SCHEDULED MAINTENANCE

(Diesel Engined Vehicles)

SERVICE WORKBOOK
This Service Workbook covers the service procedure specified for maintaining Diesel
engined LDV Convoy and Pilot vehicles (Stage 3) 2002 on. 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.

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 behalf any obligation
expressed or implied.

COPYRIGHT
 LDV 2002
All rights reserved. No part of this 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.

LDV Limited
Training & Publications
Bromford House
Drews Lane
Birmingham
B8 2QG
Part Number MVP108201GB Oct 2002
CONTENTS

Introduction
Aim of Workbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake preventative maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque wrench settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service maintenance procedure

Dealer checks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– Inside vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– On lift, wheel free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– On raised lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
– On lowered lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
– Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
– After road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
– Additional operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pilot, Convoy (Stage 3) 2002 On Introduction

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 Diesel Models Service Job Sheet part number MVP104701GB.

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 Convoy vehicles with
Duratorq engines and Pilot vehicles with DW8 engines.

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:

WARNING: 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 MVP104701GB.

A symbol such as this is shown at each Scheduled Maintenance operation

to indicate the position of the vehicle on or off the hoist.

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 Pilot, Convoy (Stage 3) 2002 On Introduction

REPAIRS AND REPLACEMENTS

When replacement parts are required, it is essential that only genuine LDV Parts are
used.

HEALTH AND SAFETY

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 lift.
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 turning / 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
recommendations:

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 over–use 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.

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Pilot, Convoy (Stage 3) 2002 On Introduction

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
return (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).
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.

Turbo engines – Do not run the engine above idle speed for approximately 30 seconds
after 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 it is slowing down.
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 returned to their respective retaining clips.

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 Pilot, Convoy (Stage 3) 2002 On Introduction

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.
• Vehicle lift with wheel–free facility
• Lead lamp (low voltage)
• Torque meters (dial indicator type preferred)
• Grease gun
• Tyre pressure gauge
• Tyre tread depth gauge
• Equipment for draining and dispensing oils / antifreeze
• Oil can
• Mirrors for checking exterior light operation
• Refractometer (for antifreeze and brake fluid checks)
• Component washing equipment
• Dial gauge
• Rule
• Spring balance
• Specified special service tools
• Health & safety approved brake cleaning equipment.
• Brake pressure bleeder
• Laser 2000
• Brake fluid tester

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Pilot, Convoy (Stage 3) 2002 On Introduction

LUBRICANT SPECIFICATIONS
It is essential that correctly specified oil, grease and fluids are used at all times.

Diesel engine, Oil can

Must meet the following minimum specifications
Pilot – ACEA B3, SAE 5W/30 or SAE 10W/30
Convoy – Ford WSS–M2C913–A or WSS–M2C913–B

Gearbox
Pilot – MTF 94
Convoy – Ford WSD–M2C200–C

Rear axle
Pilot – MIL–L–2105C or API GL 5 SAE 90 to VIN 089567
Super 90 TS from VIN 089568
Convoy – Super 90 TS

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.

Front hub bearings

– EP2 lithium Complex Grease
– LDV Part no. HBU6656

Rear hubs
– Multipurpose Lithium L2 grease

Crew cab door hinges, Locks/Strikers, Underfloor spare wheel carrier

– Multipurpose grease

Brake and Clutch fluid

– FMVSS 116 DOT 4.

Antifreeze
– LDV Part no. LBU 6577 (1 litre can)
LBU 6578 (5 litre can)

SEALANTS
Loctite 242
Loctite 270

5
 Pilot, Convoy (Stage 3) 2002 On Introduction

DATA

Capacities
Engine DW8 (Pilot) 4.75 litres
2.4l Duratorq 75PS Turbo (Convoy) 7.0 litres
2.4l Duratorq 90PS Turbo Convoy) 7.0 litres

Coolant DW8 (Pilot) 10.6 litres

2.4l Duratorq 75PS Turbo (Convoy) 9.0 litres
2.4l Duratorq 90PS Turbo (Convoy) 9.0 litres

Gearbox R380 (Pilot) 2,4 litres

MT 75 Single rail (Convoy) 1,3 litres

Rear axle Pilot ‘C’ type axle 1.9 litres

M226 axle 2.4 litres
Convoy 2.4 litres

Steering Power steering 1.5 litres

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

Convoy – Parallel to 1,6 mm toe in

Front hub bearing end float 0,05 to 0,13 mm

Handbrake adjustment 2 to 5 clicks – when pull of 10 to 20 kg is applied

to handbrake.

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Pilot, Convoy (Stage 3) 2002 On Introduction

Tyre pressures
NOTE: Refer to the vehicle identification plate for max. GVW and plated axle weights.
GVW TYRE SIZE FRONT REAR
Pilot
2175 kg 185 – 14R 2,6 bar 2,8 bar
2350 kg 185 – 14R 2,8 bar 3,1 bar
2550 kg 185 – 14C 6 PR 2,9 bar 3,7 bar
2550 kg (Crew Cab) 185 – 14C 6 PR 3,1 bar 3,7 bar
2800 kg 185 – 14C 8 PR 3,3 bar 4,5 bar
Convoy
2850 kg 205 – 14C 6 PR 2,7 bar 3,6 bar
3100 kg 205 – 14C 8 PR 2,7 bar 4,4 bar
3100 kg (Ambulance/ Crewbus) 185 – 14C 6 PR 3,2 bar 3,5 bar **
3300 kg (Minibus) 185 – 14C 6 PR 3,0 bar 3,2 bar **
3500 kg 185 – 14C 6 PR 3,2 bar 3,5 bar **
3500 kg (Crew Cab) 185 – 14C 6 PR 3,6 bar 3,5 bar **
3740 kg (Cowl) 185 – 14C 8 PR 3,5 bar 3,5 bar **
3850 kg (Police Bus) 185 – 14C 8 PR 4,1 bar 3,7 bar **
3850 kg (Minibus) 185 – 14C 6 PR 3,6 bar 3,7 bar **
4100 kg (PSV Cowl) 185 – 14C 8 PR 3,6 bar 3,7 bar **
** = with twin rear wheels.

DW8 engine
Idle speed 800 ± 25 rpm
Alternator/Power steering pump drive belt tension Fully automatic adjustment
Vacuum pump drive belt tension 6 mm deflection at centre point of
longest belt run
Valve clearances (cold):
inlet 0,15 ± 0,07 mm
exhaust 0,30 ± 0,07 mm
Fuel injection timing: Fully electronic
Heater plugs
Type Beru
Voltage 11 volts

2.4l Duratorq engines

Idle speed 750 rpm
External drive belt tension: Fully automatic adjustment
Valve clearances Hydraulic tappets
Fuel injection timing: Fully electronic
Heater plugs
Type Champion
Voltage 11 volts
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 Pilot, Convoy (Stage 3) 2002 On Introduction

BRAKE PREVENTATIVE MAINTENANCE

In addition to the recommended periodical inspection of brake components it is
advisable. As the vehicle ages and as a precaution against the effects of wear and tear
and deterioration, it is necessary to make a more searching inspection and renew parts
as necessary.
It is recommended that:

• Disc brake pads, drum brake linings, hoses and pipes should be examined at
intervals no greater than those laid down in Scheduled maintenance.
• All fluid seals in the hydraulic system and all flexible hoses should be renewed
every 4 years or at the Scheduled Service nearest to 100,000 miles (160,000
kilometres) whichever occurs first.
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 4 years or at
the Scheduled Service nearest to 100,000 miles (160,000 km) whichever is
the sooner.

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Pilot, Convoy (Stage 3) 2002 On Introduction

TORQUE WRENCH SETTINGS

Component Nm

Pilot models
Front spring ‘U’ bolt nuts 68–92
Rear spring ‘U’ bolt nuts 58–79

Road wheel nuts 68–92

Steering wheel nut 46–62

Gearbox filler/level plug 25–35

Rear axle filler/level plug 27–34

DW8 engine
Exhaust manifold nuts 30
Inlet manifold Central screw 15
Nuts 22.5–27.5
Camshaft bearing cap nuts 20
Camshaft pulley hub bolt 45
Camshaft pulley bolts 23
Camshaft cover bolts Lower cover 5
Upper cover pre–tighten 8
tighten 50°
Timing belt tensioner bolt 19–23
Fuel injection pump pulley bolts 23
Crankshaft damper bolts 10
Heater plugs 12
Sump plug 25

Convoy models
Front spring ‘U’ bolt nuts 75–95
Rear spring ‘U’ bolt nuts: 129–141
Air suspension flexi–link ‘U’ bolt nuts 183–197

Road wheel nuts – Single wheel axle 176–227

– Twin wheel axle 230–280
Steering wheel nut 46–62

Gearbox filler/level plug 25–30

Rear axle filler/level plug 20–28

2.4l Duratorq engines

Camshaft cover bolts 10
Manifold bolts 20–25
Turbocharger to manifold bolts 50–60
Sump plug 24

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 Pilot, Convoy (Stage 3) 2002 On Introduction

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Pilot, Convoy (Stage 3) Maintenance Procedure
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:
Pilot vehicles
10,000 miles, 16,000 km or 1 year*
Convoy vehicles
15,000 miles, 25,000 km or 1 year*
* Whichever occurs first.
Service Records
It is most important that the relevant
service records in the vehicle’s Operator
Information and Service Record Book are
completed and stamped to confirm:
• Completion of appropriate
Scheduled Services.
• Antifreeze renewal
• Brake fluid renewal
• Timing belt renewal (Pilot)
• External drive belt(s) renewal
• Anti–corrosion & cosmetic
paintwork warranty inspection
Service records
11
 Pilot, Convoy (Stage 3)
Fit vehicle protection kit.
A INSIDE VEHICLE
Drive vehicle on to lift, stop engine.
While placing vehicle in position:
• Check that low oil pressure warning
light and ignition/no charge warning
light extinguish while engine is
running.
A1 CHECK CONDITION,
SECURITY AND OPERATION
OF ALL SEATS, SEAT BELTS,
AND MIRRORS.
A102-021
1
2 •
3
A102-022
Checking seat security
12
Maintenance Procedure
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).
Minibus/Crew cab
• Check all passengers’ seats security
by rocking vigorously.
A102-025
Checking seat belt
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.
Minibus/Crew cab
• Check all passengers’ seat belts as
above.
Rear view mirrors:
• Check interior and exterior mirrors for
cracks, damage and security.
Pilot, Convoy (Stage 3) Maintenance Procedure

A2. CHECK OPERATION OF ALL

LAMPS, INDICATOR
SWITCHES AND HORN.

Lights
2

080802
1
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.
080801 Check main beam warning light is on.
Column switch – lights Reset switch to dip beam position and
• With ignition off, turn rotary light switch off headlights.
switch to position ‘1’. • Flick lever towards steering wheel
Check that the following illumination is and check headlights flash.
on:
Instrument panel
Console switches
Heater controls
All sidelights
Both number plate lights TRIP ODO

Radio
• With ignition on (position ‘II’):
– Check both brake lights
operate when brake pedal
depressed.
– Check that both headlights
illuminate in dim dip mode.

• Turn rotary switch to position ‘2’ and

check both headlights illuminate to
normal intensity.
A102-015
Direction indicators
• Move lever down and check that all
left hand direction indicator lights and
left hand warning light on instrument
pack flash correctly.

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 Pilot, Convoy (Stage 3) Maintenance Procedure

• Move lever up and check right–hand

direction indicators and righthand
warning light on instrument pack flash
correctly.
• Engage reverse gear and check both
reverse lights operate. Return gear
lever to neutral.

080807

Rear fog lights switch

• Turn on headlights and press rear fog
lights switch.
Check that both rear fog lights
illuminate.
Check that switch bulb glows when
rear fog lights are on.
080806
NOTE: Rear fog lights only operate when
Hazard warning switch headlights are on dipped beam.
• Press hazard warning switch on
centre console. OFF
Check that bulb in switch illuminates, 1
and that all six hazard warning lights 2
and the direction indicator lights in the 3
instrument panel flash correctly. ON
080819

Cab Light (All models except Convoy

080808
Light switch (Minibus only)
• Press light switch (Minibus only) and
check that interior lights illuminate in
passenger area.
High Roof)
To check cab light (all models except
Convoy High Roof):
• 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.

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Pilot, Convoy (Stage 3) Maintenance Procedure

Warning Lights
1 • Check that the following warning
2 lights illuminate when ignition is
3 turned on (position ‘II’):
080919 Coolant temperature (Pilot).
Cab Light (Convoy High Roof) Heater plug (Pilot). **
Heater plug engine
To check cab light (Convoy High Roof): management system light
• Move switch to position ‘1’. Check (Convoy). **
light remains on. Low oil pressure.
Handbrake and brake failure (when
• Move switch to position ‘2’. Check
light remains off when cab doors are handbrake on).
open or closed. Ignition/no charge.
Anti–lock braking system
• Move switch to position ‘3’. Check (Convoy, if fitted). **
light comes on when either cab door Engine management system
is opened. (Pilot). **
Service indicator (Convoy). **
Water trap warning (Convoy). **
** Warning light will automatically
extinguish after pre–determined time.
Turn off ignition.
If any lights remain illuminated, investigate
further.

Horn
080871

Load space light

Load Space Light (if fitted):
• Move lever anti–clockwise and check
light illuminates.

060560

Horn button
• Press horn button.
Check for loud clear blast.

15
 Pilot, Convoy (Stage 3) Maintenance Procedure

A3 CHECK OPERATION OF 3
WINDSCREEN WIPERS AND
WASHERS 2

080805

080922

Wash/wipe switch – wipe

• Turn switch to position ‘1’ and check
intermittent wipe operation.
080805
• Turn switch to position ‘2’ and check
Windscreen wipe/wash control normal wipe operation.

CAUTION; Do not operate windscreen • Turn switch to position ‘3’ and check
wipers on a dry windscreen fast wipe operation.
• Turn on ignition.
• Pull lever towards steering wheel.
– Wash/wipe 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 080804

top of wiped area.

Wash/wipe switch – intermittent wipe
(Single jets on Pilot, twin jets on
Convoy.) • Rotate intermittent wipe switch and
check that wipe delay period varies in
each position.
INT • Operate washer to lubricate screen.
Return lever to off position, allow
wipers to return to park position, turn
off ignition.
• Inspect wiper blade performance.
080921
Check / report blades for
Wash/wipe switch – single wipe deterioration, splits etc.
With ignition on, check wiper operation:
• Pull lever down and release. Check
for single wipe.

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Pilot, Convoy (Stage 3) Maintenance Procedure

Fit wing covers.

A4. OPEN BONNET, TEST BRAKE

FLUID.

Tool required; Refractometer

040851

Testing brake fluid

CAUTION: Do not allow dirt to enter

brake master cylinder.

CAUTION: Do not allow brake fluid to

contact paint finished surfaces.
• Wipe clean area around brake master
cylinder filler cap.
Remove cap.
Place a drop of brake fluid on the
refractometer and measure its
concentration in accordance with
refractometer manufacturer’s
instructions.
• Record results on job sheet.

17
 Pilot, Convoy (Stage 3) Maintenance Procedure

B ON LIFT, WHEEL FREE – Turn each wheel from lock to

CAUTION: On vehicles fitted with air
suspension, the rear axle must remain
supported in the wheel–free condition.
Raise lift to convenient working height.
B1. CHECK SWIVEL PINS FOR
WEAR AND REPORT.
LUBRICATE.
lock and check for smooth,
rotating action of swivel pin. Any
restriction to smooth action
would indicate worn or damaged
bearing(s).
– Rock and lift each front wheel in
turn in vertical plane. Check
swivel pins for excessive play
and for excessive lift.
Adjust / overhaul if lift is greater
than 0,38 mm and / or if rock
(measured at wheel rim) is
greater than 2,0 mm.
NOTE: After re–adjustment,
correct lift tolerance should be
0,05 to 0,20 mm. Rock is
non–adjustable; it is governed
by the manufacturing tolerance
of new swivel pins and bearings.
If rock greater than 2,0 mm is
found, then the swivel pin and
bearings must be overhauled.

• Report wear condition.

020154
Swivel pin grease nipples
Checking swivel pin wear
• Lubricate both grease nipples on
each swivel with the correctly
• Check wear condition of both swivel specified grease.
pins as follows: NOTE: Molybdenum grease must be
used.
– With the aid of an assistant, CAUTION: Wipe off any excess
apply footbrake to eliminate front grease to prevent brake disc / pad
hub bearing end float.
contamination.

18
Pilot, Convoy (Stage 3) Maintenance Procedure
B2. CHECK FRONT WHEEL
BEARING END FLOAT,
ADJUST IF NECESSARY.
• 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
• If either end float is excessive, adjust
as follows:
Adjusting front hub end float
Tools required: 0480048 (18G 191),
0 to 10 Nm torque wrench.
Remove dust cap, hub nut split pin
and nut retainer.
A Use torque wrench to tighten hub nut
to 7 Nm.
NOTE: Spin hub whilst tightening nut.
B Slacken nut without disturbing hub.
C 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 split
pin hole is fully exposed.
F Fit new split pin and refit dust cap.
G Check that end float is correct using
dial gauge 0480048 (18G191).
Repeat procedure if correct figure is
not attained.
19
 Pilot, Convoy (Stage 3)
Repeat operations B3 to B5 working on
one wheel at a time.
B3. REMOVE ROAD WHEELS
INCLUDING SPARE, INSPECT
WHEELS & TYRES FOR
DAMAGE / UNEVEN TREAD
WEAR. RECORD TREAD
DEPTHS.
Tool required : Tyre depth gauge
• Remove wheel trims (if 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 wheel
• Check stud locations for ovality
(indicates loose wheel nuts).
• Inspect wheels for cracks/ damage.
Damage to rim could be caused by
‘kerbing’ which in turn could distort
wheel and cause tyre run–out/wear
etc.
Severe ‘kerbing’ could affect steering
geometry.
20
Maintenance Procedure
• 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 pattern. 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,
– worn 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.
Pilot, Convoy (Stage 3) Maintenance Procedure
B4. VISUALLY INSPECT BRAKE
PADS FOR WEAR AND DISCS
FOR CONDITION. CHECK
FOR HYDRAULIC LEAKS
AND REPORT. RENEW PADS
IF NECESSARY.
070405
Inspection of brake pad thickness
• Inspect thickness of brake pads.
– If one pad is more worn than the
other, check for piston seizure
etc.
– If any pad thickness is 3 mm or
less, all pads must be renewed
to maintain vehicle safety.
(Overhaul details in workbook
‘Suspension, Steering, Brakes’).
– Report if 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.
B5. REMOVE BRAKE DRUMS,
WASH OUT DUST, INSPECT
LININGS AND DRUMS FOR
WEAR. CHECK FOR
HYDRAULIC LEAKS AND
REPORT. RENEW SHOES IF
NECESSARY.
REFIT DRUMS.
Inspection of brake lining thickness
• Remove brake drums and wash out
dust with brake cleaner solution.
WARNING: Current
production brake linings are
asbestos free, but care should be
taken not to inhale brake dust.
• Inspect brake linings for:
– Damage/contamination
– Thickness – minimum 1,5 mm.
• 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 four if any lining is too thin or
contaminated. (Overhaul details in
workbook ‘Suspension, Steering,
Brakes’).
21
 Pilot, Convoy (Stage 3) Maintenance Procedure

• Inspect drums for damage or • Temporarily raise/lower lift platform to

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.
restrain road wheels. Tighten wheel
nuts in the sequence shown in
illustration and to correct torque.
• Refit wheel trims (if fitted).
• Lubricate underfloor spare wheel
carrier with multipurpose grease (if
fitted).
• Refit spare wheel when lift position
allows convenient access.

B6. REFIT WHEELS AND B7. ADJUST TYRE PRESSURES.

TIGHTEN USING TORQUE
WRENCH.

Tool required: 0–350 Nm torque wrench • Check/adjust all tyre pressures,

• Refit road wheels, aligning correlation including spare wheel.
marks made before removal. NOTE: Adjust spare tyre to the
higher pressure.
• If pressure excessively low, check for
signs of puncture/damage.
1
NOTE: To establish correct tyre
3 4
pressures, refer to the vehicle
identification plate for max. GVW and
5 2 plated axle weights, and then identify
pressures in ‘Data’ or on ‘Forecourt
Data’ card provided with Driver’s
010205
Handbook literature.
5–stud wheel nut tightening sequence (Early models – on rear cover of
Driver’s Handbook).

6 1

3
4
5
2

010206

6–stud wheel nut tightening sequence

22
Pilot, Convoy (Stage 3) Maintenance Procedure

C ON RAISED LIFT • Use special tool LDV 179 (2) to

unscrew filter cover.
Raise lift fully • Discard the filter element and the
cover ‘O’ ring.
C1. DRAIN ENGINE OIL AND • Clean out the cover and its location in
RENEW FILTER. REPORT the cooler housing.
LEAKS

Duratorq engine

A126-004

A148-018
Oil filter
Sump drain plug 1. Filter element
• Place container beneath engine. 2. ‘O’ ring
• Remove drain plug and drain oil
• Leave to drain. • Fit new ‘O’ ring (2) onto cover.
• Examine engine for leaks, and report • Fit the new element into cover with its
as necessary. tangs, (arrowed) downwards i.e. into
the cover).
• Tighten the cover into the housing.
• Tighten the filter drain plug.
• Clean off any spilt oil.
2

1 A106-137

Removing oil filter cover

1. Filter drain plug
2. Tool LDV 179
• Clean area around filter head.
• Position oil drain tray under oil filter.
• Unscrew filter drain plug (1) until oil
drains out.

NOTE: Filter drain plug deleted on

later vehicles.
23
 Pilot, Convoy (Stage 3) Maintenance Procedure

DW8 Engine C2. CHECK/TOP UP GEARBOX

OIL LEVEL. REPORT LEAKS.

A126-002

Sump drain plug

• Place container beneath engine.
• Remove drain plug and drain oil.
• Leave to drain.
• Examine engine for leaks, and report 050612
as necessary.
Oil level check – R380 gearbox

040850 050722

Renewing oil filter cartridge Oil level check – MT 75 gearbox

1. Oil filter cartridge
2. Oil seal
• Clean area around filter head.
• Position oil drain receptacle.
• Unscrew and discard oil filter
cartridge (2).
• Smear seal (1) of new cartridge with
clean engine oil.
• Screw cartridge into position using
hand force only.
• Clean off any spilt oil.

• Refit drain plug using new

washer/gasket, and tighten to the
correct torque.
24
Pilot, Convoy (Stage 3) Maintenance Procedure

NOTE: This check must be made with C3. CHECK/TOP UP REAR AXLE
vehicle level. OIL LEVEL. REPORT LEAKS.
• Wipe clean area around oil filler/level
plug, remove plug and discard
washer.
Check oil level which should be at
bottom of aperture threads. Pilot Vehicles
Top up with correctly specified new oil
if necessary (see ‘Lubricant
Specifications’).
Refit plug and tighten to correct
torque.
NOTE – R380 Gearbox. Before
fitting, ensure adequate
sealant remains on plug
threads. If not clean off and
apply Loctite 242.

• Report any leaks.

Oil level check – Pilot rear axle

(‘C’ type axle illustrated)
1. Oil filler/level plug
2. Aperture threads

NOTE: This check must be made with

vehicle level.
• Wipe clean area around oil filler/level
plug (1) and remove plug.
Check oil level which should be at
bottom of aperture threads (2).
Top up with correctly specified new oil
if necessary (see ‘Lubricant
Specifications’).
Refit plug and tighten to correct
torque (do not overtighten).
• Report any leaks.

NOTE: ‘C’ type axle superseded by M226

axle at VIN 089568.

25
 Pilot, Convoy (Stage 3)
Convoy Vehicles
2 AND LINES FOR SECURITY,
1
A148-018
Oil level check – Convoy rear axle
NOTE: This check must be made with
vehicle level.
• Wipe clean area around oil filler/level
plug (1) and remove plug.
• Top up with correctly specified new oil
if necessary (see ‘Lubricant
Specifications’).
• Refit plug and tighten to correct
torque (do not overtighten).
• Report any leaks.
26
Maintenance Procedure
C4. CHECK VISUALLY ALL FUEL,
HYDRAULIC AND AIR PIPES
CHAFING, CRACKS, LEAKS,
CORROSION.
Fuel pipe(s)
Visually inspect fuel pipes:
• Check clipped securely.
• No possibility of chafing against other
pipes, chassis etc. Check that
chassis grommets through which
pipes pass are correctly located.
• No cracks or corrosion.
• No leaks at unions.
Pilot, Convoy (Stage 3) Maintenance Procedure

A126-003

Clutch slave cylinder (Convoy models)

• Visually examine clutch slave cylinder
070495
and unions for leakage.
• Check hydraulic pipe for chafing,
Brake pipe cracks, security and corrosion.
Visually inspect brake pipes and hoses: Check that lock clip is secure.
• Check clipped securely.
• No leaks at unions or along pipe runs.
• No chafing 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.
010324

Air suspension harness

Models with air suspension.
• Visually inspect harness/pipes for
correct routing and security in clips.
• Ensure pipes cannot chafe.
• Check pipe security at each
connector.
• Check that chassis grommets through
which pipes pass are correctly
located.
Clutch slave cylinder (Pilot models)

27
 Pilot, Convoy (Stage 3) Maintenance Procedure

C5. LUBRICATE HANDBRAKE C6. CHECK SECURITY AND

EXTERNAL LINKAGE. CONDITION OF ALL
STEERING AND
SUSPENSION JOINTS,
BUSHES AND
COMPONENTS, AND ALL
SPRING ‘U’ BOLTS USING
TORQUE WRENCH.
Tool required: 0–200 Nm torque wrench

Handbrake linkage
• Lubricate handbrake linkage clevis
pins, arrowed, with engine oil.

Checking ball joint security

• Inspect following components /
bushes for signs of deterioration,
wear and free play. Visually check
tightness of securing nuts/bolts.
– Steering box (including drop arm
attachment).
– Steering damper and bushes (if
fitted).
– Drag link ball joints/gaiters.
– Steering arm attachment.
– Track rod arms attachment.
– Track rod ball joints/gaiters.
– Drop arm.
CAUTION: Always check with
engine switched off.

28
Pilot, Convoy (Stage 3) Maintenance Procedure

• 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.
• Use torque wrench to check tightness
of front and rear spring ‘U’ bolts,
including air suspension flexi link ‘U’
bolts (if fitted). See ‘Torque Wrench
Settings’ for specific torque figures.
• If air suspension fitted check:
– Flexi–links / flexi–link bushes.
– Air springs.
– Panhard rod ball joint and bush.
NOTE: Special tool LDV 137
should be used when replacing
shock absorber bushes.

C7. CHECK FOR OIL LEAKS

FROM STEERING SYSTEM.

• Visually examine steering box, pump,

connections and hoses for signs of
fluid leakage.
010274
• Check hoses for routing and chafing.
Checking shock absorber security
• Check security of steering damper (if
fitted) and shock absorber mountings
by grasping and lift / turn to check
bushes. Check steering damper
rotates with track rod.
• 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/bolts.
– Springs / spring bushes.
– Spring shackles.
– Anti–roll bar(s).
– Propshaft and joints / bearings
for wear and damage.

29
 Pilot, Convoy (Stage 3)
C8. CHECK EXHAUST SYSTEM
FOR SECURITY &
TIGHTNESS; INSPECT FOR
LEAKS AND CHECK
MOUNTINGS.
Checking exhaust mounting
WARNING: Exhaust system may
be hot; wear insulated gloves when
examining exhaust system and
mountings.
• Examine mountings for wear and
condition.
• Visually check exhaust system for
damage, corrosion or leaks.
• Check tightness of manifold, pipe
connections and mountings.
30
Maintenance Procedure
C9. RENEW BRAKE FLUID. (ABS
VEHICLES ONLY).
Tool required: Pressure bleeder
• Use an approved brake pressure
bleeder, and bleed the brakes in the
same sequence as described below.
1. Top up master cylinder reservoir with
recommended fluid. 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
half turn, 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 and 3 at bleed
screw on each front caliper, starting
with caliper furthest from master
cylinder.
6. Remove pressure bleeder (if used);
top–up brake master cylinder.
7. Start engine to make brake servo
operational. Apply pressure to brake
pedal several times, checking for
firmness of pedal.
8. Check hydraulic system for leaks.
Pilot, Convoy (Stage 3) Maintenance Procedure
9. During road test, check pedal travel
which should be short and feel solid,
with no indication of ‘sponginess’. The
vehicle should pull up squarely.
10. Ensure that brake fluid renewal is
recorded in the customer’s ‘Operator
Information and Service Record’
book.
Service record
C10. SEE A4. IF NECESSARY,
RENEW BRAKE FLUID.
(NON–ABS VEHICLES)
Tool required: Pressure bleeder
• Use an approved brake pressure
bleeder, and bleed the brakes in the
same sequence as described below.
1. Top up master cylinder reservoir with
recommended fluid. 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
half turn, 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 and 3 at bleed
screw on each front caliper, starting
with caliper furthest from master
cylinder.
NOTE: If difficulty experienced in
bleeding front brakes satisfactorily,
remove rubber dust cover from delay
valve (if fitted) and depress plunger
for duration of caliper bleeding
procedure.
(Continued ...)
31
 Pilot, Convoy (Stage 3) Maintenance Procedure

6. Remove pressure bleeder (if used);

top–up brake master cylinder.
7. Start engine to make brake servo
operational. Apply pressure to brake
pedal several times, checking for
firmness of pedal.
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 pull up squarely.
10. Ensure that brake fluid renewal is
recorded in the customer’s ‘Operator
Information and Service Record’
book.

Service record

32
Pilot, Convoy (Stage 3) Maintenance Procedure

D LOWER LIFT
Lower lift to ground.

D1. REFILL ENGINE WITH

CORRECT GRADE OIL TO
THE CORRECT LEVEL.
DO NOT OVERFILL.

1
1

A148-017

Oil filling – DW8 engine

A148-016
1. Dipstick
Oil filling – Duratorq engine
2. Oil filler cap
1. Dipstick
2. Oil filler cap
• Check vehicle is standing level.
• 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 then repeat the level checking procedure. Top up if
necessary until the level is correct.
NOTE: Quantity required to raise level from ‘MIN’ to ‘MAX’:–
DW8 1.5 litres
Duratorq 2.0 litres
CAUTION: Do not overfill.
Refit oil filler cap and check it is secure.
33
 Pilot, Convoy (Stage 3) Maintenance Procedure

D2. CHECK/TOP–UP POWER Brake and Clutch fluid

STEERING/BRAKE/ CLUTCH
AND WINDSCREEN WASHER
FLUID LEVELS.

Power Steering fluid

070457

MAX

MIN
020150

Power assisted steering reservoir

NOTE: Fluid level should be checked with 070494

engine cold and stationary. Brake master cylinder

• Wipe area clean around filler cap on
reservoir.
Remove cap and wipe dipstick blade
clean with lint free cloth or paper. MAX
Refit cap, then withdraw and check
fluid level indicated. MIN
Should be up to MAX mark.
If necessary, top up with specified
fluid (see ‘Lubricant Specifications’).
• Replace cap. MAX

MIN

070745

Brake master cylinder (ABS)

34
Pilot, Convoy (Stage 3) Maintenance Procedure

Windscreen washer fluid

050588

Clutch master cylinder

• Inspect fluid level, which should be A102-053
between MAX and MIN marks on side
of reservoirs. Pilot windscreen washer reservoir
If 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.
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. A102-007

Replace cap. Convoy windscreen washer reservoir

• Check windscreen washer reservoir
level.
• Top up if necessary with
water/proprietary screenwash
mixture.
CAUTION: Do not use denatured
alcohol (methylated spirit) as this
will discolour the paintwork.

35
 Pilot, Convoy (Stage 3) Maintenance Procedure

D3. CHECK COOLING SYSTEM,

HOSES AND CONNECTIONS
FOR LEAKS.

• 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.

A148-009

Cooling system – Convoy vehicle

36
Pilot, Convoy (Stage 3) Maintenance Procedure

KEY
VENTING
COOLANT
FLOW DIRECTION

A148-010

Cooling system – Pilot vehicle

37
 Pilot, Convoy (Stage 3) Maintenance Procedure

D4. CHECK COOLANT D5. CHECK CONDITION AND

SOLUTION STRENGTH. TOP
UP IF REQUIRED WITH
SPECIFIED ANTI–FREEZE
(50% SOLUTION). RECORD
READING BY
REFRACTOMETER ........%
Tool required: Refractometer
TENSION OF ALL EXTERNAL
DRIVE BELTS (NOT
CAMSHAFT BELT). ADJUST
OR RENEW AS NECESSARY.
• Inspect external drive belt(s) (not
camshaft drive belt) for damage,
fraying, excessive wear etc. Renew
as necessary.
• Check vacuum pump drive belt
tension as detailed, and adjust if
necessary (Pilot only).

Duratorq engine

WARNING: Do not attempt to

check belt or make belt adjustments
with engine running. Serious injury
040851
could result.
Checking antifreeze strength
2
1
WARNING: If engine is hot, place
thick cloth over cap and expansion
tank before attempting to remove cap. 3
• 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
4
instructions.
If weak, add correctly specified 5
8 7
anti–freeze until correct. 6
Use only LDV approved A106-001

anti–freeze. External drive belt, Duratorq engine

• If level low, add 50% anti–freeze 1. Power steering pump pulley
solution to level mark on side of 2. Idler pulley
expansion tank. 3. Vacuum pump pulley
4. Water pump pulley
• Record anti–freeze concentration (%) 5. Fan pulley
on job sheet. 6. Crankshaft pulley
7. Tensioner pulley
• If level is excessively low, check 8. Alternator pulley
system for cause of leakage, e.g:
– Hoses and connections.
– Radiator / expansion tank.
– Engine, internal or external
leakage.
– Heater and water valve.

38
Pilot, Convoy (Stage 3) Maintenance Procedure
A106-002
Releasing drive belt tension
The Duratorq drive belt tension is not
adjustable. If it requires renewal, proceed
as follows.
NOTE: If a fan cowl is fitted, it is first
necessary to uncouple the viscous fan
from the idler pulley.
• To remove the drive belt, insert a 3/8”
square drive into the tensioner as
illustrated. Turn counter–clockwise to
release the tension and remove the
belt.
• To fit belt, thread over all pulleys
except idler pulley.
• Insert a 3/8” square drive into the
tensioner as illustrated. Turn
counter–clockwise to release the
tension on tensioner pulley. Slip belt
over tensioner pulley. Ensure the belt
locates centrally on all the pulleys.
• Slowly release the tensioner and
remove the square drive from the
tensioner.
DW8 engine.
Vacuum pump drive belt
WARNING: Do not attempt to
check belt tension or make belt
adjustments with engine running.
Serious injury could result.
1 2
040377
Vacuum pump drive belt
1. Tensioner bracket secure nut
2. Tensioner adjustment bolt
Vacuum Pump Drive Belt.
• Apply hand pressure on belt midway
between the two pulleys, check for
6 mm (0.25 in.) belt deflection. If
necessary, adjust as follows:
• Slacken pump mounting nut/bolt.
• Slacken adjustment bracket nuts/bolts
(1 & 2).
• Pivot pump to tension belt; tighten
adjustment bracket nuts/bolts.
• Tighten pump mounting nut/bolt.
• Re–check tension and re–adjust if
necessary.
(Continued ...)
39
 Pilot, Convoy (Stage 3) Maintenance Procedure

Alternator/ power steering drive belt WARNING: Tensioner spring is

very strong. Use caution when turning
NOTE: Notches on tensioner indicated in tensioner to avoid personal injury.
illustration can be used to indicate drive
belt wear. If notch ‘A’ aligns with or has
passed notch ‘B’, this indicates that the
belt should be renewed.

Drive belt tensioner Releasing drive belt tension

The DW8 drive belt tension is not
• Use a square drive with suitable
adjustable. If it requires renewal, proceed socket to turn tensioner roller
as follows. counter–clockwise and secure in
Remove vacuum pump drive belt. ‘de–tension’ position with pin as
illustrated.
• Remove drive belt.
NOTE: Clean and dry rollers.
To fit belt, thread over all pulleys.
• Ensure the belt locates centrally on all
the pulleys.
• Turn tensioner roller
counter–clockwise and remove pin.
• Slowly release the tensioner and
remove the square drive.

40
Pilot, Convoy (Stage 3) Maintenance Procedure

D6. (PILOT ONLY)

CHECK OPERATION OF
COOLING FANS

YB
S
LD 103[
V E
Ver - ABSN]
sion
1 1230
.
560.

A119-001

Laser 2000

Using Laser 2000 check operation of electric cooling fans.

41
 Pilot, Convoy (Stage 3) Maintenance Procedure

D7. (PILOT ONLY) D8. (CONVOY ONLY)

DRAIN WATER FROM FUEL FUEL FILTER SERVICE
FILTER. INDICATOR. RESET, TEST OR
RENEW AS NECESSARY.

A102-066

Fuel filter service indicator

1
• Switch off the ignition.
040875
• Press the yellow button on the
Fuel filter Service indicator and hold for 3
seconds.
1. Drain screw • Start the engine and let it run for 5
2. Pumping button seconds at 4,000 rpm. On vehicles
without a tachometer, fully depress
CAUTION: the accelerator for 3 seconds.
Take precautions to avoid fuel • Check the service indicator.
dripping onto electrical equipment If it is the green area, a filter change
below. is not required.
• Attach suitable pipe to drain screw (1) If it is in the clear or red area, change
in filter base and place other end in the filter.
receptacle.
• Slacken drain screw and operate To renew fuel filter element:
pumping button (2).
• Tighten drain screw when pure diesel WARNING: Do not smoke or
is emitted. allow open flame of any type when
CAUTION: Do not operate pumping working on or near any fuel related
button when drain screw is closed. components. Fuel vapour can
• Inspect contents of receptacle. If ignite and cause damage and/or
excessive debris or water evident, personal injury.
inspect fuel system for point of CAUTION: Fuel injection
ingress. equipment is manufactured to fine
clearance. It is essential to
observe absolute cleanliness when
working on any part of the system.
• Detach heater air duct.
42
Pilot, Convoy (Stage 3) Maintenance Procedure

• Detach the fuel pipe connections to

and from the injection pump.
• Turn the fuel filter element locking
ring counter–clockwise and remove
the filter.
• Disconnect the water–in–fuel sensor
electrical connection.

