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.
Commercial Director
Updated 3 May 2026
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What is a light vehicle / van 100,000 km service procedure?
A 100,000 km service is the highest tier of scheduled preventive maintenance for a light vehicle, van or ute. It is a comprehensive (major) service that includes all tasks from the minor (10,000 km) service plus extensive additional inspections and replacements. The procedure covers engine oil and filter replacement, air filter and spark plug replacement (petrol), timing belt/chain inspection, fuel injector cleaning, transmission and differential fluid change, full coolant system flush, brake fluid flush, complete suspension and steering inspection (including shock absorbers, ball joints, tie rod ends, wheel bearings and alignment), full electrical system testing, and body and safety checks. It is typically performed by a qualified mechanic and takes 3 to 5 hours depending on the vehicle and whether timing belt replacement is required.
This service includes all minor (10,000 km) service tasks plus comprehensive inspection and replacement items.
The 100,000-kilometre milestone represents a critical decision point in a fleet vehicle's lifecycle. At this interval, major components such as timing belts, transmission fluid, coolant, spark plugs and suspension bushes are due for replacement, and the cost of the service must be weighed against the vehicle's remaining useful life and resale value. In Australia, fleet managers must consider WHS obligations, roadworthiness requirements and manufacturer service schedules when deciding whether to invest in a major service or dispose of the vehicle.
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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.
Benefits of digitising forms in MapTrack
When you digitise light vehicle service procedures in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
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- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Trigger work orders automatically when a fault is logged during an inspection.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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What to include in a light vehicle / van 100,000 km service procedure
This light vehicle / van 100,000 km service procedure covers 11 key areas:
- Engine: drain and replace engine oil, replace oil filter, replace air filter, inspect/replace spark plugs (petrol), inspect timing belt/chain, inspect exhaust manifold gaskets, clean fuel injectors, inspect engine mounts.
- Transmission: drain and replace transmission fluid, drain and replace differential oil, inspect CV joints/boots or universal joints, inspect clutch operation.
- Cooling: drain, flush and replace coolant, pressure test cooling system, inspect water pump, inspect thermostat.
- Brakes: measure pad thickness, flush and replace brake fluid, inspect lines and hoses, inspect callipers, measure rotor/drum thickness and runout, inspect handbrake.
- Suspension and steering: inspect shock absorbers, control arm bushes, ball joints, tie rod ends, steering rack, wheel bearings, 4-wheel alignment.
- Tyres and wheels: check pressures, inspect tread depth, torque wheel nuts.
- Electrical: full battery load test, inspect alternator, starter motor, wiring harnesses, check all lights, test wipers.
- Fluids: top up windscreen washer fluid, check power steering fluid.
- Safety: check seatbelts, horn, windscreen, registration dates.
- Body and safety: inspect door hinges and locks, seat rails, windscreen seal, check safety recalls.
- Cabin: replace cabin filter, check A/C operation.
How to use this light vehicle / van 100,000 km service procedure
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
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Get the free templateEnter your email above to download the full light vehicle / van 100,000 km service procedure as a PDF.Back to download formHow often should you complete this service procedure?
The 100,000 km major service is a milestone service typically performed once in the vehicle life cycle, with subsequent major services at 200,000 km and 300,000 km. Between major services, minor (10,000 km) services maintain the vehicle on an ongoing basis. The manufacturer service schedule is the primary reference for exact intervals, fluid types and component replacement timing. Vehicles in harsh operating conditions, such as dusty rural roads, frequent towing or heavy stop-start driving, may need some major service items performed earlier. Always cross-reference with the vehicle handbook.
After the 100,000 km service, subsequent services revert to the standard 10,000 km interval, but additional major items will come due again at the manufacturer-specified repeat interval. For fleet vehicles approaching 100,000 km, schedule a pre-service assessment. In MapTrack, lifecycle alerts can be configured to prompt a fleet review when vehicles reach 90,000 km.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 3706 Condition monitoring of fleet vehicles
- NHVR chain-of-responsibility (CoR) principles
- WHS Regulations (duty of care for fleet vehicles)
- Manufacturer service schedule and warranty requirements
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#0E7490;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Light vehicle / van 100,000 km service procedure</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Engine: drain and replace engine oil, replace oil filter, replace air filter, inspect/replace spark plugs (petrol), inspect timing belt/chain, inspect exhaust manifold gaskets, clean fuel injectors, inspect engine mounts.</li>
<li style="margin:4px 0;">Transmission: drain and replace transmission fluid, drain and replace differential oil, inspect CV joints/boots or universal joints, inspect clutch operation.</li>
<li style="margin:4px 0;">Cooling: drain, flush and replace coolant, pressure test cooling system, inspect water pump, inspect thermostat.</li>
<li style="margin:4px 0;">Brakes: measure pad thickness, flush and replace brake fluid, inspect lines and hoses, inspect callipers, measure rotor/drum thickness and runout, inspect handbrake.</li>
<li style="margin:4px 0;">Suspension and steering: inspect shock absorbers, control arm bushes, ball joints, tie rod ends, steering rack, wheel bearings, 4-wheel alignment.</li>
<li style="margin:4px 0;">Tyres and wheels: check pressures, inspect tread depth, torque wheel nuts.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/light-vehicle-100000-km-service" style="color:#071D49;font-weight:600;text-decoration:none;">Light vehicle / van 100,000 km service procedure</a> by MapTrack</p>
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