200,000KM service (any useful tips?)

[jko]

Hello,

Currently sitting on 192,000KM's and creeping up towards that 200,000 mark and would like to start preparing and purchasing parts to prepare for the major service. I would appreciate if you guys could provide some helpful tips and information on things to look out for, and things I should do.

I'm not actually too sure what needs to be done. Would it basically be a 100,000km service again? Should I change any bushings etc? Let me know.

I've done a bit of research and nothing really came up in regards to what needs to be done for the big 200,000 service, so any help would be very appreciated

Sorry im noob

[StanTheMan]

NA? NB? NC?

In general.
Timing belts
Water pump


At 200 k lots of things may already have been replaced. Others will be due soon but open to opinion if it is required. Or fix them as they come up depending on age of car. But I'd certainly look at all the 100k
My clutch lasted 190 k km if yours is the original....
Bushings..... On NA's at least . There is a massive difference between 150k km & 200 k km. I changed mine at around 220k and they were toast. What to replace them with is another totally different discussion.
I'd certainly inspect all the hosing . Mine should all have been replaced at about 20 years of.

At 200 k it's kind of .....apart from the obvious. Fix things as they come up. Some will be expected, others will be unexpected

[hks_kansei]

The 200,000km is essentially just repeating the 100,000km service.
Do the waterpump at the same time, it's only an extra $70 or something for a new pump. (also give it a cooling system flush/clean before taking the old stuff off, may as well start with a clean system)

All you really need to do beyond that is inspect more of the things that wear slowly, like bushes etc as mentioned.
Do inspect the bushes before just buying new ones, a full set isnt cheap.
My GF replaced the bushes in her NA with 400,000km on the clock, the factory bushes that came out were perfectly fine. (she didn't put them back though, since she had the new kit sitting right there ready)


If the clutch was dead you'd have noticed it by now.


Engine mounts are probably worth looking at, they dont tend to last long, especially the passenger side one which gets roasted by the exhaust.



Most of it is just to look at what's wearing out and replace it.

Probably do gearbox and diff oils as well, from memory they should be done every 80,000km by the book.

[93_Clubman]

A baseline service for an NA8 as applicable would involve:
check/ replace engine oil, oil filter, & sump plug crush washer (every 6 months)
check/ replace gearbox oil, including turret (every 2 years)
check/ replace differential oil 75W-90 (every 2 years)
check/ flush/ replace brake fluid (every 2 years)
check/ flush/ replace clutch fluid (every 2 years)
check/ flush/ replace coolant in radiator & expansion tank (every 2 years)
clean/ replace air filter (every year)
replace fuel filter (every 2.5 years/50k kms)
check/ clean/ replace 4 sparkplugs NGK BKR5E-11 (every year)gap=1.1mm
check/ replace spark plug leads
check & clear ECU codes by disconecting battery
check/ clean/ adjust idle screw 850RPM +/- 50RPM
check/ adjust timing - 10 degrees BTDC
check/ replace CAS O-ring
check rear main seal drain hole
check/ adjust throttle cable freeplay 1-3mm
check/ clean throttle body & fuel injectors
check/ clean MAF element
check/ clean PCV valve
check/ clean restrictor operation
check throttle position sensor
check/ replace O2 sensor
check evaporative system
check/ clean cold start pipe fittng & connections
check fuel lines & hoses
check/ adjust/ replace alternator belt 4PK885 - new / used belt: 8-9mm / 9-10mm deflection with moderate pressure
check/ adjust handbrake
check/ adjust clutch pedal freeplay
check/ adjust brake pedal freeplay
check/ adjust front & rear wheel alignment
check/ adjust wheel balance
check/ adjust wheel nut tightness
check/ fill washer bottle level
check/ adjust/ replace tyres & pressures
check/ replace wiper inserts (annually just prior to Winter)
check/ replace front & rear brake pads, grease caliper slider pins & machine discs as necessary
check/ replace timing belt (every 100k kms)
check/ replace waterpump (best replaced in conjunction with timing belt)
check/ clean power window switch contacts
check/ tighten hardtop latches securing screws
check/ clean inside front lower quarter panels
check/ clean windscreen cowl drains & ventilation intake
check/ clean soft-top drains & drain pipes, as well as sill drains & front windscreen frame rubber side drains
check/ clean battery terminals & under battery tray for rust
check/ clean underbody
check/ clean boot, especially boot floor & arms for water or rust
check/ clean engine bay
check/ clean interior, especially parcelshelf & floorpan for water or rust
check/ clean/ polish exterior
check cooling system
check/ replace inner & outer gearshift boots & gearshift base collar/ cap
check brake lines, hoses & connections
check clutch line, hose & connections, including slave cylinder
check/ adjust/ replace front wheel bearing freeplay
check engine mounts
check steering operation & gear housing
check steering linkages, rack guide & tie rod ends
check front & rear suspension ball joints
check/ tighten bolts & nuts on chassis & body
check/ replace driveshaft dust boots
check tighten exhaust system heat shields
check/ tighten exhaust manifold bolts & nuts
check/ replace damper dust boots
check/ replace fuel pump wiring harness top tank connection
When present:
check/ adjust/ replace AC & PS belt - new/used AC belt 8-9mm / 9-10mm deflection with moderate pressure
check/ adjust/ replace powersteering fluid & lines
check adjust/ replace automatic transmission fluid

[jko]

Sorry, forgot to confirm that its for an NA6.

