK | ☐ | |
| 35 | Inspect tread depth (mm) and sidewall condition | INSPECT | ☐ | |
| 36 | Torque wheel nuts to manufacturer specification | ADJUST | ☐ | |
| Electrical | ||||
| 37 | Full battery load test | CHECK | ☐ | |
| 38 | Inspect alternator output | INSPECT | ☐ | |
| 39 | Inspect starter motor operation | INSPECT | ☐ | |
| 40 | Inspect all wiring harnesses for damage | INSPECT | ☐ | |
| 41 | Check all exterior lights (head, tail, indicators, reverse, brake, fog) | CHECK | ☐ | |
| 42 | Test wiper blades and washer fluid operation | CHECK | ☐ | |
| Fluids | ||||
| 43 | Top up windscreen washer fluid | DRAIN/FILL | ☐ | |
| 44 | Check power steering fluid level (if hydraulic) | CHECK | ☐ | |
| Safety | ||||
| 45 | Check seatbelts - all positions | CHECK | ☐ | |
| 46 | Check horn operation | CHECK | ☐ | |
| 47 | Inspect windscreen for chips or cracks | INSPECT | ☐ | |
| 48 | Check registration and roadworthy sticker dates | CHECK | ☐ | |
| Body and Safety | ||||
| 49 | Inspect door hinges and locks | INSPECT | ☐ | |
| 50 | Inspect seat rails and adjustment | INSPECT | ☐ | |
| 51 | Inspect windscreen seal | INSPECT | ☐ | |
| 52 | Check all safety recalls completed | CHECK | ☐ | |
| Cabin | ||||
| 53 | Replace cabin/pollen air filter | REPLACE | ☐ | |
| 54 | Check air conditioning operation and vent temperature | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 5W-30 | 4 - 6 L |
| Transmission fluid | ATF or MTF | 3 - 8 L |
| Differential oil | 75W-90 | 1 - 2 L per diff |
| Coolant | 50/50 ethylene glycol | 6 - 10 L (full system) |
| Brake fluid | DOT 3 / DOT 4 | 0.5 - 1 L |
| Power steering | ATF (if hydraulic) | As required |
Specifications are general guidelines for typical light vehicles, vans and utes. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by engine and drivetrain.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (5W-30) | 4-6 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Air filter element | 1 | ☐ | |
| 4 | Cabin/pollen filter | 1 | ☐ | |
| 5 | Spark plugs (petrol only) | 4-6 | ☐ | |
| 6 | Transmission fluid (ATF or MTF) | 3-8 L | ☐ | |
| 7 | Differential oil (75W-90) | 1-2 L | ☐ | |
| 8 | Coolant (pre-mixed or concentrate) | 6-10 L | ☐ | |
| 9 | Brake fluid (DOT 3/4) | 0.5-1 L | ☐ | |
| 10 | Timing belt + tensioner (if due - major cost item) | 1 kit | ☐ | |
| 11 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager