Service Workbook Scheduled Maintenance Pilot And Convoy Diesel Engined Vehicles pees SERVICE JOB SHEET PILOT AND C(Sy SCHEDULED MAINTENANCE (Diesel Engined Vehicles) Service Workbook ‘This Service Workbook covers the service procedure specified for maintaining Diesel engined LDV Convoy and Pilot vehicles. This workbook is primarily designed to assist skilled technicians in the efficient servicing of these vehicles, but can also be used as a reference workbook for training purposes. This service workbook should always be consulted prior to servicing work. SPECIFICATION LDV (the Company) reserves the right to change the procedures, material, specification, dimensions or design of the vehicles shown, described or referred to herein at any time and without prior notice in accordance with the Company's policy of constant product improvement. Every reasonable effort is made to ensure that the Company's publications are accurate, but nothing shown, described or referred to herein should be regarded as an infallible guide to the procedures, materials, specifications, dimensions, design or availability of any particular vehicle, nor does this Publication constitute an offer for the sale of any particular vehicle. No liability can be accepted by the Company or any Distributor or Dealer for any mechanical malfunction, damage, loss, injury or death caused by the use of incorrect or misrepresented information, omissions or errors that may have arisen during the preparation of this workbook. Purchasers are advised that the specification details set out in this publication apply to a range of vehicles and not to any particular vehicle. For the specification of any particular vehicle, purchasers should consult their LDV Distributor or Dealer. Please note that LDV Distributors and Dealers are not agents of the Company, and have no right or authority whatsoever to bind the Company in any way, or to assume on its behait any obiigation expressed or implied. COPYRIGHT © LDV 1996 Allrights reserved. No part ofthis publication may be reproduced, stored in a retrieval system or transmitted in any form, whether electronic, or mechanical, or by photocopying, recording or other means without prior permission in writing of LDV. Published by LDV, from whom further copies may be obtained through your normal ordering procedure. Bromford House Drews Lane Birmingham B8 20G Publication Part No. DW03960402 09/00CONTENTS Page ‘Aim of Workbook Fault reporting . Warnings and Cautions . References ....... Health and Safety . General precautions Equipment Lubricant specifications Sealants . : Data . cece ve Brake preventative maintenance . Torque wrench settings ...... Service maintenance procedure Driver/operator checks ... Dealer checks: — Inside vehicle .... — Oniift, whee! free — Onraised tft .. — On lowered ltt — Roadtest ....... — After road test ........ — Additional operationsAIM OF WORKBOOK ‘The aim of this Service Workbook is to define the service standards required, and the sequence of procedures to be carried out by the Servicing Dealer. It must be used in conjunction with Pilot and Convoy Diesel Models Service Job Sheet part number DW03936801 ‘The workbook describes inspection and adjustment procedures; for detailed information on specific ‘operations consult the appropriate workbook. In compiling this book it has been assumed that skilled, trained technicians will carry out the tasks. Vehicles Covered by Workbook. This workbook includes all the operations required to service Diesel engined Convoy and Pilot vehicles. FAULT REPORTING When carrying out routine maintenance on LDV vehicles, any additional work such as the renewal of non-service components, adjustments in addition to those covered by the service and other non-service procedures, must be reported to the customer and their permission obtained for repairs prior to proceeding with the additional work. Where safety related work is required and permission not granted to carry out the work, the customer should be advised that their vehicle has not been road tested and that they may be breaking the law by driving the vehicle away. WARNINGS, CAUTIONS & NOTES. WARNINGS and CAUTIONS are given throughout this Service Workbook in the following form: \ wannine: Procedures which must be followed precisely to avoid the possibility of personal injury. CAUTION: This calls attention to procedures which must be followed to avoid damage to components. NOTE: This calls attention to methods which make a job easier to perform. REFERENCES References to the left or right hand side in this Service Workbook are made when viewing the vehicle from the rear. The number given to each operation in this Service Workbook cross—refers directly to the operation numbers listed on the Service Job Sheet DW03936901. ‘A symbol such as this is shown at each Scheduled Maintenance operation to indicate the J position of the vehicle on or off the hoist.LDyv REPAIRS AND REPLACEMENTS When replacement parts are required, itis essential that only genuine LDV Parts are used. HEALTH AND SAFETY Itis recommended that scheduled maintenance work is carried out on a Four Post Lift with a wheel free facility. Do not work under the vehicle when supported only by a jack; always use safety stands. Chock the road wheels while the vehicle is on the lit. When carrying out service / repair work on a vehicle that has been driven recently, the fluids in the ‘systems and therefore the components containing the fluids will be hot. ‘Always remove the ignition keys from the vehicle to prevent accidental turing / starting of the engine when working under the bonnet. Dangerous substances WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin. These substances among others include acid, anti-freeze, brake fluid, fuel, windscreen wash additives, lubricants and various adhesives. Used engine oils: Prolonged exposure to used engine oils can cause serious skin disorders; avoid excessive skin contact and always adhere to the following recommendation: Always read carefully the instructions printed on labels or stamped on components and obey them implicitly. Such instructions are included for reasons of your health and personal safety. Never disregard them. Don'ts . Don't use kerosene, thinners or solvents to wash the skin; they remove the skin's natural protective oils, and can cause dryness, irritation and possibly more serious toxic effects. Don't overuse waterless hand cleaners, soaps or detergents. They can remove the skin's protective barrier oils. Don't put contaminated or oily rags in pockets, or tuck them under a belt; the contamination may penetrate to the skin, Protect the environment. Don't dispose of dangerous fluids by pouring them on the ground, or down drains and sewers. Do's Do follow work practices that minimise the amount of skin exposed, and the length of time liquids or substances stay on the skin, Do thoroughly wash contaminants from the skin, e.g. used engine oil, as soon as possible with soap and water. A waterless hand cleaner can be used when soap and water are not available. Always apply skin cream after using waterless hand cleaner. Do wash contaminated or oily clothing before wearing it again.GENERAL PRECAUTIONS ‘When disconnecting the vehicle battery, always disconnect the earth return (negative) cable first, and then the positive cable. On twin battery installations, disconnect both retum (negative) cables first, and then the positive cables, ‘When re-connecting the battery(s), connect the positive cable(s) first, then the negative cable(s). In all cases, the item being tested must be switched off after completing the test. ‘Where it is necessary to disturb cables, pipes and wires to access components, always ensure the cables etc. are correctly retumed to their respective retaining clips. Power Assisted Steering only — When the engine is running never hold the steering wheel on full lock for more than 30 seconds in any one minute, otherwise there will be a tendency for the fluid to overheat and possible damage to the seals may result. When topping up fluids, thorough cleanliness must be observed at all times to prevent ingress of dirt particles, When on road test, observe the following Statutory road speed limits. © Other road users. ‘The vehicles utilise a mixture of Imperial (AF) and Metric nut/bolt sizes. Always ensure the correct size of hand tool is selected. ‘Turbo engines only - Do not run the engine above idle speed for approximately 30 seconds atter the oil Pressure warning light goes out. This ensures the turbocharger bearings receive adequate lubrication before being run at speed. Before stopping a turbo engine allow it to idle for 10 seconds to ensure adequate lubrication to the turbocharger while itis slowing down. EQUIPMENT . ‘The following equipment is the recommended minimum necessary to carry out a Service in the prescribed manner: NOTE: All equipment which is a measuring device, i.e. torque meters, tyre pressure gauge etc. must be regularly calibrated to maintain accuracy. ‘© Four post vehicle lft with wheel free facility ‘© Refractometer (for antifreeze checks) © Lead lamp (iow voltage) ‘© Component washing equipment ‘© Torque meters (dial indicator type preferred) © Dial gauge © Grease gun © Rule © Tyre pressure gauge © Spring balance © Tyre tread depth gauge © Specified special service tools ‘© Equipment for draining and dispensing oils / © Health & safety approved brake cleaning antifreeze ‘equipment © Oilcan ‘© Pressure Brake bleeder Mirrors for checking exterior light operationi py LUBRICANT SPECIFICATIONS Its essential that correctly specified oil, grease and fluids are used at all times. Diesel engine, Oil can = CCMC PD2 (or higher) or RES.22.0L PD2 Gearbox Pilot - ATF M2C 33G or M2C 33F Convoy - P5-100 gearbox - CCMC PD2 (or higher) or RES.22.0L PD2 MT75 gearbox — M2C 186-A Rear axle and Manual steering box ~ MIL-L-2105C or APIGL5 SAE 90 Power assisted steering = Donax TA ‘Swivel pins = Castrol MS3, Duckhams Admax LM2, BP Energrease L21M, Shell Retinax AM, ‘Texaco Molytex 2, Fina Marson LM2, Esso Multipurpose Moly, Mobilgrease Super. ‘Crew cab door hinges, Locks/Strikers, Underfloor spare wheel carrier, Hubs — Multipurpose grease Brake and Clutch fluid = FMVSS 116 DOT 4. Antifreeze = LDVPartno. —_LBU 6577 (1 litre can) LBU 6576 (6 litre can) SEALANTS Loctite 242 Loctite 270DATA Capacities Engine XUDSA (Pilot) 5.2 litres (2.1 pints) ENSS (Convoy) 74 litres (13 pints) ET70 (Convoy) 7,7 litres (13.5 pints) Coolant XUDBA (Pilot) 10.6 litres (18.7 pints) EN/ET (Convoy) Sires (15.8 pints) Gearbox F380 (Pilot) 2,4 litres (4.2 pints) 5-100 (Convoy) 4,8 titres (8.12 pints) MT 75 (Convoy) 1,3 litres (2.29 pints) Rear axle 205 (Pilot) 4,9 tres (3.25 pints) 306 (Convoy) 2.4 litres (43 pints) Steering Manual steering box 0,45 litres. (0.8 pints) Power steering 4,5 litres (26 pints) Headlamp dip beam set aiming tolerances: Vertical 1.4% (0.8°) down from horizontal line. Horizontal Straight ahead. Wheel alignment Pilot - 1,6 to 3,2 mm toe out (1/16 to 1/8 in. toe out) Convoy ~ Parallel to 1,6 mm toe in (parallel to 1/16 in. toe in) Front hub bearing end float 0,05 t0.0,18 mm (0.002 to 0.008 in.) Handbrake adjustment 2 to 5 clicks — when pull of 10 to 20 kg (2244 Ibs.) pull is applied to ‘Tyre pressures handbrake. NOTE: Refer to the vehicle identification plate for max. GVW and plated axle weights. evw Pilot 2175 kg 2350 kg 2550 kg 2580 kg 2800 kg Convoy 2850 kg 3100 kg 3100 kg (18 seat minibus) 3500 kg with: 1875 kg F. axle 1500 kg F. axle 1600 kg F. axle ‘TYRE SIZE 185-148, 185-14R, 185-14C 6 PR 185-140 6 PR 185-140 8 PR 205-146 6 PR 205 - 14C 8 PR 185-140 6 PR 185-1406 PR 185-14C.6 PR 185-14R 8 PR FRONT 2,6 bar (38 Ibt/in?) 2,8 bar (40 Ibtin?) 2,9 bar (42 Ibtin?) 3,1 bar (45 Iofin?) 3,3 bar (48 Ibtin?) 2,8 bar (40 Ibt/in?) 8 bar (40 Ibt/in2) 2,9 bar (42 Ibtin?) 3,2 bar (46 Ibt/in?) 3,6 bar (63 loin?) 4,1 bar (60 Ibn?) REAR 2,8 bar (41 Ibffin2) 3,1 bar (45 Ibffin2) 3,7 bar (54 Ibf/in?) 3,7 bar (54 Ibtin2) 45 bar (65 Ibffin2) 3,6 bar (53 Ibf/in2) 4.4 bar (64 Ibt/in2) 3,2 bar (46 Ibtfin2) 3,5 bar (50 Ibtfin2) 3,5 bar (50 Ibt/in2) 3,7 bar (54 lbtfin2)DATA (Continued) XUD9A engine Idle speed 800 + 50 1pm ‘Alternator drive belt tension 6 mm (0.28 in) deflection ‘Vacuurn pump drive belt tension 6 mm (0.25 in) deflection Valve clearances (cold): inlet 0,15: 0,04 mm (0.006 + 0.0015 in) exhaust 0,30 = 0,04 mms (0.012 = 0.0016 in) Fuel injection pump timing: Static ‘See figure on pump Dynamic 12° BTDC at idle (engine hot) Heater plugs Type Bosch Vottage 11 volts Tip starts to glow 3 seconds Initial current draw 25 amps Current draw after 20 seconds 12 amps EN/ET engines {dle speed 775 25 rpm Drive belt tensions Alternator 9 mm (0.35 in.) deflection ‘Vacuum pump 6 mm (0.25 in) deflection Fan 9 mm (0.35 in.) deflection (manual steer) 5 mm (0.20 in) deflection (power assisted steer) Valve clearances (cold): inlet 0,15 mm (0.006 in) exhaust 0,25 mm (0.010 in) Fuel injection pump timing (cold): static See figure on pump Dynamic EN engine 12° BTDC 1° at idle (engine hot) ET engine 9° BTDC : 1° at idle (engine hot) Heater plugs Type Bosch Vottage 11 volts Tip starts to glow 8 seconds 40 Initial current draw 25 amps Current draw after 20 seconds 12 ampsi BRAKE PREVENTATIVE MAINTENANCE In addition to the recommended periodical inspection of brake components its advisable, as the vehicle ages and as a precaution against the effects of wear and tear and deterioration, to make a more searching inspection and renew parts as necessary. Itis recommended that: '* Ifthe vehicle is frequently subjected to severe driving or operating conditions, it may be ecessary to change the brake fluid at shorter intervals than those detailed on the Service Job Sheet. © All fluid seals in the hydraulic system and all flexible hoses should be renewed every 4 years or 96,000 miles (160,000 kilometres) whichever is the sooner. At the same time the working surfaces of the pistons and bores of the master cylinder, wheel cylinders and other slave cylinders should be examined, and new parts fitted where necessary. ‘* The direct acting servo should be replaced or overhauled every 5 years or 96,000 miles (160,000 km) whichever is the sooner. 1”ipy TORQUE WRENCH SETTINGS Component Pilot models Front spring "U' bolt nuts Rear spring "U' bolt nuts Road wheel nuts Steering whee! nut Gearbox fillerlevel plug Rear axle filler/level plug XUDSA engine Exhaust manifold nuts Inlet manifold botts Camshatt bearing cap nuts Camshatt pulley nut Camshatt cover bolts Crankshaft damper Timing belt tensioner Heater plugs ‘Sump plug Convoy models. Front spring 'U’ bolt nuts Rear spring 'U’ bolt nuts Air suspension flexi-link 'U’ bott nuts Road wheel nuts single wheel axle —twin wheel axle Steering wheel nut Gearbox filler/level plug (P5-100) Gearbox filler/level plug (MT 75) Rear axie fillertevel plug ENET engines Rocker cover nuts Manifold bolts ‘Turbocharger to manifold bolts (ET engine only) Sump plug 12 Nm 68-92 58-79 68-92 46-62 25-35 27-34 20 22.5 155 40 10 40+60° 15 22 25 75-95 129-141 183-197 176-227 230-280 46-62 25-30 35 20-28 20-25 50-60 Lot ft 50-68 43-68 50-68 3448 19-26 20-25 15 7 13 30 " 16 18 55-70 95-105 135-145 130-168 170-206 34~46 18-22 26 15-20 15-19 37-44 25MAINTENANCE PROCEDURE Diese! engined vehicles Driver/Operator Checks The following checks should be carried out by the Griver/operator at the stipulated intervals: Daily © Check operation of exterior lights (clean the lenses if necessary.) warning indicators and hom (see operation A2). © Check operation of screen washers and wipers (see operation A). ‘© Check operation of interior and exterior mirrors. Checking oil level - ENET engines © Check condition/operation of seat belts, © Check engine oil level: = Place vehicle on level surface and allow = Check condition and security, to stand for 10 minutes before checking. = Totest, see operation At — Withdraw dipstick (1) and wipe blade clean. © Check for correct functioning of hand and - Re-insert dipstick, then withdraw and footbrakes. check that oil evel is between upper and lower marks. © Visually check for signs of water, ol, fuel, — CAUTION: Do not overfi exhaust and other leaks under vehicle. = Iflow, remove oil filler cap (2) and top-up with correctly specified new oil. Replace cap. Weekly, and before a long journey. = Allow time for ol to drain to sump then re-check level. ‘© Check coolant level. © Check windscreen washer fluid level. ‘© Check condition and pressure of all tyres, including spare (see operation B3). Adjust pressure if necessary (see operation B7). © Check power assisted steering fluid level (see operation D2). ‘© Pilot models only. Check clutch fluid level (see operation D2). ‘© Check brake fuid level (see operation D2). WARNING: If level excessively low, ‘cause requires immediate Checking oil level - XUD9A engine 13By MAINTENANCE PROCEDURE Diesel engined vehicles Dealer Checks ‘The following checks should be carried out by the dealer at the stipulated intervals: NOTE: The intervals are given as mileages. However, time intervals are stipulated for vehicles that cover low mileages as follows: 1,000 miles or 1 month 6,000 miles or 6 months* 42,000 miles or 12 months" 24,000 miles or 2 years* 36,000 miles or 3 years* 48,000 miles or 4 years* * “Whichever ocours first. NOTE: Re tachograph vehicles — the mileage intervals are converted to kilometres as follows: 7,000 miles 7,500 Kilometres 6,000 miles 10,000 kilometres 12,000 miles 20,000 kilometres 24,000 miles 40,000 kilometres ‘36,000 miles 60,000 kilometres 48,000 miles = _ [80,000 kilometres Fit vehicle protection kit. A __ INSIDE VEHICLE Drive vehicle on to lift, stop en: ‘White placing vehicle in position: © Check that low oil pressure warning light and ignition/no charge warning light extinguish while engine is running. 