A106-153

Aligning fuel filter element

• Locate the element to the housing,
ensuring the arrow on the element
points to the cutaway in the housing
rim.
• Push the element fully up into the
housing rim.
• Fit the locking ring and turn it
clockwise until an audible click is
heard.
• Connect the water–in–fuel sensor
connector.
• Connect the fuel pipes.
2
• Connect the heater air duct.
1

(Continued ...)
A106-232

Water–in–fuel sensor
1. Sensor electrical connection
2. Sensor

• Unscrew the water–in–fuel sensor

and remove it from the filter.
• Discard the element.
• Fit the water–in–fuel sensor to the
new element.

43
 Pilot, Convoy (Stage 3) Maintenance Procedure

D9. (CONVOY ONLY)

CHECK AIR FILTER SERVICE
3 INDICATOR. RENEW FILTER
AS NECESSARY.

A102-057

Bleeding the filter

1. Bleed valve
2. Plastic pipe
3. Hand primer

• Connect a suitable length of clear A102-067

plastic pipe to the filter bleed valve, Air filter service indicator
and place the other end in a suitable
drain container. • Check the position of the yellow
• Unscrew the bleed valve by plunger through the clear casing of
approximately 1 turn to open it. the Service indicator.
• Operate the hand primer slowly for If it is the green area, a filter change
approximately 80 to 100 strokes until is not required.
a continuous flow of air–free fuel can If it is in the clear or red area, change
be seen passing through the plastic the filter as follows.
pipe.
• Close the bleed valve and operate the
hand primer again to check that there
is now resistance to the pumping
action.
• Remove the plastic pipe.
• Start the engine and check for leaks.

44
Pilot, Convoy (Stage 3) Maintenance Procedure

D10. VISUALLY CHECK

CRANKCASE BREATHER
2 SYSTEM AND BRAKE SERVO
HOSE FOR LEAKS,
SECURITY AND CONDITION.
• Visually examine crankcase breather
system for signs of leaks.
• Check that breather hoses and valves
are securely clipped and in good
condition.
3
• Check that breather hoses and valves
do not chafe.
1

A148-011

Convoy air cleaner

1. Toggle catch
2. Cover
3. Element

• Release toggle catches (1) and

remove cover (2).
070474

• Discard used element (3).

Brake servo hose (Pilot)
• Clean container and cover.
• Fit new element and refit cover.
(Continued ...)
• Ensure air ducts are connected
correctly and hoses are in good
condition.
• After replacing the filter, reset the
indicator by pressing the yellow
button.

45
 Pilot, Convoy (Stage 3) Maintenance Procedure

D11. LUBRICATE BRAKE /

CLUTCH PEDAL CLEVIS
PIN(S), ACCELERATOR
PEDAL PIVOTS, ALL DOOR
LOCK LATCHES, BONNET
AND DOOR HINGES.

A148-012

Cam cover air bleed hole (Convoy)

• Check that air bleed hole in cam

cover is clear (Convoy only).

CAUTION: Do not poke wire into air

bleed hole. Do not puncture
diaphragm.

050567

Pilot pedal assembly lubrication points

• Remove lower fascia on driver’s side.
• Lubricate with engine oil:
CAUTION: Ensure floor carpets,
mats and pedal rubbers do not
become contaminated.
– Push rod clevis pins of clutch
master cylinder and brake
master cylinder.
– Accelerator pedal pivots (Pilot
only).
070473

Brake servo hose (Convoy Diesel) • Lubricate accelerator cable

• Visually inspect the brake servo hose attachment to pedal with Lithium
and connections for leaks, security based grease.
and condition. • Refit lower fascia.

46
Pilot, Convoy (Stage 3) Maintenance Procedure
060466
Hinged cab door lock latch
• Lubricate all door lock latches and
striker plates with multipurpose
grease.
060571
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 similar.
Do NOT lubricate sliding cab door
runners.
ALWAYS wipe off excess grease / oil
from paintwork etc.
D12. CHECK/TOP UP BATTERY
ELECTROLYTE LEVEL.
• Remove battery cell covers and check
level of electrolyte.
• If necessary top up to a level
approximately 5 mm above the cell
plates with distilled water.
• Replace the battery covers.
NOTE: Vehicles fitted with special
features or bodies, e.g.:
• Tipper body
• Tail lift
• Wheel chair lift
are more likely to require topping up due
to the additional battery duty cycle.
081646
Checking battery electrolyte level
All vehicles:
• Remove wing covers, close bonnet.
47
 Pilot, Convoy (Stage 3) Maintenance Procedure

E ROAD TEST • Check vehicle comes to rest without

NOTE: Before driving off, check vehicle
has valid tax disc and MOT test certificate
(if applicable). Use trade plates if unsure.
WARNING, Before driving off:
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.
E1. CHECK OPERATION OF
FOOTBRAKE AND
HANDBRAKE.
undue deviation.
If vehicle does not stop squarely,
cause may be:
– Odd tyres/tread
patterns/pressures.
– Pad/shoe contamination.
– Air in system.
– Siezed caliper piston(s) and/or
wheel cylinder(s).
– Mixed grades of pad/lining
material used.
– Hydraulic leaks.
• Turn off ignition. Press pedal several
times and hold down. Start engine.
Pedal should fall slightly under
influence of servo unit.
Handbrake

Before driving off:

• Apply footbrake and check ‘feel’ and
firmness of brake pedal. (i.e. that
adequate pedal pressure exists).
• Check that handbrake operates.
• Ensure footbrake is operational
before commencing road test.
During road test
Footbrake
When safe to do so, bring vehicle to rest
in straight line.
NOTE: When assessing performance, Checking handbrake operation
remember brakes require a period to bed
When safe to do so, stop vehicle on slope
in if pads/linings have just been renewed.
and apply handbrake.
• Check for firm, responsive braking. • Check that ratchet operates correctly
Brakes should act smoothly and and vehicle is held securely.
quietly, i.e. without squeal. • Ensure adjustment setting is correct:
• Check pedal travel and feel. 2 – 5 clicks, with pull–on load of 10 to
– If excessive pedal travel, rear 20 kg.
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.
48
Pilot, Convoy (Stage 3) Maintenance Procedure
E2. REPORT ANY NOTICEABLE
DEFECTS DURING ROAD
TEST WHICH MAY REQUIRE
FURTHER INVESTIGATION.
080823
Checking indicator self–cancelling
Before driving off:
• Operate direction indicator switch for
each direction in turn and check for
correct cancellation by the steering
wheel.
During road test:
Engine
• Check fast idle speed reduces to idle
when engine reaches normal
operating temperature.
• Check power transmitted smoothly.
• 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
fault.
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).
Steering
• Check vehicle does not deviate from
straight ahead position, allowing for
road camber.
• Check steering moves smoothly and
easily, and without undue noise.
• Check for correct self centre action
after cornering.
NOTE: If vehicle being tested
contains payload, this may affect
handling if badly positioned.
• Check for noise from power assisted
steering pump or drive belt when
under turning load.
CAUTION: Do not hold steering on full
lock.
(Continued ...)
49
 Pilot, Convoy (Stage 3) Maintenance Procedure

080918

Kneel switch
Checking air suspension kneel operation:

WARNING: Stop only when safe to

do so.
• Stop the vehicle and apply
handbrake.
• Check that kneel switch operates to
020157
lower rear suspension only when the
Right and wrong position of steering handbrake is applied.
wheel • Check that switch illuminates while
• Check steering wheel alignment when suspension is lowering.
• Check that suspension kneels fully,
driving straight ahead.
If adjustment is required, re–check and that kneel switch light goes out.
self–cancellation of indicators. • Apply the footbrake, release the
Re–torque steering wheel nut if handbrake (ignition in position II) and
disturbed. check that suspension returns to
correct ride height.
Suspension
• Listen for abnormal suspension noise, Body
indicating one or more of the • Listen for abnormal body noises –
following: rattles, exhaust system blowing or
– Loose, worn or collapsed spring, fouling.
spring shackle, or anti–roll bar
bolts/bushes.
– Loose spring ‘U’ bolts.
– Loose/worn shock absorber(s)
or their bush(es).
– Chafing or insecure items.
– Loose sound suppression panel
(Convoy only).
• 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.

