S12 Checklist
Vehicle___________________________
Mileage___________________________
Date______________________________
ITEM	OK	NOT OK	NA	R&R Date	Notes	Action
Tires
1. Drives Side Front Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean rims
d. Tire Protectant inside and out
e. Lug Nut Torque 58-72ft-lbs
2. Passenger Side Front Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean Rims
d. Tire Protectant inside and out
e. Lug Nut Torque 58-72ft-lbs
3. Drivers Side Rear Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean Rims
d. Tire Protectant inside and out
e. Lug Nut Torque 58-72 ft-lbs
4. Passenger Side Rear Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean Rims
d. Tire Protectant inside and out
e. Lug Nut Torque  58-72ft-lbs
5. Spare Tire Inflation OK / Pressure Can Present
6. Spare Tire Condition
7. Spare Tire Lug nuts present
BRAKES
1. Drives Side Front
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.630”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
2. Passenger Side Front
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.630”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
3. Drivers Side Rear
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.350”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
4. Passenger Side Rear
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.350”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
5. Brake Lines
a. No leaks
b. No cracks
c. No corrosion
6. Master Cylinder
a. Brake fluid color is clear
b. Change brake fluid DOT3 every 1-2 years
c. Brake Fluid Level
d. No Leaks
7. Proportioning Valve No Leaks
8. Brake Pedal
a. Free Height 7.44”-7.83”
b. Depressed Height 4.33”
9. Emergency Brake
a. Works Freely
b. 8-9 notches
10. Brake Booster
a. No Vacuum leaks
b. No fluid leaks
c. No chafing
CLUTCH
1. Clutch free height
2. Clutch free travel
3. Clutch smooth operation
4. Clutch leaks (master)
5. Clutch leaks (servo)
6. Clutch plumbing leaks, chafing, deterioration
7. Clutch fluid color clear
8. Clutch fluid replace every 2 years
9. Clutch fluid level and air bleed
10. Clutch fork boot no cracks
TRANSMISSION
1. Check for leaks
2. Drain fluid
3. Check magnetic drain plug
4. Check color
5. Refill fluid API GL-4   2.1 liter capacity
6. Check top boot for leaks
7. Check speedometer cable for cracks
8. Replace fluid every 2-4 years depending on conditions
DRIVESHAFT
1. damage check (dents in tube)
2. damage check  (journal wear)
3. looseness check (center bearing)
4. grease leakage
5. tightening torque (center bearing mount)
6. tightening torque (differential)
DIFFERENTIAL
1. Check for leaks
2. Check oil level  (GL-5) 2-3/4 pt 75W-90 cold climate , 140W if above 100 F
3. Check oil color
4. Replace oil every 2-4 years depending on conditions
HALF SHAFTS
1. check for leaks
2. check boots
3. check for loose tripod joints
POWER STEERING
1. check for leaks
2. check fluid color
3. replace fluid every 2-4 years depending on condition
4. check fluid level
5. check lines for chafing
6. check for loose connections
STEERING GEAR
1. check for leaks
2. check boots
3. check for loose fittings
4. check pinion seal
5. check ball joint
6. check dust cover
7. check for missing cotter pins
8. check for grease leakage
9. check steering wheel freeplay < 1.38”
Shocks/Suspension Parts
1. check axle and suspension for looseness
2. Check all bushings for damage
3. retighten all nuts and bolts to specified torque
4. check axle and suspension for wear, cracks, or damage
5. check shock/strut for leakage
6. shock/strut bounce test
Alignment
1. only toe is adjustable
2. camber and castor require aftermarket parts/shims
3. camber –25’ to 1 05’
4. castor 2 45’ to 4 15’
5. kingpin inclination 11 40’ to 13 10’
6. toe in –0.020” to  0.059”
Front wheel bearings
1. check wheel for play
2. check for grease leakage
3. adjust wheel bearing preload if needed
4. replace grease every 2 years
Rear Wheel Bearings
1. check wheel for play
2. replace bearings if play is present
Windshield Glass
1. check for cracks
2. check for crazing, or contamination
3. clean windshield
4. Rain-x inside and out
Lights
1. head lights
2. tail lights
3. clearance lights
4. fog lights
5. step lights
6. door lights
7. dome lights
8. hvac panel lights
9. instrument lights
10. glove box light
11. engine light
12. tail gate light
13. license plate light
Warning Lamps Chime