14 Al. CHECK CONDITION, SECURITY AND OPERATION OF ALL SEATS, SEAT BELTS, AND MIRRORS. Interval: Every 12,000 miles/12 months Checking seat security Seats: © Check seat(s) security by rocking vigorously. © Check locking action and security of tipping mechanism (if fitted), © Check that driver's seat fore/aft adjustment catch locks into position correctly. © Check that rake and height adjustments operate correctly and lock into position (if fitted)(Checking seat belts Seat belts: ‘© Extend and examine for cleanliness, cuts, chafing and damage. © Check mountings security. ‘© Check belt tongue locks into clip correctly. © Check reel locks by ‘snatching’ webbing. © Check full extension and correct reel retraction Rear view mirrors: © Check interior and exterior mirrors for cracks, damage and security. ipy LAMPS, INDICATOR SWITCHES AND HORN. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months Lights Column switch — lights © With ignition off, turn rotary light switch to position 1". ‘Check that the following illumination is on: Instrument panel Console switches Heater controls. All sidelights Both number plate lights Check that sidelight waming light is on. © With ignition on (position = Check clock illumination is on. = Check both brake lights operate when brake pedal depressed. = Check that both headlights illuminate in dim dip mode. ‘© Tur rotary switch to position '2" and check both headlights illuminate to normal intensity. 18Headlight main and dipped beams © Pull lever fully towards steering wheel (an audible ‘click’ will be heard) and check both headlights operate on main beam. Check main beam warning light is on. © Reset switch to dip beam position and switch off headlights. '® Flick lever towards steering wheel and check headlights flash, Direction indicators © Move lever down and check that all left hand direction indicator lights and left hand warning light on instrument pack flash correctly. 16 Move lever up and check right hand direction indicators and right hand waming light on instrument pack flash correctly. © Engage reverse gear and check both reverse lights operate. Retum gear lever to neutral. Hazard warning switch © Press hazard waming switch on centre console. ‘Check that bulb in switch illuminates, and that all six hazard warning lights and the direction. indicator lights in the instrument panel flash correctly. Light switch (Minibus only) © Press light switch (Minibus only) and check that interior lights illuminate in passenger area.Rear fog guard lights switch © Tum on headlights and press fog guard lights switch. ‘Check that both rear fog guard lights illuminate. Check that switch bulb glows when rear fog guard lights are on. NOTE: Rear fog guard lights only operate when headlights are on, '* Move switch to position 1". Check light remains off when cab doors are open or closed. '* Move switch to position '2'. Check light comes ‘on when either cab door is opened. ‘© — Move switch to position ’3’. Check light remains on. Load space light Load Space Light (it fitted): © Move lever anti-clockwise and check light illuminates. Warning Lights © Check that the following waming lights illuminate when ignition is turned on (position WN: Low oil pressure. Handbrake and brake failure (when handbrake on). Ignition/no charge. Heater plug. NOTE: Heater plug waming light will automatically extinguish atter pre-determined time. ‘Tum off ignition. Horn button © Press horn button. Check for loud clear blast. 7CHECK OPERATION OF WINDSCREEN WIPERS AND WASHERS 1a) Interval: Every 12,000 miles/12 months Windscreen wipefwash contro! © Tum onignition. '* Pulllever towards steering wheel ~ Washiwipe should continue until switch is released When released, washers will stop immediately, wipers will continue for approximately 6 seconds. — Check all washer jets are operating and are directed to top of wiped area, (Single jets on Pilot, twin ets on Convoy, Wash/wipe switch — single wipe With ignition on, check wiper operation: © Pulllever down and release. Check for single wipe. 18 Wash/wipe switch - wipe Tum switch to position '1' and check intermittent wipe operation. © Tum switch to position '2" and check normal wipe operation. © Tum switch to position '3' and check fast wipe operation. Wash/wipe switch — intermittent wipe ¢ Rotate intermittent wipe switch and check that wipe delay period varies in each position. © Operate washer to lubricate screen. Retum lever to off position, allow wipers to retum to park position, tum off ignition. @ Inspect wiper blade performance. Check / report blades for deterioration, splits etc.B ONLIFT, WHEEL FREE CAUTION: On vehicles fitted with air ‘suspension, the rear axle must rer ‘supported in the whee!-free condition. Raise lift to convenient working height. BI. CHECK SWIVEL PINS FOR WEAR AND REPORT. LUBRICATE. Checking swivel pin wear Check wear condition of both swivel pins as follows: — With the aid of an assistant, apply footbrake to eliminate front hub bearing end float. = Tum each wheel from lock to lock and check for smooth, rotating action of swivel pin. Any restriction to smooth action would indicate worn or damaged bearing(s). = Rock and it each front wheel in tum in vertical piane. Check swivel pins for excessive play and for excessive lift. Adjust / overhaul if lift is greater than 0,38 mm (0.015 in) and / or if rock (measured at whee! rim) is greater than 2.0 mm (0.078 in). NOTE: After re-adjustment, correct lt tolerance should be 0,05 to 0,20 mm (0.002 to 0.008 in). Rock is on-adjustable; it is governed by the ‘manufacturing tolerance of new swivel pins and bearings. If rock greater than 2,0 mmis found, then the swivel pin and bearings must be overhauled. Report wear condition. ‘Swivel pin grease nipples Lubricate both grease nipples on each swivel with the correctly specified grease. NOTE: Molybdenum grease must be used. CAUTION: Wipe off any excess grease to Prevent brake disc / pad contamination. 19éjpy B2, CHECK FRONT WHEEL BEARING END FLOAT, ADJUST IF 42 NECESSARY. Interval: Every 12,000 miles/12 months Spin each hub and listen for bearing noise which, if evident, will indicate potential bearing failure. Report if necessary. Inspect both front wheel bearing end floats by checking in and out movement of the hub. (Special tool 18G 191 can be used to check ‘end-float accurately). Front hub bearing end float = 0,05 to 0,13 mm (0.002 — 0.005 in) If either end float is excessive, adjust as follows: Adjusting front hub end float 20 Tools required: 0480048 (18G191) 0 to 10 Nm (0-7 Ibf ft) torque wrench. ‘A Use torque wrench to tighten hub nut to 7 Nm Git. NOTE: Spin hub whilst tightening nut. B__ Slacken nut without disturbing hub. © Tighten hub nut again, finger tight only. D_ Without disturbing position of nut, fit nut retainer so that one arm of retainer covers LEFT HAND SIDE of split pin hole in stub axle. E _ Slacken nut and nut retainer until spit pin hole is fully exposed. Fit new split pin and refit dust cap. G Check that end float is correct using dial ‘gauge 0480048 (186191) Repeat procedure if correct figure is not attained.Repeat operations BS to BS working on one wheel ata time. 83, REMOVE ROAD WHEELS INCLUDING SPARE, INSPECT WHEELS & TYRES FOR DAMAGE / .