Free light vehicle / van 100,000 km service procedure

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Free light vehicle 100,000 km service checklist (PDF-ready). Engine, transmission, cooling, brakes, suspension, steering and electrical. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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Benefits of using this light vehicle / van 100,000 km service procedure

• Prevents major failures: replacing timing belts, flushing coolant and changing transmission fluid at 100,000 km prevents catastrophic engine, gearbox and cooling system failures.
• Extended vehicle life: a vehicle that receives a thorough 100,000 km service can reliably run to 200,000 km and beyond with continued maintenance.
• Lower long-term costs: replacing a timing belt at $800-$1,500 prevents an engine rebuild at $5,000+. Flushing brake fluid prevents calliper seizure.
• Driver safety: comprehensive brake, suspension and steering inspection identifies worn components before they become dangerous.
• Compliance: documented comprehensive service records demonstrate full duty-of-care for fleet vehicles under WHS and chain-of-responsibility legislation.
• Resale value: a vehicle with a documented 100,000 km service commands a significantly higher resale price than one without.

How to use this light vehicle / van 100,000 km service procedure

1. Park the vehicle on a level surface, apply the handbrake and turn off the engine. Allow the engine to cool before draining fluids.: Position the vehicle on a workshop hoist or flat concrete surface. Apply the handbrake and chock the wheels. Allow at least 15 minutes for fluids to cool and settle before draining engine oil, coolant or transmission fluid.
2. Record the vehicle details, registration and current odometer reading at the top of the service checklist.: Capture make, model, year, VIN, registration number, fleet ID and exact odometer reading. Note the previous service odometer and calculate the distance since last service to confirm the interval is correct.
3. Start with the engine section: drain engine oil, replace oil filter and air filter, fill with new oil, inspect or replace spark plugs (petrol), inspect the timing belt/chain, check exhaust manifold gaskets, clean fuel injectors and inspect engine mounts.: Drain the sump, replace the oil filter and air filter element, and refill with the manufacturer-specified oil grade. For petrol engines, remove and inspect spark plugs, replace if electrodes are worn or the gap is out of specification. Inspect the timing belt for cracking, fraying or glazing, and replace if at or near the manufacturer interval (typically 100,000 to 150,000 km). Clean fuel injectors using an ultrasonic cleaner or fuel system treatment. Inspect engine mounts for cracking or separation.
4. Drain and replace transmission fluid and differential oil. Inspect CV joints/boots or universal joints and check clutch operation.: Drain the automatic or manual transmission and refill with the manufacturer-specified fluid. Drain and refill the rear differential (and front differential if AWD). Inspect CV boots for splits and grease leakage, and check universal joints for play. For manual transmissions, check clutch pedal free play and engagement point.
5. Drain, flush and replace the coolant system. Pressure test the system and inspect the water pump and thermostat.: Drain the radiator and engine block. Flush the system with clean water or a coolant flush product to remove scale and sediment. Refill with the manufacturer-specified coolant mix, typically 50/50 antifreeze and demineralised water. Pressure test the system to the radiator cap rating and check for leaks. Inspect the water pump for weeping and bearing play, and check the thermostat opens at the correct temperature.
6. Measure brake pad thickness, flush and replace brake fluid, inspect callipers, measure rotor/drum thickness and runout, inspect lines and hoses, and check the handbrake.: Measure pad thickness with a calliper and compare to minimum specification. Bleed and flush the entire brake system with fresh DOT 3 or DOT 4 fluid. Inspect callipers for leaks and piston condition. Measure rotor thickness and runout with a dial indicator, compare to manufacturer minimum. Check the handbrake holds on a grade and adjust if necessary.
7. Perform a full suspension and steering inspection: shock absorbers, control arm bushes, ball joints, tie rod ends, steering rack, wheel bearings, and 4-wheel alignment.: Bounce each corner and assess shock absorber damping. Inspect control arm bushes for cracking and separation. Check ball joints and tie rod ends for play by levering with a pry bar. Inspect the steering rack for leaks and mounting security. Check wheel bearings for roughness and play. Perform or recommend a 4-wheel alignment if the vehicle shows uneven tyre wear or pulls.
8. Check tyre pressures, inspect tread depth and torque wheel nuts to specification.: Check all tyre pressures including the spare against the vehicle placard. Measure tread depth at three points across each tyre. Torque wheel nuts to the manufacturer specification using a calibrated torque wrench.
9. Full electrical check: battery load test, alternator output, starter motor, wiring harnesses, all lights and wipers.: Perform a battery load test, checking that voltage stays above 9.6 V under load. Measure alternator output, which should be 13.5 to 14.5 V at idle. Listen for starter motor noise or slow cranking. Inspect wiring harnesses for chafing, heat damage or rodent damage. Test all exterior and interior lights and wiper speeds.
10. Check all safety items, body inspections (door hinges, seat rails, windscreen seal), confirm all safety recalls are completed.: Check seatbelts, horn and windscreen condition. Inspect door hinges for wear, seat rail latches for secure locking and windscreen seal for leaks. Check the manufacturer recall database and confirm all outstanding safety recalls have been completed.
11. Replace cabin filter and test A/C operation.: Remove and replace the cabin or pollen filter. Run the A/C system and verify cold air output at the cabin vents. Check for unusual odours that may indicate mould growth in the evaporator.
12. Start the engine and check for leaks, abnormal noises or warning lights. Record any defects or recommendations in the notes section.: Start the engine and let it idle. Verify all warning lights clear. Inspect underneath the vehicle for any new fluid leaks. Listen for abnormal noises from the engine, exhaust or drivetrain. Record all findings and recommendations for corrective action.
13. Set the next service due kilometres (next minor and next major service). Sign off and update the vehicle's maintenance log.: Calculate the next 10,000 km minor service and the next major service due odometer readings. Update the windscreen sticker and fleet management system. Obtain technician and fleet manager signatures.

In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.

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