Thanks guys for all this awesome information!!

[manga_blue]

93-clubman's list is pretty sensible really, except it's missing one of the most important things:

check EVERY coolant hose, including main hoses, heater hoses and all the little ones between the front of the motor, the throttle body, the inlet manifold, the oil filter and the back of the head. Replace the whole lot as a set if more than one or two seem soft, bulging, oil-soaked, slimy or cracked.

I've seen more motor write-offs from one of these failing than all the other causes added together

[StanTheMan]

Sorry, forgot to confirm that its for an NA6.

Thanks guys for all this awesome information!!

Which year?
Short nose crank needs extra care with timing belt crank bolt and woodruff key. If It is pre 1991.

[jko]

1991.

[StanTheMan]

1991.

You can safely sleep at night.

The short nose crank is an issue. Not a massive big deal if you do it right.

That's all.

[OMY005]

Might as well do the cam and front crank seal's while the timing belt is being done as they're easy to get to then. Do the rear cranks seal if/when doing the clutch.

Andrew.

[93_Clubman]

check cooling system

Implicit in above Phil for those familiar, but indeed worth noting for less familiar - revised list:

A baseline service for an NA8 as applicable would involve:
check/ replace engine oil, oil filter, & sump plug crush washer (every 6 months)
check/ replace gearbox oil, including turret (every 2 years)
check/ replace differential oil 75W-90 (every 2 years)
check/ flush/ replace brake fluid (every 2 years)
check/ flush/ replace clutch fluid (every 2 years)
check/ flush/ replace coolant in radiator & expansion tank (every 2 years)
clean/ replace air filter (every year)
replace fuel filter (every 2.5 years/50k kms)
check/ clean/ replace 4 sparkplugs NGK BKR5E-11 (every year) gap=1.1mm
check/ replace spark plug leads
check & clear ECU codes by disconecting battery
check/ clean/ adjust idle screw 850RPM +/- 50RPM
check/ adjust timing - 10 degrees BTDC
check/ replace CAS O-ring
check rear crankshaft seal drain hole
check/ adjust throttle cable freeplay 1-3mm
check/ clean throttle body & fuel injectors
check/ clean MAF element
check/ clean PCV valve
check/ clean restrictor operation
check throttle position sensor
check/ replace O2 sensor
check evaporative system
check/ clean cold start pipe fittng & connections
check fuel lines & hoses
check/ adjust/ replace alternator belt 4PK885 - new / used belt: 8-9mm / 9-10mm deflection with moderate pressure
check/ adjust handbrake
check/ adjust clutch pedal freeplay
check/ adjust brake pedal freeplay
check/ adjust front & rear wheel alignment
check/ adjust wheel balance
check/ adjust wheel nut tightness
check/ fill washer bottle level
check/ adjust/ replace tyres & pressures
check/ replace wiper inserts (annually just prior to Winter)
check/ replace front & rear brake pads, grease caliper slider pins & machine discs as necessary
check/ replace timing belt (every 100k kms)
check/ replace waterpump (best replaced in conjunction with timing belt & front crankshaft & cam seals)
check/ clean power window switch contacts
check/ tighten hardtop latches securing screws
check/ clean inside front lower quarter panels
check/ clean windscreen cowl drains & ventilation intake
check/ clean soft-top drains & drain pipes, as well as sill drains & front windscreen frame rubber side drains
check/ clean battery terminals & under battery tray for rust
check/ clean underbody
check/ clean boot, especially boot floor & arms for water or rust
check/ clean engine bay
check/ clean interior, especially parcelshelf & floorpan for water or rust
check/ clean/ polish exterior
check cooling system (including all coolant hoses, ie main hoses, heater hoses & all small hoses between front of motor, throttle body, inlet manifold, oil filter & back of head. Replace as a set if more than one or two seem soft, bulging, oil-soaked, slimy or cracked)
check/ replace inner & outer gearshift boots & gearshift base collar/ cap
check brake lines, hoses & connections
check clutch line, hose & connections, including slave cylinder
check/ adjust/ replace front wheel bearing freeplay
check engine mounts
check steering operation & gear housing
check steering linkages, rack guide & tie rod ends
check front & rear suspension ball joints
check/ tighten bolts & nuts on chassis & body
check/ replace driveshaft dust boots
check tighten exhaust system heat shields
check/ tighten exhaust manifold bolts & nuts
check/ replace damper dust boots
check/ replace fuel pump wiring harness top tank connection
When present:
check/ adjust/ replace AC & PS belt - new/used AC belt 8-9mm / 9-10mm deflection with moderate pressure
check/ adjust/ replace powersteering fluid & lines
check adjust/ replace automatic transmission fluid
If replacing:
clutch then also replace rear crankshaft seal (clutch kit should contain clutch pressure plate, clutch plate, thrust/throw out bearing, spigot/pilot bearing & clutch alignment tool)