| UNEVEN TREAD WEAR. RECORD TREAD DEPTHS. Interval: Every 12,000 miles/12 months Too! required : Tyre tread depth gauge Remove whee! trims (i fitted). Make temporary correlation marks on wheels / studs. Remove all road wheels including spare. NOTE: Remove and check spare wheel when lift position allows convenient access. Inspecting road whee! ‘Check stud locations for ovality (indicates loose whee! nuts). Inspect wheels for cracks/ damage. Damage to rim could be caused by ‘kerbing’ which in tum could distort wheel and cause tyre run-outWwear etc. Severe ‘kerbing’ could affect steering geometry. iby Inspect both tread and sidewalls of each tyre for cuts, ply or cord exposure, lumps or bulges. Report any damage to customer. Examine circumference of tyre tread for regular wear pattem. Report signs of uneven wear to customer Excessive wear on both shoulders = tyre under-inflated Excessive wear in centre of tread = tyre over-inflated. Feathering = incorrect steering geometry. Irregular wear = excessive play in ball joints, swivel pin, hub etc., = heavy braking, = wom shock absorbers. Excessive wear on one shoulder = incorrect steering geometry, = fast cornering. Checking tyre tread depth Use a proprietary gauge to measure tread depth across face of tyre. Enter smallest depth recorded in appropriate box on job sheet. CAUTION: Ensure tyre tread depth and condition meets current legal requirements, Report / replace any tyres below the legal limit. Report any tyres which are likely to be below the legal limit before the next service. 21ipy BA, VISUALLY INSPECT BRAKE PADS FOR WEAR AND DISCS FOR CONDITION, CHECK FOR HYDRAULIC LEAKS AND REPORT. RENEW PADS IF NECESSARY. Interval: Every 6,000 miles/6 months Every 12,000 miles/12 months BS. REMOVE BRAKE DRUMS, WASH ‘OUT DUST, INSPECT LININGS AND DRUMS FOR WEAR. CHECK FOR HYDRAULIC LEAKS AND REPORT. RENEW SHOES IF NECESSARY. REFIT DRUMS. Interval Every 12,000 rriles/12 months Inspection of brake pad thickness ‘© Inspect thickness of brake pads. =~ Ifone pad is more womn than the other, check for piston seizure etc. = Weany pad thickness is 3 mm (1/8 in) or less, all pads must be renewed to maintain vehicle satety. (Overhaul details in workbook ’Suspension, Steering, Brakes’) = Report thickness is acceptable but likely to require renewal before next service is due. NOTE: Convoy model brake pads have a chamfer which must be located at the top of each pad. © Inspect discs for damage or excessive scoring. © Check for hydraulic leaks from flexible pipes, connections, calipers. Report as necessary. Inspection of brake lining thickness ¢ Remove brake drums and wash out dust with brake cieaner solution. WARNING: Current production brake linings are asbestos free, but care ‘should be taken not to inhale brake dust. ‘© snspect brake linings for: = Damage/contamination = Thickness — minimum 1,5 mm (176 in). © Report if thickness is acceptable but likely to require renewal before next service is due. NOTE: Pilot model brake shoes have ‘unequal lining thicknesses. ‘® To maintain vehicle safety, renew as set of {our if any lining is too thin or contaminated, (Overhaul details in workbook ‘Suspension, Steering, Brakes’)© Inspect drums for damage or excessive scoring, © Check for hydraulic leaks from wheel cylinders or pipe connectors. Report as necessary, © Check for oil contamination from hub seals, Report as necessary. © Inspect self-adjusting mechanism for correct operation. © Refit drums. Be. REFIT WHEELS AND TIGHTEN USING TORQUE WRENCH. Interval: Every 12,000 miles/12 months Tool required: 0-350 Nm (0-250 Ibf tt) torque © Refit road wheels, aligning correlation marks wrench made before removal. 5-stud whee! nut tightening sequence 6-stud wheel nut tightening sequence ‘Temporarily raise/tower lft platform to restrain. road wheels. Tighten wheel nuts in the ‘sequence shown in illustration and to correct torque. * Refit wheel trims (if fitted). © Lubricate undertioor spare wheel carrier with multipurpose grease (if fitted). © Refit spare wheel when ift position allows convenient access. 23(Sy 87, ADJUST TYRE PRESSURES Interval: Every 12,000 miles/12 months Check/adjust all tyre pressures, including spare wheel NOTE: Adjust spare tyre to the higher pressure. If pressure excessively low, check for signs of puncture/damage. NOTE: To establish correct tyre pressures, refer to the vehicle identification plate for max. GVW and plated axle weights, and then identity pressures in ‘Data’. 24 C ONRAISED LIFT Raise lift fully ct. DRAIN ENGINE OIL AND RENEW FILTER. REPORT LEAKS Interval: First 1,000 miles/1 month (Convoy only) Every 6,000 miles/6 months Every 12,000 miles/12 months ‘Sump drain plug © Place container beneath engine, © Remove drain plug and drain ol. © Leave to drain, © Examine engine for leaks, and report as necessary.Renewing oil filter cartridge - EN engine Renewing oil filter cartridge - ET engine Clean area around filter head. Position oil drain receptacle. Unscrew and discard oil fter cartridge (1). ‘Smear seal (2) of new cartridge with clean engine oil. Screw cartridge into position using hand force only. Clean off any spit oil Refit drain plug using new washer, and tighten to the correct torque.CHECK/TOP UP GEARBOX OIL LEVEL. REPORT LEAKS. Interval: Every 12,000 miles/12 months Oil level check - P5-100 gearbox 26 Oil level check - MT 75 gearbox NOTE: This check must be made with vehicle level. © Wipe clean area around oil filler/ievel plug and remove plug. Check oil level which should be at bottom of aperture threads. ‘Top up with correctly specified new oil if necessary (see ‘Lubricant Specifications’). Refit plug and tighten to correct torque. NOTE - R380 gearbox. Before fiting, ensure adequate sealant remains on plug threads. If not clean off and apply Loctite 242. = P5-100 gearbox. Refit plug using new washer. © Report any leaks.3. a CHECK/TOP UP REAR AXLE OIL LEVEL. REPORT LEAKS. Interval: Oil level check ~ Pilot rear axle Every 12,000 miles/12 months Oil level check — Convoy rear axle NOTE: This check must be made with vehicle level © Wipe clean area around oil filer/level plug (1) and remove plug. Check oil level which should be at bottom of aperture threads (2). ‘Top up with correctly specified now oll f necessary (see ‘Lubricant Specifications’) Refit plug and tighten to correct torque (do not overtighten). © Report any leaks. 4, CHECK VISUALLY ALL FUEL, a HYDRAULIC AND AIR PIPES AND LINES FOR SECURITY, CHAFING, Interval: CRACKS, LEAKS, CORROSION. First 1,000 miles/1 month Every 12,000 miles/12 months Visually inspect fuel pipes: © Check clipped securely. * No possibilty of chafing against other pipes, chassis etc. Check that chassis grommets through which pipes pass are correctly located, No cracks or corrosion. © Noleaks at unions. a7Air suspension hamess Models with air suspension. © Visually inspect harness/pipes for correct routing and security in clips. Ensure pipes cannot chate. © Check pipe security at each connector © Check that chassis grommets through which om pipes pass are correctly located. Brake pipe cs. LUBRICATE HANDBRAKE EXTERNAL LINKAGE. Visually inspect brake pipes and hoses: © Check clipped securely. I © Nolleaks at unions or along pipe runs. © Nochafing against other pipes, chassis etc. No corrosion. © Check chassis grommets through which pipes pass are correctly located. © Check flexible pipes for leaks, chafing, ‘damage and deterioration. Interval: Every 12,000 miles/12 months Cluteh slave cylinder (Pilot models) Handbrake i © Visually examine Pilot clutch slave cylinder rake linkage oe ryan sine chating, cracks © Lubricate handbrake linkage clevis pins, securiy and conosfon ores, arrowed, with engine ol. 28ce. CHECK SECURITY AND CONDITION OF ALL STEERING AND SUSPENSION JOINTS, «| BUSHES AND COMPONENTS, AND ALL SPRING ’U’ BOLTS USING ‘TORQUE WRENCH Interval: First 1,000 miles/1 month Every 12,000 miles/12 months ‘Tool required: 0-200 Nm (0-150 Ibf tt) torque wrench Checking ball joint security © Inspect foliowing components / bushes for signs of deterioration, wear and free play. Visually check tightness of securing nuts/botts. ~ Steering box (including drop arm attachment) ‘Steering damper and bushes (i ited) Drag link ball joints/gaiters Steering arm attachment Track rod arms attachment Track rod ball joints/gaiters Drop arm CAUTION: Power assisted steering models: always check with engine switched off. Check for wear at track rod and drag link joints; no play should be evident when moving by hand. IMPORTANT: Do not lever joint upwards; as this will compress nylon insert and damage joint Checking shock absorber security Check security of steering damper (it fitted) and shock absorber mountings by grasping and lift/ tum to check bushes. Visually examine shock absorbers for signs of fluid leakage and report. Inspect following components / bushes for signs of deterioration. Visually check tightness of securing nuts/botts. — Springs / spring bushes. = Spring shackles. = Anti-roll bars). = Propshaft and joints / bearings for wear and damage. Use torque wrench to check tightness of front and rear spring 'U’ bolts, including air suspension flexi link "U' bolts (fitted). See ‘Torque Wrench Settings’ for specific torque figures. If air suspension fitted check: = Flexitinks /flexi~link bushes. = Airsprings. = Panhard rod ball joint and bush. 29Sy c7. Interval CHECK FOR OIL LEAKS FROM ‘STEERING SYSTEM. First 1,000 miles/1 month Every 12,000 miles/12 months © Visually examine steering box, pump, connections and hoses for signs of fluid leakage. © Check hoses for routing and chafing. ca. CHECK EXHAUST SYSTEM FOR SECURITY & TIGHTNESS; INSPECT FOR LEAKS AND CHECK’ "4| MOUNTINGS. Interval: Every 12,000 miles/12 months 30 ZX WARNING: Exhaust system may bo hot; wear insulated gloves when examining exhaust system and mountings. © Examine mountings for wear and condi n. ‘© Visually check exhaust system for damage, corrosion or leaks. © Check tightness of manifold, pipe connections and mountings. CHECK/ADJUST LOAD SENSING VALVE Interval: First 1,000 miles/1 month NOTE: tis desirable for vehicle to be unladen when making this check. a. _ Establish weight on rear road wheels. For future reference record weight on the job sheet. 