50
Pilot, Convoy (Stage 3) Maintenance Procedure
E3. CHECK OPERATION OF ALL
INSTRUMENTS AND
CONTROLS.
• Check speedometer for steady
operation, and without noise.
• Check mileage recorder operates
correctly.
(DO 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 ‘normal’ position, and fuel gauge
registers a fuel level.
• If tachometer is fitted, ensure engine
speed indication rises and falls with
throttle operation (engine running).
F AFTER ROAD TEST
WARNING: Certain components
will be hot after road test.
Refit protection items removed earlier.
F1. CHECK OPERATION OF
ENGINE MANAGEMENT
WARNING LIGHT.
RESET SERVICE INDICATOR
LIGHT ‘SYSTEM’ (CONVOY
ONLY)
• Turn ignition to position ‘II’ (without
starting engine.
• Fully depress accelerator and brake
pedals simultaneously for at least
15 seconds until light flashes.
• Turn ignition off.
• Release the pedals.
51
 Pilot, Convoy (Stage 3) Maintenance Procedure

F2. USING LASER 2000, READ AND CORRECT ANY FAULT CODES.

YB
S
LD 103[
V E
Ver - ABSN]
sion
1 1230
.
560.

A119-001

Connecting Laser 2000, Pilot/Convoy vehicles

Connect Laser 2000.
Interrogate all systems, record all fault codes generated.
– Engine management system.
– Anti–lock braking system (ABS).
– Passive anti–theft system (PATS).
Rectify causes of fault codes.
Clear fault codes.

52
Pilot, Convoy (Stage 3) Maintenance Procedure
F3. RE–CHECK TENSION OF
VACUUM PUMP DRIVE BELT
IF RENEWED AND
RE–ADJUST IF NECESSARY.
Check Pilot vacuum pump drive belt
tension as detailed in operation D5 and
re–adjust if necessary.
F4. COMPLETE REPORT ON
FINDINGS.
• Record any findings not already
entered, and report any additional
work required.
Complete and stamp the relevant service
records in the vehicle’s Operator
Information and Service Record Book to
confirm:
• Completion of appropriate
Scheduled Service.
• Antifreeze renewal.
• Brake fluid renewal.
• Timing belt renewal (Pilot).
• External drive belt(s) renewal.
• Anti–corrosion & cosmetic.
paintwork warranty inspection.
Service records
Remove protection kit from seats, doors,
footwells etc.
• Wipe clean:
– Steering wheel.
– Gear lever.
– Handbrake grip.
– Door handles, window winders.
– Excess oil from door hinges etc.
53
 Pilot, Convoy (Stage 3) Maintenance Procedure

ADDITIONAL OPERATIONS TO BE • Twist filter cartridge (2) to detach from

CARRIED OUT AT THE SPECIFIED filter head.
INTERVAL. • Remove and discard four sealing
rings (3) from head, base and centre
G EVERY 2 YEARS. bolt.
• Clean filter base.
G1. RENEW FUEL FILTER. • Reassemble unit using new filter
(PILOT) element and sealing rings.
• Bleed system as follows:
– Open bleed screw (4).
– Operate pumping button (5) until
Interval: air–free fuel flows from bleed
Pilot Every 20,000 miles/32,000 screw.
km/24 months – Tighten bleed screw.
– Gently operate pumping button
until resistance is felt.
1
3

040853

DW8 Fuel filter

1. Centre Bolt
2. Filter Cartridge
3. Sealing Rings
4. Bleed Screw
5. Pumping button
CAUTION: Take precautions to
avoid fuel dripping onto electrical
equipment below.
• Clean filter.
• Position suitable container under filter.
• Support filter base, remove centre
bolt (1) and plain washer to release
base.
54
Pilot, Convoy (Stage 3) Maintenance Procedure

G2. RENEW ANTI–FREEZE.

Interval:
Pilot Every 70,000 miles/112,000
km/24 months
Convoy Every 75,000 miles/120,000
km/24 months

A102-002
1

2 3

040876

DW8 engine coolant drain and refill

1. Pressure relief cap A148-019

2. Bottom hose Duratorq engine coolant drain and refill

1. Pressure relief cap
3. Cylinder block drain plug
WARNING: If the engine has been
running recently, the cooling system • Remove pressure relief cap (1).
and engine components may be
sufficiently hot to cause burning to • Disconnect bottom hose (2) from
skin on contact. radiator. (DW8 bottom hose
illustrated).
• Set cab heater control to ‘hot’
position. • On Duratorq engines, remove cylinder
• Position container to collect coolant. block drain plug (3).
Allow coolant to drain.
WARNING: If the engine is hot, • Flush system through with water.
place a thick cloth over the filler cap
and expansion tank before attempting • Connect bottom hose.
to remove the cap. Remove cap slowly
• On Duratorq engines, apply Hylomar
to prevent possibility of scalding.
to cylinder block drain plug, fit and
tighten to 18 Nm.

(Continued ...)

55
 Pilot, Convoy (Stage 3)
• CAUTION: Use only LDV approved
special anti–freeze.
Prepare coolant solution:
50% water
50% antifreeze
• Fill system with coolant until
expansion tank is half full.
• Squeeze bottom hose to expel air,
and top up as necessary.
• Fit pressure 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.
56
Maintenance Procedure
G3. RENEW BRAKE FLUID IF
NOT ACTIONED AT C10.
Interval:
Pilot Every 30,000 miles/48,000
km/24 months
Convoy Every 30,000 miles/48,000
km/24 months
Tool required: Pressure bleeder
• Use an approved brake pressure
bleeder, and bleed the brakes in the
same sequence as described below.
1. Top up master cylinder reservoir with
recommended fluid. 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
half turn, 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.
Pilot, Convoy (Stage 3) Maintenance Procedure

5. Repeat operations 2 and 3 at bleed H EVERY 4 YEARS

screw on each front caliper, starting
with caliper furthest from master H1. CLEAN AND INSPECT
cylinder. COOLING SYSTEM
NOTE: If difficulty experienced in PRESSURE CAP. RENEW IF
bleeding front brakes satisfactorily, ANY EVIDENCE OF SEAL
remove rubber dust cover from delay DETERIORATION.
valve (if fitted) and depress plunger
for duration of caliper bleeding Interval:
procedure. Pilot Every 40,000 miles/64,000
6. Remove pressure bleeder (if used); km/48 months
top–up brake master cylinder. Convoy Every 45,000 miles/72,000
km/48 months
7. Start engine to make brake servo
operational. Apply pressure to brake
pedal several times, checking for
firmness of pedal.
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 pull up squarely.
10. Ensure that brake fluid renewal is
recorded in the customer’s ‘Operator
Information and Service Record’
book.