1. Function is model dependant
Horn
1. check operation
Windshield Washer
1. check front operation
2. check rear operation
3. check fluid level
Windshield Wiper Front
1. check operation
2. rain sensor
3. wiper (replace every 6 months)
Windshield Wiper Rear
1. check operation
2. wiper (replace every 6 months)
Windshield Defroster
1. No fan noise
2. No contamination in vents
3. Hot air present
Hatch Defroster
1. Windscreen heats up
2. Indicator works
3. Control works properly
Rear View Mirror
1. Check for looseness
2. Check for visual clarity
Drivers Side Mirror
1. Check for looseness
2. Check for visual clarity
Passenger Side Mirror
1. Check for looseness
2. Check for visual clarity
Locks Hinges & Hood Latch
1. Check for looseness
2. Check hood latch
3. Check hood latch release
3. Check hatch latch
4. Check gas door
5. Lube locks with graphite
6. Lube hinges and moving parts
Seats
1. Check adjuster
2. Check angle adjust
3. Check quick release
4. Check seat height (eg worn foam)
5. Check for rips or tears
6. Clean seats with appropriate cleaner
Seat Belts Buckles retractors anchors, & adjuster
1. Check for proper operation
2. Check for integrity of mounts
Accelerator Pedal
1. Check for free height
2. Check for smooth operation
3. Check for proper connection
Cruise Control ASCD
1. No vacuum leaks
2. Check proper operation
Engine
Drive Belts
1. Inspect for cracks or wear
2. Check tension
Air Cleaner
1. Check level of cleanliness
2. Replace yearly
Charcoal Canistor
1. Check hoses
2. Check air filter and replace if needed
3. Check solenoid valve
Vacuum Hoses
1. Check for damage
2. Check for leaks
Fuel Lines
1. Check for corrosion or chafing of metal lines
2. Check rubber hoses for deterioration
3. Check rear fuel lines off tank
4. Check fuel vapor lines
5. Check gas cap
Fuel Filter
1. Replace yearly
2. Check for proper flow
Fuel Gauge Top Surface
1. Check for corrosion
2. Check wiring integrity
Coolant
1. Check level in radiator
2. Check level in over flow tank
3. Replace yearly
Radiator and Hoses
1. Check for deterioration
2. Check for chafing
3. Check coolant level sensor
4. Check wheel hole for impending pump failure
Oil
1. Check level
2. Check color
3. Replace every 3 months or 3000 miles
Oil Filter
1. Replace every 3 months or 3000 miles
2. Check for leaks
Sparkplugs
1. Check color
2. Check Gap
3. Replace every 2 years (engine cold)
4. Use anti seize when installing
5. Torque to proper spec
Ignition Wires
1. Check for chafing
2. Check for deterioration
3. Check resistance
4. Check boot integrity
5. Replace every 5 years
6. Use dielectric grease to ease removal
Intake and Exhaust Valve Clearance
1. Adjust to proper spec
2. Check rocker shaft torque
Timing Belt
1. Inspect yearly or every 10,000 miles
2. Replace at 60,000
3. Replace tensioner concurrently with belt
4. Use loctite on stud (not the heat to remove stuff)
5. Torque to spec
Timing
1. Check timing
2. Check vacuum advance
Idle RPM
1. Verify meets spec
2. Verify idle up circuit works under load
Gaskets
1. check for leaks
Emissions Control
1. Check EGR valve
2. Check PCV valve
3. Check air regulator
4. Check idle up valve ACC
5. Check fuel pressure
6. Run ECCS self diagnostics
7. Check Oxygen sensor heater
Oxygen Sensor
1. Check wiring
2. Check operation
3. Replace every 5 years
Exhaust
1. Check pipes for rust and corrosion
2. Check system for leakage inc gaskets
3. Check mounting system for integrity
4. Check for heat shield integrity
Battery
1. Battery Cables
2. Starter Solenoid Connector
3. Engine Ground
4. Note battery age
5. Clean off top surface of battery
6. Check foam anti corrosion pads
7. Check battery box for corrosion/rust
8. Note battery specific gravity, each cell
9. Fill each cell to proper height
INTERIOR
1. Vacuum
2. Clean all surfaces
3. Check for stains/dirt
4. Check for rips/tears
5. Vinyl Shine appropriate surfaces
BODY
1. Check for nicks/dings
2. Check for rust
3. Check for proper panel alignment
Driveability test
1. Check for differential noise
2. Check for smooth shifting
3. Check for smooth idle, when cold
4. Check for smooth idle, when hot
5. Check for no vibration
6. Brakes straight ahead, no judder
7. Check for wind noise (weather seals)
8. Check for proper handling
9. Check for proper cornering
10. Check acceleration
copyright Ron Amundson 2000-2005
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