1000 1100 1200 1300 REAR AXLE WEIGHT (KG) Setting data label example b. Consult setting data label located on cab Passenger door (stepwell face on sliding cab door models). WARNING: Label illustrated above is ‘only for example; reference must be made to specific label on vehicle.Establish actual rear axle weight on horizontal scale. Use straight edge to locate point on diagonal line directly above this weight, Then draw line horizontally to the vertical scale and read off setting dimension ‘Z required. (See dotted line example in illustration). This is your setting dimension. c. _Disconnect load sensing valve spring at upper attachment. d. Lift spring to vertical position and eliminate all slack at lower mounting bracket. & Measuring dimension ‘2° fe. Measure distance between centre of spring eye and centre of load sensing valve arm ‘eye. This is actual dimension ‘Z. f. Compare actual dimension ‘Z' obtained in ‘e" with required dimension ‘Z' obtained in ‘b’. 9. Iincorrect, adjust spring length at lower mounting. h. Refit spring, D LOWER LIFT Lower lift to ground. bt. REFILL ENGINE WITH CORRECT GRADE OIL TO THE CORRECT LEVEL. DO NOT OVERFILL. Interval: First 1,000 miles/1 month (Convoy only) Every 6,000 miles/6 months Every 12,000 miles/12 months Oil filing ~ EN & ET engines 31Remove oil filler cap (2). Fill with the correct grade and quality of new oil to the top mark on the dipstick (1). ‘Allow time for oil to drain to sump before checking level. NOTE: Quantity required to raise level from 'MIN’ to ‘MAX'— XUD9A — 1 litre (1.75 pints) ENET — 2.5 lltres (4.4 pints) CAUTION: Do not overfill. Refit ol filler cap. D2. CHECK/TOP UP POWER STEERING RESERVOIR/STEERING BOX, BRAKE/CLUTCH FLUID(S), AND WINDSCREEN WASHER: | RESERVOIR. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months Power Steering fluid Power assisted steering reservoir NOTE: Fluid level should be checked with engine cold and stationary. ‘Wipe area clean around filler cap on reservoir. Remove cap and wipe dipstick blade clean with lint free cloth or paper. Refit cap, then withdraw and check fluid level indicated. Should be up to MAX mark. necessary, top up with specified fluid. (See ‘Lubricant Specification’) Replace cap. Manual Steering Box Fluid If manual steering is fitted: Wipe clean area around oi filer/level plug and remove plug. Check oil level which should be at bottom of aperture threads. ‘Top up with correctly specified new oil if necessary (see ‘Lubricant Specifications’) Refit plug and tighten to correct torque.Clutch fluid (Pilot models only) Brake fluid Clutch master cylinder Inspect fiuid level, which should be between MAX and MIN marks on side of reservoir. It level is excessively low, investigate and report If topping-up is required: CAUTION: Do not allow brake fluid to contact paint finished surfaces, ‘Wipe area clean around filler cap on clutch Brake master cylinder fluid reservoir. Fomove cap andtop up with nm brake hid ngpet uid iove, which shou be between ‘Only use fluid which complies with MAX and MIN marks on side of reservoir. ‘specification FMVSS 116 DOT 4 ‘fatay check bonthor hoe cap clear WARMING: Estabih cause hid Replace cap. rectify, © ttopping-up is required: CAUTION: Do not allow brake fluid to contact paint finished surfaces. © Wipe area clean around filler cap on clutch fluid reservoir. Remove cap and top up with new brake fluid to MAX mark. Only use fluid which complies with specification FMVSS 116 DOT 4 Visually check breather hole in cap is clear. Replace cap,Sy Windscreen washer reservoir Pilot windscreen washer reservoir illustrated © Check windscreen washer reservoir level. © Top up it necessary with water/proprietary screenwash mixture. CAUTION: Do not use denatured alcohol (methylated spirit) as this will discolour the paintwork. D3. CHECK COOLING SYSTEM, HOSES AND CONNECTIONS FOR LEAKS. Interval: Every 12,000 miles/12 months ¢ Examine all coolant hoses and connections for leaks. Check security of connections. Check radiator and expansion tank for leaks. Check condition of filler cap. Visually check engine for signs of coolant loss. CHECK COOLANT SOLUTION STRENGTH. TOP UP IF REQUIRED WITH SPECIFIED ANTI-FREEZE (50% SOLUTION). RECORD et | ekowe ev nernactomeren %| Interval: Every 12,000 miles/12 months Tool required: Refractometer Checking anti-freeze strength ZA WARNING: If engine is hot, place thick cloth over cap and expansion tank before attempting to remove cap. Remove pressure relief cap from coolant expansion tank. Place a drop of coolant on the refractometer and measure its concentration in accordance with refractometer manufacturer's instructions. tweak, add correctly specified antifreeze until correct. Use only LDV approved antifreeze. © Iflevel low, add 50% anti-freeze solution to level mark on side of expansion tank. © Record anti-freeze concentration (%) on job sheet. © Iflevel is excessively low, check system for cause of leakage, e. = Hoses and connections. = Raadiator / expansion tank. = Engine, intemal or extemal leakage. — Heater and water vaive.Ds. CHECK CONDITION AND TENSION OF ALL EXTERNAL DRIVE BELTS (NOT CAMSHAFT BELT). ADJUST a OR RENEW AS NECESSARY. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months Inspect external drive belts (not camshaft rive belt) for damage, fraying, excessive wear etc. Renew as necessary. ‘Check belt tensions as detailed below, and adjust if necessary, XUDSA engine. WARNING: Do not attempt to check belt tension or make belt adjustments with engine running. Serious injury could result. Alternator drive belt (models with power steering) 1. Tensioner securing bolts 2. Tensioner bolt cSy Alternator Drive Belt (models with power steering) © Apply hand pressure on belt, check for 6 mm, (0.25 in.) belt deflection at mid point of longest belt run. Itnecessary, adjust as follows: Slacken belt tensioner securing bolts (1), adjust tensioner bolt (2) until correct tension is achieved, tighten securing bolts. © Re-check tension and readjust if necessary. Alternator drive belt (models without power steering) 1. Belt tensioner bracket securing nut 2. Alternator pivot bolt 3. Tensioner bolt Alternator Drive Belt (models without power steering) © Apply hand pressure on belt, check for 6 mm (0.25 in.) belt deflection at mid point of longest belt run. Htnecessary, adjust as follows: © Slacken tensioner bracket securing nut (1), alternator pivot bolt (2) and tensioner bolt (3). © Adjust tensioner bolt until correct tension is achieved, tighten alternator pivot bolt and tensioner bracket securing nut. © Re-check tension and readjust if necessary.EN or ET engines. WARNING: Do not attempt to check belt ‘tension or make belt adjustments with engine running. Serious injury could result. Vacuum pump drive belt 1. Tensioner bracket securing nut 2. Tensioner adjustment bolt Vacuum Pump Drive Belt © Apply hand pressure on belt, check for 6 mm (0.25 in.) belt deflection at mid point of longest belt run. Vacuum pump drive belt Ii necessary, adjust as folows: © Slacken belt tensioner bracket securing nut .