Convoy cooling system pressure cap

(Continued ...)

Service record

57
 Pilot, Convoy (Stage 3) Maintenance Procedure

H2. (PILOT DW8 ENGINE ONLY).

RENEW AIR FILTER
ELEMENT.

Interval:
Pilot Every 40,000 miles/64,000
km/48 months

Pilot cooling system pressure cap

Remove cooling system pressure relief
cap and inspect.
If seal shows signs of deterioration,
replace cap.

DW8 air cleaner

1. Toggle catches
2. Cover
3. Element

To renew DW8 air cleaner element:

• Release toggle catches (1) and
remove cover (2).
• Discard used element (3).
• Clean container and cover.
• Fit new element and refit cover.
• Ensure air ducts are connected
correctly and hoses are in good
condition.

58
Pilot, Convoy (Stage 3) Maintenance Procedure

J EVERY 5 YEARS OR EVERY

60,000 MILES (whichever occurs
first)

J1. (PILOT ONLY)

RENEW TIMING BELT.

Interval:
Pilot Every 60,000 miles/96,000
km/60 months

DW8 engine only 6. Restrain crankshaft from turning

Tools required: LDV 104, LDV 167 or (engage 5th gear), and remove
23–019, P–57B. crankshaft damper.

WARNING: If engine has been

running recently, cooling system and
engine components may be
sufficiently hot to cause burning to
skin on contact.
1. Switch off ignition. 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.
5. Remove external drive belts.

Timing pulleys
1. Camshaft pulley
2. Fuel injection pump pulley
3. Idler roller
4. Crankshaft pulley
5. Water pump pulley
6. Timing belt tensioner roller

59
 Pilot, Convoy (Stage 3) Maintenance Procedure

8. Turn crankshaft clockwise until no. 4

cylinder (front of engine) is at TDC
firing position. Fit tool LDV 104.
7. Remove 3–piece timing case.
NOTE: Bolt number 6 is larger (11mm).
NOTE: Removal of bolt (arrowed) may
cause coolant to seep out. Seepage will
stop when bolt is refitted. Ensure coolant
level is topped up after re–fitting.

60
Pilot, Convoy (Stage 3) Maintenance Procedure

11. Remove and discard timing belt.

CAUTION: Unless instructed, do
not turn camshaft or crankshaft
when belt is not fitted.
w If old belt has been
contaminated, all pulleys and
rollers must be cleaned.
• Do not contaminate
pulleys/rollers when handling
them.

12. Inspect all components for wear,

damage, contamination. Clean/renew
as necessary.

9. Fit suitable length M8 bolt in camshaft

pulley timing hole, and tool LDV 167
or 23–019 in injection pump pulley
timing hole.

13. IMPORTANT: Check tensioner and

idler rollers:
– turn freely and quietly,
– cleanliness of surfaces.

10. Slacken belt tensioner bolt (13 mm).

Turn tensioner to full off position using
tool P–57B and tighten bolt.

61
 Pilot, Convoy (Stage 3) Maintenance Procedure

16. Fit new timing belt, keeping it taut on

drive side, in the following order:–
14. Slacken bolts illustrated (6 x 13 mm).
Locate round crankshaft pulley (A).
Check pulleys free to turn on hubs.
– Idler roller (B).
Finger tighten bolts then slacken1/6th
– Injection pump pulley (C),
turn.
turning pulley anti–clockwise if
necessary by no more than 1
tooth to allow belt to engage.
– Camshaft pulley (D), turning
pulley anti–clockwise if
necessary by no more than 1
tooth to allow belt to engage.
– Tensioner roller and water pump
pulley.

17. Pre–tighten tensioner bolt to 1 Nm.

15. Turn both pulleys fully clockwise when

timing pins are fitted.

62
Pilot, Convoy (Stage 3) Maintenance Procedure

Tension timing belt as follows:

19. IMPORTANT:
Remove one injection pump pulley
securing bolt, check that bolt is not
against end of slot as illustrated. Refit
bolt.
Repeat with camshaft pulley bolt.
If either is incorrect, repeat belt fitting
operation.
CAUTION: Do not turn crankshaft
anti–clockwise.

18. Locate tension gauge to timing belt in

centre of span as illustrated.
Use tool P–57B to turn tensioner
anticlockwise until 106 ± 2 SEEM
units can be registered on gauge.
Hold position of tensioner and tighten
bolt to 19–23 Nm.
20. Tighten camshaft and injection pump
pulley bolts to 23 Nm.

63
 Pilot, Convoy (Stage 3) Maintenance Procedure

22. Turn crankshaft 8 revolutions

clockwise.
Do NOT turn anticlockwise.

21. Remove timing pins (LDV 104,

LDV167 or 23–019, M8 bolt).

Remove tensioner gauge.

23. Refit flywheel timing pin LDV 104,

followed by camshaft and injection
pump timing pins.

64
Pilot, Convoy (Stage 3) Maintenance Procedure

If either pulley timing pin will not enter,

slacken appropriate pulley securing
bolts and adjust pulley position.

24. Slacken:
– camshaft and injection pump
pulley bolts,
– tensioner bolt.
Finger–tighten pulley bolts then
slacken 1/6th turn. 25. Use tool P–57B to turn tensioner
Position tensioner gauge at centre of anticlockwise until 41 ± 2 SEEM units
span as before. registers on gauge.
Hold position of tensioner and tighten
bolt to 19–23 Nm.

65
 Pilot, Convoy (Stage 3) Maintenance Procedure

28. Check setting as follows:

– Turn crankshaft 2 revolutions

clockwise. Do NOT turn
Tighten camshaft and injection pump
anticlockwise.
pulley bolts to 23 Nm.
– Fit timing pin LDV 104.
1mm

FUEL PUMP PULLEY

1mm

26. Re–check belt tension; value should

now be 38 to 46 SEEM units.
Remove tool.
CAUTION: If tension value is
outside tolerance, slacken belt and CAMSHAFT PULLEY
repeat tensioning procedure.
27. Remove 3 timing pins (LDV 104, – Visually check that timing holes
LDV167 or 23–019, M8 bolt). in camshaft and injection pump
pulley align with their respective
timing location holes.

If a mis–alignment of more than 1 mm

exists, repeat timing procedure.
– Remove LDV 104.

66
Pilot, Convoy (Stage 3) Maintenance Procedure

30. Fit crankshaft damper, tighten bolts to

10 Nm.
31. Fit external drive belts and adjust to
correct tension.
32. Fit radiator, re–connect all hoses and
fan cables.
33. Fit bonnet locking platform and
radiator grille.
34. Fit intake air duct.
35. Refill with coolant (50% anti–freeze)
to correct level.
36. Re–connect battery, positive terminal
first.
29. Refit timing covers.
37. Start engine and run until normal
NOTE: Bolt number 6 is larger (11mm). 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.

67
 Pilot, Convoy (Stage 3) Maintenance Procedure

38. Ensure that camshaft drive belt

renewal is recorded in the customer’s
‘Operator Information and Service
Record’ book.

K REPORT ADDITIONAL WORK

REQUIRED
• Enter the operation number(s) being
referred to, and state clearly the work
required.

L IS THIS VEHICLE SUBJECT TO

ANY OUTSTANDING SERVICE
ACTION/RECALLS. IF YES
PLEASE ACTION.
• Check page at rear of the customer’s
‘Operator Information and Service
Record’ book to make sure all service
actions/recalls have been completed.
• Any outstanding actions/recalls can
be identified by a chassis enquiry on
Vanscan.
• Ensure that any service actions/recall
is recorded in page at rear of the
customer’s ‘Operator Information and
Service Record’ book.
• This information is available at LDV
Dealerships.

68