1. Drain and replace engine oil every 2,500 miles. Replace
oil filter and seals every 2nd oil change. Before
starting engine after an oil change, turn engine without
ignition until oil pressure is indicated on gauge. Then
start engine. This procedure should also always be
followed if the vehicle has been left to stand for more
than 3 weeks.
If the vehicle is used predominantly off-road, oil
change intervals should be based on the amount of fuel
used since the last oil change (265 US gallons).
2. Check and adjust engine valve clearances between camshaft
and rocker arms with feeler gauges every 5,000 miles:
Engine cold: Inlet: 0,10mm Exhaust: 0,20mm
0.004" 0.008"
Engine warm: Inlet: 0,15mm Exhaust: 0,25mm
0.006" 0.010"
If the clearance is not correct, it must be adjusted by
turning the ball pin head adjuster either in or out as
required. This procedure is facilitated by use of
adjustment tool (111 589 00 01 00). Should the adjuster
be loose on its base (<14.5 ft.lb) - either the ball pin
head or its base or both should be replaced to prevent
rotation and changes to the valve clearances whilst the
engine is running.
If the adjuster screw bottoms out in the base before the
minimum clearance is achieved, the plate in the top of
the valve spring keeper can be replaced with a thinner
one.
3. Clean out fuel filter every 2,500 miles.
4. Clean mesh filter in fuel pump every 5,000 miles.
5. Drain and replace oil in air compressor (if fitted) every
2,500 miles.
6. Check and tighten all manifold and exhaust fittings every
5,000 miles.
7. Replace oil and clean air filter every 2,500 miles.
Weekly if operating in very dusty conditions.
8. Remove and check spark plugs every 2,500 miles. If to be
reused, clean and reset gap to 0,50mm (0.020"). Replace
plugs every 10,000 miles.
9. Check mobility of butterfly valve in exhaust manifold
every 2,500 miles. (DO NOT LUBRICATE!). If necessary
replace bimetallic spring.
10. Check and adjust tightness of all V-belts every 2,500
miles.
11. Check oil levels (EP90) in water pump and fan hub every
5,000 miles. Top-up if necessary. If water is present
in the water pump oil, the seal in the housing will need
to be replaced. Do not block the drain hole of a leaking
pump as this will cause water to accumulate and damage
the bearings in the pump.
12. Check distributor components and breaker gap every 5,000
miles. Inspect distributor cap for cracks and wear.
Check points are not burnt and that gap is 0,40mm
(0.016"). Engine can be rotated by jacking up one rear
wheel with 6th gear engaged and turning wheel forwards to
allow adjustment of gap. The setting should be checked
using electronic equipment to achieve a dwell angle of
36-38. If the vehicle is fitted with braided ignition
wires, it will be necessary to improvise connections to
allow hooking up to electronic test equipment.
Moisten felt in distributor shaft with a few drops of oil
and lightly grease rubbing block and cam. Ensure no oil
or grease on points.
Pack connections of ignition leads to distributor with
silicone grease.
13. Check tightness of screws on fuel lift pump every 10,000
miles.
14. Lubricate choke cable every 10,000 miles with a few drops
of oil.
15. Remove and clean out carburetor every 10,000 miles.
Before loosening from manifold, remove the fragile
mixture control screws from the base. A gasket set will
be required to rebuild the carburetor.
16. Check brake fluid level and brake drum adjustments (cold)
every 2,500 miles. Check hoses and brake lines for
damage and corrosion. Avoid contaminating hoses with
solvents. Check brake pedal has 10mm (0.4") free-play.
Adjust handbrake settings (through hole in rear brake
plate and not the cable) only after brake shoes have been
correctly adjusted.
17. Check tightness of all chassis frame nuts and bolts
including engine/gearbox mountings, suspension components
and axles every 2,500 miles.
18. Check clutch pedal free-play with engine running every
2,500 miles. The clutch pedal must have at least 35mm
(1.4") travel before the release bearing makes contact
with the clutch pressure plate. To adjust, stop engine
and adjust the length of the threaded push-rod as
required. Recheck free-play with engine running until
required travel is achieved.
19. Check operation of differential lock linkage every 2,500
miles.
20. Check gearbox oil level every 2,500 miles. Drain and
replace oil every 10,000 miles (EP80/90). Note that
there are 2 drain plugs.