—_Tensioning adjuster b (1), adjustment bott (2) and vacuum pump ensioning adjuster bots pivot bolt * Pivot vacuum pump until correct tension is, achieved, tighten the adjustment bott, ‘securing nut and vacuum pump pivot bolt. ¢ Re-check tension and readjust if necessary. ‘Vacuum Pump Drive Belt. © Apply hand pressure on belt midway between the two pulleys, check for 6 mm (0.25 in.) belt detlection. If necessary, adjust as follows: © Slacken pump mounting nuvbolt. @ ~— Slacken adjustment bracket nuts/bolts (1). © Pivot pump to tension belt; tighten adjustment bracket nuts/bolts. ‘© Tighten pump mounting nuvbot. © Re-check tension and re~adjust if necessary.Fan / power steering pump belt 1. Pump pivot bolts 2. Retaining bracket bolts Fan/power steering pump belt. ‘© Apply hand pressure on drive belt midway between pump and fan pulley. ‘Check bet deflection which should be 5 mm. (0.20 in) lf necessary, adjust as follows: ‘¢ Slacken pump pivot bolts (1) and retaining bracket botts (2). © Pivot pump until correct tension is achieved. Tighten retaining bracket bolts and pivot bots, © Re-check tension and re-adjust if necessary, Alternator drive belt 1. Altemator mounting bolt 2 Adjusting bolts ‘Alternator Drive Belt. ‘© Apply hand pressure on belt midway between the two pulleys, check for 9 mm (0.35 in) belt deflection. Hf necessary, adjust as follows: ‘© Slacken altemator adjusting botts (2) and ‘mounting bott (1), © Pivot altemator until correct tension is achieved. Tighten adjusting bolts and mounting bot. © Re-check tension and re-adjust if necessary. =). Ds. (PILOT ONLY) CHECK CONDITION OF CAMSHAFT DRIVE BELT, RENEW IF pee CONTAMINATED OR DAMAGED. Interval: Every 12,000 miles/12 months XUDSA engine only Timing belt access Timing belt inspection © Remove timing belt inspection panel. © Rotate engine 8 revolutions by hand, ‘examining belt for cracks, fraying and oil contamination. Examine teeth for wear and damage. © Refit inspection panel, If faulty, timing belt must be renewed. 37p7. {PILOT ONLY) CHECK OPERATION OF COOLING FANS pe. DRAIN WATER FROM FUEL FILTER ia Interval: Every 6,000 miles/6 months Every 12,000 miles/12 months Pilot cooling fan terminals Pitot only. AA WARNING: Ensure loose clothing, fingers etc. cannot foul the fans. © Tumignition switch to position I Bridge terminal wires and check that both fans operate. 38 Interval: Every 6,000 miles/é months Fuel fitter CAUTION: On Pilot models, take precautions to avoid fuel dripping onto electrical equipment below. © Attach suitable pipe to drain screw and place other end in receptacle. ¢ Slacken drain screw (1) in filter base and operate pumping bution (2). © Tighten drain screw when pure diesel is emitted. CAUTION: Do not operate pumping button when drain screw is closed. © Inspect contents of receptacle. If excessive debris or water evident, inspect fuel system for point of ingress.De. RENEW FUEL FILTER © Remove and discard four sealing rings (3) from head, base and centre bot. Clean fitter base. Reassemble unit using new fiter element and sealing rings. © Bleed system as follows: — Open bleed screw (4). — Operate pumping button (5) until air-tree fuel flows from bleed screw. ~ Tighten bleed screw. = Gently operate pumping button unt resistance is felt. p10. VISUALLY CHECK CRANKCASE BREATHER SYSTEM AND BRAKE SERVO HOSE FOR LEAKS, a SECURITY AND CONDITION. Interval: Every 12,000 miles/12 months ‘© Visually examine crankcase breather system for signs of leaks. © Check that hoses and valves are securely lipped and in good condition ‘© Check that hoses and valves do not chafe. Fuel filter ‘CAUTION: On Pilot models, take precautions to avoid fuel dripping ‘onto electrical equipment below. © Clean fiter. Position suitable container under filter. © Support fter base, remove centre bolt (1) ‘and plain washer to release base ‘© Twist filter cartridge (2) to detach from fiter Brake servo hose (Pilot) head.Dit. LUBRICATE BRAKE/CLUTCH PEDAL CLEVIS PIN(S) ACCELERATOR PEDAL PIVOTS, ALL DOOR LOCK LATCHES, ‘| BONNET AND DOOR HINGES. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months Brake servo hose (Convoy Diesel) © Visually inspect the brake servo hose and connections for leaks, security and condition. Pilot pedal assembly lubrication points © Remove lower facia on driver's side. © Lubricate with engine oit: CAUTION: Ensure floor carpets, mats and Pedal rubbers do not become contaminated. = Push rod clevis pins of clutch master cylinder (Pilot only) and brake master cylinder. — Accelerator pedal pivots. © Lubricate accelerator cable attachment to Pedal with Lithium based grease. © (Convoy oniy) Lubricate clutch cable attachment to pedal with DOW CORNING. DC3s lithium based grease. Refit lower facia,Hinged cab door lock latch ‘© Lubricate all door lock latches and striker plates with multipurpose grease. Crew cab door hinge Crew cab door only © Lubricate door hinges at grease nipples with multipurpose grease. All other door and bonnet hinges: © Lubricate with engine oil Do NOT spray with WD40 or simitar. Do NOT lubricate sliding cab door runners. ALWAYS wipe off excess grease / oll from paintwork etc. If carrying out a 6,000 mile service: © Remove complete protection kit, close bonnet. All other services, all vehicles: © Remove wing covers, close bonnet. a—E ROAD TEST NOTE: Before driving off, check vehicle has valid tax disc and MOT test certificate (if applicable) Use trade plates if unsure. AN warnina, setore diving ot: 1. Ensure that any items requiring attention which render the vehicle unroadworthy have been corrected. 2. Check adjustment of rear view mirrors. and fasten seat belt. NOTE: If tachograph installed, ensure blank plastic disc fitted, or fit a paper disc. et. CHECK OPERATION OF FOOTBRAKE AND HANDBRAKE. Interval: First 1,000 miles/t month Every 12,000 miles/12 months Before driving off: ‘© Apply footbrake and check ‘fee!’ and firmness of brake pedal. (ie. that adequate pedal pressure exists) ‘© Check that handbrake operates. © Ensure footbrake is operational before ‘commencing road test. During road test Footbrake When sate to do so, bring vehicle to rest in straight line. NOTE: When assessing performance, remember brakes require a period to bed in if padsttinings have just been renewed. © Check for firm, responsive braking. Brakes should act smoothly and quietly, i.e. without squeal. 42 © Check pedal travel and feel. = Ifexcessive pedal travel, rear brakes may not be self-adjusting, NOTE: On Convoy models rear brakes self-adjust by applying brakes when travelling in reverse. If pedal action feels ‘spongy’, suspect air leaks in hydraulic system. © Check vehicle comes to rest without undue deviation. It vehicle does not stop squarely, cause may = Pad/shoe contamination. = Airin system. ~ _ Siezed caliper piston(s) and/or wheel cylinderis). — Mixed grades of padilining material used. = Hydraulic leaks. ‘© Tum off ignition. Press pedal several times. and hold down. Start engine. Pedal should fall slightly under influence of servo unit. Handbrake Checking handbrake operation When safe to do so, stop vehicle on slope and apply handbrake. © Check that ratchet operates correctly and Vehicle is held securely. Ensure adjustment setting is correct: 2~5 clicks, with pul-on load of 10 to 20 kg.£2. CHECK AND REPORT ANY NOTICEABLE DEFECTS DURING ROAD TEST WHICH MAY REQUIRE .@ FURTHER INVESTIGATION. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months aw Clutch © Check clutch operation. It should engage smoothly, without judder, slipping or noise. Gearbox © Check for smooth, quiet gear changes. © Check for efficient synchromesh action in all gears. © Listen for abnormal transmission noise (gearbox, propshaft, centre bearing and rear axle). Checking indicator selt-cancelling Before driving off: © Operate direction indicator switch for each direction in tum and check for correct cancellation by the steering wheel Before driving off: Engine Check fast idle speed reduces to idle when engine reaches normal operating temperature, © Check power transmitted smoothiy. © Check engine noise level and performance is OK. © Check accelerator pedal for smooth operation. © Check engine is responsive to accelerator pedal movement. © Throughout road test, listen for any noise which may indicate an engine faut. Convoy gear lever (P5-100 Gearbox) Convoy only (P5-100 Gearbox) © With the vehicle stationary, check that reverse gear can only be selected when sliding collar on selector lever is raised, and that the collar retums when released. Steering ‘© Check vehicle does not deviate from straight ahead position, allowing for road camber. © Check steering moves smoothly and east and without undue noise, © Check for correct self centre action after comering NOTE: If vehicle being tested contains payload, this may affect handling if badly positioned. Ht power assisted steering fitted (in addition to. above checks): © Check for