. 5
l)
Every
40 000
kilometres
{24 000
miles)
or
2
years whichever
is
the
earlier
1.
Air
conditioning system: Check the
refrigeration system for correct operation,
rectify
as necessary. Any work must
be
carried out by
an
experienced engineer.
2.
Air
injection
pump: Check tension
of
pump
pulley
driving
belt
•
3.
Air
injection
system: Check the
air
injection
system for leaks and correct functioning. Renew
any
defective
items.
4.
Air
silencer:
Fit
a new paper
filter
element.
5.
Automatic choke: Check the
flow
through the
choke stove pipe
and
check the system for correct
functioning.
6.
Carburetters: Clean
air
valves. Remove
inlet
unions from the
float
chamber covers
and
fit
new
paper
filter
elements. Top-up
oil
level in
air
valve
dampers. Check tightness of
float
chamber covers.
Check
float
chamber depression. Check and
if
necessary reset the
idle
speed. Check and
if
necessary reset the choke
'fasHdle'
speed.
7.
Carburetter mixture weakening device: Renew
air
filter
element for the carburetter mixture
weakening
device.
8.
Crankcase emission control system: Remove
and
clean the gauze flame traps in the crankcase
breather tube. Clean the adapter in the choke
butterfly
housing.
9. Engine: Change the engine oi I
and
fit a new
oil
filter
element.
10. Engine
cooling
system:
Fit
a new engine
coolant thermostat and heater tap feed hose.
Examine the condition
of
al I coolant hoses.
Fit
new hoses if necessary.
11.
Exhaust system: Check grass~fire heat-
shields
for damage.
Rectify
or renew
shields
to
ensure that a minimum clearance of 5
mm
(0.2
in.)
is
maintained between the heatshields and
the
exhaust
pipes.:
12. Fuel evaporation emission control system:
Fit
a new foam
filter
element in the evaporation
loss control
canister.
Check the purge rate;
this
should
be
between
1.41
cu.m. per hour
and
1,~8 cu.m. per hour {50
cu.ft.
per hour
and
70
cu.ft.
per hour} at 600 r.p.m. in neutral. Renew
the purge I
ine
f ii
ter
if
necessary.
13.
Ignition
system:
Fit
new sparking plugs
ensuring
that
the gaps are set
to
0,9
mm
(0.035 in.).
Lubricate
distributor
spindle (shaft bearings)
and
automatic advance mechanism
with
engine
oil.
Check
ignition
timing
with
stroboscope and
adjust
if
necessary. The
ignition
timing should
be
15°B.T.O.C.
with
the engine running at 1 600 r.p.m.,
the vacuum capsule disconnected
and the feed hose
blanked
off.
Check the vacuum advance mechanism.
14.
Battery:
Check the
level
of
the electro·lyte in
the battery;
if
necessary top-up
with
distilled
water.
15.
Belt
tension:
Check the tension
of
all
driving
belts.
16. Brakes: Inspect footbrake and handbrake
or
parking brake
pad
linings;
fit new pads
if
necessary.
When
renewing footbrake pads, examine
condition
of
dust excluders
on
calip~rs
and
renew:if necessary.
Manually adjust the handbrake or parking brake
caliper
mechanism.
Inspect
all
pipes
and
connections,
rectify
if
necessary.
17.
Final
drive
unit:
Change
oil.
18.
Fluid
levels:
Check
all
fluid
levels.
19. Front suspension:
The
front suspension bal I
joints
are sealed for
life
and no maintenance
is
required unti I renewal
is
necessary
or
the
ball
joint
rubber covers are damaged. Inspect the rubber
covers on the front suspension
ball
joints;
if
the
covers are damaged,
fit
new
joints
and covers.
20. Fuel pumps: Remove the
fuel
pumps and check
for pumping
efficiency.
Fit
new pumps
if
necessary.
21.
Hydraulic
systems: Completely drain the
fluid
from the
hydraulic
circuits.
Thoroughly clean
the brake
fluid
reservoirs
and
sight
glasses.
Ensure no foreign matter enters the systems.
Fi
11
the
hydraulic
systems
with
new approved
fluid.
Bleed the brakes and height control systems.
22. Rear wheel drive-shafts:
Lubricate
the outer
universal
joints
with
approved grease.
23. Steering bal I
joints:
Lubricate
the
six
grease
nipples.
Inspect the rubber covers
on
the
ball
joints;
if
the covers are found
to
be
damaged the
joints
should be dismantled and new parts
fitted
as
necessary. .
24. Torque converter transmission: Renew
transmission
fluid.
Fit
a new intake strainer.
When
checking
fluid
level,
avoid contact with the exhaust
gas recirculation
valve,
heatshield and associated
pipes as these components wi
11
be hot.
Servicing after 40
000
kilometres
{24
000 miles)
or
2 years whichever
is
the
earlier
After
40
ooo
kilometres (24 000 miles)
or
2 years,
servicing
is
sti
II
due
at
the fol I owing
intervals.
50
000 kilometres (30 000 miles)
or
2
1
h years
whichever
is the earlier
Carry out the 10 000
km
(6 000 miles)
service.
60 000 kilometres (36 000 mites) or 3 years
whichever is the
Hrlier
Carry out the
20
000
km
(12 000 miles)
service.
70 000 kilom""9S (42 000 miles) or
31/i
years
whichever
is
the
earlier
Carry out the 10 000
km
{6 000 miles)
service.
80 000 kilometres (48 000 miles) or 4 years
whichever
is the earlier
Carry out the 40 000
km
(24 000 mi I es) service and
in addition, the fo
11
owing operati ens.
1. Exhaust gas
recirculation
system: Remove and
clean the exhaust gas
recirculation
valve
and
feed
pipes. Clean the
orifices
in the carburetter
'Tee'
piece. Check the exhaust gas
recirculation
valve
for correct operation.
2.
Exhaust system:
Fit
a new
catalytic
converter
assembly. Inspect the condition
of
the
catalytic
converter thermocouple and
wiring;
renew
if
there
is
visual
evidence
of
damage.
E9 - 3
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