21. Check axle and hub reduction oil levels in both axles
every 2,500 miles. Drain and replace oil every 10,000
miles (EP80/90). Note that there are 3 drain plugs per
axle.
22. Apply grease gun every 2,500 miles to:
Transmission output ball housings (2)
Swivel (king) pins on front axle (4)
Universal joints of front axle drive shafts (4)
Steering ball joints (6)
Handbrake and control lever shafts
Clutch release shaft on bell housing (1)
PTO shaft joints (if fitted)
23. Rotate wheel and tire assemblies every 2,500 miles.
Check toe-in: +3-1 mm. Try for 0 with vehicle unladen.
24. Lightly spray underside of vehicle with oil to protect
against corrosion every 2,500 miles, shielding all rubber
components.
25. Check oil level in steering box every 5,000 miles.
26. Check oil level in PTO relay housing (if fitted) every
5,000 miles.
27. Check air brake equipment (if fitted) for correct
function and leaks every 5,000 miles.
28. Check drop arm for tightness on steering box every 5,000
miles.
29. Check suspension and steering dampers for leaks and
damage every 5,000 miles.
30. Remove and clean brake drums (use 2 M10 bolts to pull off
drums after shoes have been slackened), check and clean
brake linings (do not use solvents) every 5,000 miles.
Replace linings if worn down to the rivets.
31. Check battery acid level and density every 2,500 miles.
Clean and grease terminals.
32. Check all electrical equipment for correct operation and
headlamp adjustment every 5,000 miles.
33. Check all electrical cables and connections for damage,
tightness and corrosion every 10,000 miles. Check
alternator mountings.
34. Lubricate all hinges on body and towing hitch every 5,000
miles.
35. Check all cab and body mountings for tightness every
10,000 miles.
If you find that a part number has been changed, please send me mail so I can update this list.
Head gasket set 180 586 44 90 Head gasket 180 016 35 20 Piston ring set STD 002 586 22 03 Carburetor O/H kit 180 586 01 90 Fuel lift pump kit 180 586 02 90 DC Generator brush 000 154 26 14 600W/24V Starter drive gear 000 151 16 13 Ignition components for short-distance radio shielded, splashproof ignition system: Distributor service kit 180 586 03 90 Cap 000 158 25 02 Bosch 1.235.522.267 Rotor 000 158 20 31 Bosch 1.234.332.088 Points 000 158 08 90 Bosch 1.237.013.010 Spark plug 000 159 84 03 Oil filter 000 180 00 09 Fan belt 9.5 x 875mm 007753 009505 Fan belt 9.5 x 925mm 007753 009507 Fan belt 9.5 x 900mm 007753 009506 Hot climate (2x) Hub oil seal 404 337 02 60 Wheel stud 404 401 00 71 Wheel nut 074361 018105 Brake lining axle set 404 421 05 10 oversize 6.4mm Brake drum screw 404 990 02 30 Suspension damper STD 404 323 01 00 (4x) Suspension damper HD 002 323 69 00 (4x) HD front spring 404 321 00 04 SA 35254/1 HD rear spring 404 324 01 04 SA 35254/1 Brake master cyl. kit 000 586 01 88 Clutch pressure plate 000 250 20 04 Clutch paddle plate 003 250 38 03 Sintermetall Clutch release bearing 000 250 32 15 Gearbox gasket set 404 586 00 85 Fuel pre-filter 000 477 91 01 Sealing ringng exhaust 153 492 01 08 Pipe to manifold Silencer 404 491 00 01 or 404 491 01 01 Rubber mounting G/B 404 241 00 13 Water pump 127 200 04 01 Thermostat 001 203 08 75 Coolant vent pipe 180 200 04 58 Radiator mtg 404 504 00 12 Radiator mtg 404 504 02 12 Wiper blade 270mm 000 824 21 26 Speedocable 075532 000000 Windscreen 404 671 04 10 Unimog hydraulic jack 000 583 88 15 Gaiter H/B cable 000 427 02 96 Boot steering joint 000 330 02 85 Steering joint 000 338 18 10 Bush front engine mtg 180 223 04 12 Fuel gauge 001 542 18 03 Fuel level transmitter 001 544 29 32 Electric fuel pump 24V 000 470 07 94