noise from pump or drive belt when under turning load.Right and wrong position of steering wheel © Check steering wheel alignment when driving straight ahead. I adjustment is required, recheck selt-cancellation of indicators. Re-torque steering wheel nut if disturbed. Suspension ¢ Listen for abnormal suspension noise, indicating one or more of the following: = Loose, worn or collapsed spring, spring shackle, of anti-roll bar bolts/bushes. = Loose spring 'U’ botts. = Loose/worn shock absorber(s) or their bush(es). - Chafing or insecure items. © Check for ride irregularities, e.g. excessive roll. © Check wheel balance = Vibration felt through steering wheel may be caused by front wheel(s) out of balance. — Vibration through vehicle body may be caused by rear wheel(s) out of balance. Knee! switch ‘Checking air suspension kneel operation: AS wannwna: stop ‘only when safe to do so. © Stop the vehicle and apply handbrake. © Check that kneel switch operates to lower rear suspension only when the handbrake is applied and ignition in position I. Check that switch iluminates while suspension is lowering. © Check that suspension kneels fully, and that, knee! switch light goes out. Apply the footbrake, release the handbrake {ignition in position Il) and check that suspension retums to correct ride height. Body ‘© Listen for abnormal body noises ~ rattles, exhaust system blowing or fouling. E3. (CHECK OPERATION OF ALL INSTRUMENTS AND CONTROLS. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months Check speedometer for steady operation, and without noise. Check mileage recorder operates correctly. (D0 NOT ZERO TRIP METER). Check that all instruments and gauges operate correctly, and respond to changing conditions. e.g. Temperature gauge moves from ’cold’ to ‘normat' position, and fuel gauge registers a fuel level. ‘© Iftachometer is fitted, ensure engine speed indication rises and falls with throttle operation (engine running).F AFTER ROAD TEST WARNING: Certain e¢ hot after road test. Refit protection items removed earlier. mponents will be FA. RE-CHECK TENSION OF ANY EXTERNAL DRIVE BELTS WHICH HAVE BEEN RENEWED AND Interval: Every 12,000 miles/12 months RE-ADJUST IF NECESSARY. © Check belt tensions as detailed in operation DS and re-adiust if necessary. F2. COMPLETE REPORT ON ta PROINGS. Interval: First 1,000 miles/1 month Every 12,000 miles/12 months © Record any findings not already entered, and report any additional work required. Remove protection kit from seats, doors, footwells ete. © Wipe clean: = Steering wheel. = Gearlever. = Handbrake grip. = Door handles, window winders. = Excess oil from door hinges et. ADDITIONAL OPERATIONS TO BE CARRIED OUT AT THE SPECIFIED INTERVAL. G EVERY 2 YEARS OR EVERY 72,000 MILES (whichever occurs first) ai. RENEW ANTI-FREEZE. Ut Interval: Every 2 years/72,000 miles AA\\A\ MAL XUD9A coolant drain and refillH_ EVERY 2 YEARS OR EVERY 24,000 MILES (whichever occurs first) Ht. RENEW BRAKE FLUID ENET coolant drain and refill Position container to collect coolant. Remove pressure relief cap (1). Disconnect bottom hose (2) from radiator. ‘On EN/ET engines remove cylinder block drain plug (3) and discard sealing washer (4). Allow coolant to drain. © Flush system through with water. * Connect bottom hose. (On EN/ET engines fit cylinder block drain plug using new sealing washer. © CAUTION: Use only LDV approved special antifreeze. Prepare coolant solution: 50% water 50% antifreeze © Fill system with coolant until expansion tank is half ful, © Squeeze bottom hose to expel air, and top up as necessary, © Fitpressure relief cap. ‘© Run engine until normal operating temperature is reached. ‘© Stop engine, allow system to cool. © Top up expansion tank to correct level. © Ensure that anti-freeze renewal is recorded in the customer's ‘Operator Information and ‘Service Record’ book. 46 ori Interval: Every 2 years/72,000 miles Tool required: Pressure bleeder © Use an approved brake pressure bleeder, and bleed the brakes in the same sequence as. described below. Single Line System (Front / Rear Split) 1. Top up master cylinder reservoir with recommended fiuid. Connect pressure bleeder (if available), 2, Attach bleed tube to bleed screw on rear brake furthest from master cylinder. Immerse ‘tube end in brake fluid in suitable container. 3a. If using pressure bleeder, open bleed screw and allow brake fluid to flow until clean fluid is seen, Tighten bleed screw. 3b. If pressure bleeder not available, with aid of assistant, open bleed screw haif tun, press brake pedal slowly through full stroke. Close bleed screw and allow pedal to return slowly. Continue sequence until clean fluid is seen, and tighten bleed screw at end of downward stroke. NOTE: Ensure sufficient fluid is maintained in master cylinder at all times. 4, Repeat operations 2 and 3 at other rear brake.5. Repeat operations 2 and3 at bleed screwon 2. each front caliper, starting with caliper furthest from master cylinder. NOTE: If dificulty experienced in bleeding front brakes satisfactorily, remove rubber dust cover from delay vaive (if fitted) and depress plunger for duration of caliper bleeding procedure. 6. Remove pressure bleeder (if used); top-up brake master cylinder. 7. Start engine to make brake servo operational. 3, Apply pressure to brake pedal several times, checking for firmness of pedal. 4 8. Check hydraulic system for leaks. 9. During road test, check pedal travel which should be short and feel solid, with no indication of 'sponginess’. The vehicle should 6. pull up squarely, 10. Ensure that brake fluid renewal is recorded in the customer's ‘Operator Information and 7. Service Record’ book. 8 Dual Front Line System (HI Split) 1. Bleed rear brakes as instructed in ‘Single Line System (Front/Rear Spit)’, operations 1 to 4. 8. Bleeding front brakes — Dual front line system ‘At front brakes, 2 bleed tubes are required. Start at caliper furthest from master cylinder and attach tubes to the two lower screws ’B' and’'C’. Slacken both screws at same time to bleed as previousty described, tightening both when clean fluid is seen. NOTE: If difficulty experienced in bleeding front brakes satisfactorily, remove rubber dust cover from delay valves (i fitted) and depress plungers for duration of caliper bleeding procedure. Bleed upper screw ‘A’ on same caliper. Repeat operations 2 and 3 on opposite caliper. Remove pressure bleeder (if used); top-up brake master cylinder. ‘Start engine to make brake servo operational. Apply pressure to brake pedal several times, checking for firmness of pedal. Check hydraulic system for leaks. During road test, check pedal travel should be short and feel solid, with no indication of ‘sponginess’. The vehicle should pull up squarely. Ensure that brake fluid renewal is recorded in the customer's ‘Operator Information and Service Record’ book. 47He, RENEW AIR CLEANER ELEMENT Interval: Every 24,000 miles/2 years XUDS9A air cleaner ‘To renew XUDSA air cleaner element: Release toggle catches (1) and remove cover @). Discard used element (3) and clean container and cover. Fit new element and refit cover. Ensure air ducts are connected correctly and hoses are in good condition. ENET air cleaner To renew EN/ET air cleaner element: Detach air intake duct (1) at air cleaner. Release 3 rubber straps (2) securing filter container (3) and lift container clear. Release 3 clips (4) to remove container base, and withdraw and discard used element (5). Clean container and base. Fit new element, open end into container first. Refit container base and secure with clips. Refit container and secure with straps. Refft air duct#3. (CONVOY ENET ENGINE ONLY). CHECK/ADJUST VALVE CLEARANCES Interval: Every 24,000 miles/2 years Adjusting vaive clearance 1. Feeler gauge 2. Locknut 3. Adjustment screw © Remove rocker cover. © Check each valve clearance as follows: = Tum the engine until No.4 cylinder (nearest the timing cover) inlet and exhaust valves are ‘on the rock’ No.1 valve (nearest flywheel) No.2 valve No.4 valve No.6 valve = Tum the engine unti! No.1 cylinder intet and exhaust valves are ‘on the rock’ Check clearances: No.8 valve No.7 valve No.5 valve No.3 valve ~ Insert a feeler gauge between the valve rocker arm and the valve stem. The ‘gauge (1) should be a sliding fit. iSy Valve clearances (cold): Inlet valves 0,15 mm (0.006 in) Exhaust valves 0,25 mm (0.010 in) Adjust © Slacken adjusting screw locknut (2) © Rotate screw (3) clockwise to decrease or anti-clockwise to increase clearance. ¢ Re-tighten locknut when clearance is correct, holding screw against rotation with screwdriver, © Re-check clearance. © Clean rocker cover sealing surfaces and examine seal bead for damage. Repair or renew seal if necessary. ‘© Fitrocker cover. Progressively tighten nuts to.4 Nm (3 Ibf ft). Do not over-tighten. 