Just Bought a D40 - What Maintenance to you Suggest?

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sedy92

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Hi All,

Just picked up a D40 with approx 250,000kms, it's a 2008 STX 4x4 Manual with a YD25.

It runs great and has heaps of power, but I would like to know what model specific maintenance I should do for longevity and to avoid any common problems.

My list so far is,
- Check / Replace timing chain with double row unit and water pump.
- Block off EGR
- Clean out intercooler
- Replace intercooler soft hoses
- Replace neutral position switch
- Add catch can
- Add secondary fuel filter.

Is there anything else I should check / replace / add?

I'm sure this info is all spread through the forum but I couldn't find a combined list of common faults and breakages.

Thanks, Nathan
 

Billy54

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buy a 1 litre bottle of Fuel Doctor at Supercheap. Put in 300mm to a full tank then 100mm every tank after that. cleans everything from tank to tailpipe, smoother ride and better klms per tank.
 

Old.Tony

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As above, and throw some new vac hoses on it. 3mm ID hose, I bought 3m of it to do mine from Supercheap $15 and about an hour's effort with a sharp blade to remove the old bits and cut new pieces to length.
 

Tappet

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Again as above. Looks like your done some homework, your list is good. Be a little careful adding a secondary filter. It can create issues. The pump on these things are weak on the suction side. I have heard of cases and know first hand of one case where a supplementary fuel pump has been added to overcome the problem. I just change the filter often, use Nippon Max filters. Only once have I had a problem with the SCV in the life of the vehicle. Added a can of fuel system conditioner, problem gone never came back.
 

jld40

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Hi all I'm in the same boat with a 2014 model that I want to use as a camping / light 4x4 - can you think of any additional items that would apply to later models?
 
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Hi all I'm in the same boat with a 2014 model that I want to use as a camping / light 4x4 - can you think of any additional items that would apply to later models?
Hi all I'm in the same boat with a 2014 model that I want to use as a camping / light 4x4 - can you think of any additional items that would apply to later models?
Hi all, just a bit of info about the Alternator on my 2013 2.5 lt D40. We were coming across the Nullabor when the Alternator pulley departed and destroyed the alternator shaft. We never had any warning or noises from the vehicle until it came off and went under our caravan and punchers one of the tyres. I have heard this is a common problem.
 

Pat

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Sorry to hijack your thread, but saw your comment about replacing the neutral position switch.

Can anyone tell me if a faulty neutral position switch has any real effect?

I've been using the fast idle switch on cold mornings (2009 UK spec manual D40), and the fast idle doesn't disengage when I put it in 1st unless I push and hold the lever pretty hard.

I'd assumed this meant a faulty switch but was ignoring it... should I replace it?

NB, I've always thought my D40 needs more revs than it should on hill starts - any possible relationship due to the ute thinking it's still in natural?
 

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