49area J EVERY 4 YEARS OR EVERY 48,000 MILES (whichever occurs first) at. (PILOT ONLY) RENEW CAMSHAFT DRIVE BELT. Interval: Every 48,000 miles/4 years XUDSA engine only Tools requit (0480066, LDV 102, LDV 104. 1. Disconnect battery, negative (earth) terminal first. 2. Detach intake air duct. 3. Drain coolant, and disconnect radiator hoses. and cables to fans. 4, Remove radiator grille, bonnet locking platform and radiator complete with fans. Remove external drive belts. 6. Restrain crankshatt from tuming (flywheel locking tool LDV 102 can be used), and remove crankshaft damper. 50 ‘Camshaft pulley Fuel injection pump pulley Idler roller Water pump pulley 1 2 3 4. Crankshaft pulley 5. 6. Timing belt tensioner roller Remove timing belt inspection plate and 3-part timing covers.Fitting timing pin and timing bolts 1. Flywheel timing pin LDV 104, 2. Camshaft timing bolt. 3. Injection pump timing bolts. Tum crankshatt clockwise until no.4 cylinder (front of engine) is at TDC fring position. Fit timing pin LDV 104 in flywheel location. Fit suitable length MB bolts in camshaft pulley {and fue! injection pump pulley timing holes, finger tight onty. Releasing timing belt tension 1. Tensioner securing bolt 2. Tensioner roller 3. Tensioner securing nut Siacken belt tensioner securing nut and bott. Release bett tension by pulling tensioner roller fully away from camshaft drive belt against spring pressure, and tighten securing bolt. NOTE: A square drive hole is provided in tensioner bracket to facilitate this. ‘Check that tensioner plunger can move freely in its bore. 10. Remove camshatt drive belt. CAUTION: 1 2 a Uniess instructed, do not turn camshaft or crankshaft when drive belt is not fitted. Hold belt is contaminated, all pulleys must be cleaned. Do not contaminate pulleys when handling them. 51Timing pulleys ‘Crankshaft pulley Idler roller Fuel injection pump pulley Camshaft puiley Tensioner assembly Water pump pulley eosene 11. Fitrnew drive belt as follows, ensuring that printing on belt can be read from the front. To fitbel, start at crankshaft pulley then fit round the other pulleys in the following sequence, keeping its run taut. © Crankshaft pulley Idler rolier Fuel injection pump pulley ‘Camshaft pulley Tensioner roliet © Water pump pulley. 12, Remove timing bolts and flywheel timing pin LDV 104. Timing belt adjuster 13 14. 1, Tensioner bolt 2. Tensioner nut Slacken tensioner securing bolt and nut by two tums, and allow spring and plunger to sel-tension drive belt. Temporarily tighten bolt and nut. Fit lower timing cover. Fit crankshaft damper, and tighten securing bolt finger tight.18, Fitting timing pin and timing bolts 1. Flywheel timing pin LDV 104. 2. Camshaft timing bott 3. Injection pump timing bolts. 19. 18. Tum crankshaft clockwise 7 complete tums, then continue tuming unt flywheel timing pin LDV 104 can be fitted, together with camshaft and injection pump timing bolts. NOTE: Ifitis not possible to fit ll timing pins bolts, timing belt fiting procedure has not been carried out correctly and must be repeated. NOTE: Do not turn crankshaft anti-clockwise. 7. Sy Slacken tensioner nut and bolt by two tums, and allow spring and plunger to re-tension camshaft drive belt. Then tighten bolt and nut to correct torque. Remove camshaft and fue! injection pump timing bolts, and the flywheel timing pin LDV Tightening crankshaft damper ‘Secure crankshaft damper as follows: ‘© Fit flywheel locking tool LDV 102. © Carefully degrease and clean bolt threads, bolt head, bearing faces of ‘washer and threaded hole in crankshaft. Coat bolt threads with Loctite 270. ‘Torque tighten bolt to 40 Nm (30 Ibf ft). Tighten bott a further 60°. Remove flywheel locking tool. Check fue! injection pump timing as follows: NOTE: This requirement oniy applies at this stage if timing is being checked statically (for greatest accuracy). If timing is to be checked dynamically, fuel injection pump will have remained in such a position to enable engine to be started, and dynamic check can then be made with engine running. 53Fuel injection pump timing setting NOTE: Every pump is individually timed, Timing setting is marked on label (A) on pump body, and also on plate (B) attached to throttle lever. Fuel injection pump 1. Threaded plug 2. Timing connector 20. Thoroughly clean top of fue! injection pump. Remove threaded plug 't' to gain access to timing hole in timing connector 2’. Timing pin fitted 1. Timing pin of tool 0480066 21. Insert into timing connector the timing pin from tool 0480066. 22. Ensure engine is positioned with no.4 cylinder at TDC firing position; check using camshaft and fuel injection pump timing bolts and ‘lywheel timing pin if necessary. Then remove bolts and pin, 23. Observe timing pin 0480066, and tum crankshaft anti-clockwise until pin bottoms ‘on timing connector. OA Timing too! fitted 1. Dial gauge 2, 0480066 bracket 3. 0480066 timing pin \24. Fit bracket of tool 0480066 to connector so that one arm of tool crank rests on pin already fitted 25. Fit flat stylus from tool 0480086 to dial gauge and fit dial gauge to bracket, pushing gauge in until it is pre-loaded by approximately 1 mm before tightening clamping screw. Dial gauge reading (Example 'B’) In example *B’, gauge reading is now 7,74 mm. Subtract from this figure example reading previously noted (1,00 mm, example 'A), and result is 6,74 mm. Compare this result with figure marked on pump. Dial gauge reading (Example 'A) Hf they are the same, timing is correct, 26. Zero gauge, and note position of small In example being checked, correct setting is pointer (see example ‘A’) 6,51 mm and therefore must be adjusted as follows. 27. 104 can be fitted in flywheel, noting movement of gauge needles, and in particular recording the reading when timing pin is fitted.Slackening fuel injector pipes 28, 29. 30. 56 Slacken 4 fuel injector pipes at pump, making sure each union is restrained trom ‘turning while its nut is slackened. Slacken injector pump rear mounting and 3 flange fixings at front. ‘Turn pump away from engine as far as adjustment slots will allow. Timing figure, and gauge reading (Example) 31. Slowiy turn pump towards engine until required gauge reading of 6,51 mm (7.51 - 1.00 mm) is obtained. Tighten 3 pump flange nuts. The adjustment just made must be checked as follows: ¢ Remove flywheel timing pin LDV 104. © Tum engine anti-clockwise until timing pin of tool 0480066 bottoms in timing connector, Check that dial gauge has retumed to previously zeroed position. If incorrect, re-set pre-load as in operation 26. © Tum engine clockwise unti timing pin LDV 104 can be fitted in flywheel. © Check that gauge reads correct timing figure, in our example 6,51 mm (7,51 - 1,00 mm). © Itincorrect, continue to readjust pump and recheck until correct timing position33, 36. 40 a 42. 47. Tighten pump rear mounting, Remove dial gauge, and bracket and timing Pin of too! 0480066. ‘Check that '0" ring is in good condition before re-fitting plug in timing connector. Do NOT overtighten plug. Tighten injector pipe nuts, while restraining Unions. Remove flywheel timing pin LDV 104. Fit upper timing covers and belt inspection plate. Fit extemal drive belts and adjust to correct, tension. Fit radiator, re-connect all hoses and fan cables. Fit bonnet locking platform and radiator grille. Fit intake air duct. Refill with coolant (50% anti-freeze) to correct level. Re-connect battery, positive terminal first. Start engine and run until normal operating temperature is reached. Check coolant level and top up as necessary. WARNING: PLACE THICK CLOTH OVER CAP AND EXPANSION TANK BEFORE ATTEMPTING TO REMOVE CAP SLOWLY, TO AVOID POSSIBILITY OF SCALDING IF ENGINE IS HOT. ‘Check / adjust fuel injection pump timing dynamically (if not already checked / adjusted statically). Ensure that camshatt drive belt renewal is recorded in the customer's ‘Operator Information and Service Record’ book. K j Sy REPORT ADDITIONAL WORK REQUIRED Enter the operation number(s) being referred to, and state clearly the work required. IS THIS VEHICLE SUBJECT TO ANY OUTSTANDING SERVICE ACTION/RECALLS. IF YES PLEASE ACTION. Any outstanding actions/recalls can be identified by a chassis enquiry on Vanscan. ‘This information is available at LDV Dealerships.