LDV Pilot rear wheel drum and hub: changing the wheel cylinder

Ok -

This is just some basic information on how I changed the rear wheel cylinder on a 2003 Pilot - I think most cylinders in most vehicles operate the same - I watched a few video's and saw various methods and fixings - here's what I found...

BTW - there is a way to do this without taking the shoes out - but I was going to change the shoes anyway.

Stuff I needed:
Research:
http://www.youtube.com/watch?v=p8k5GfTpZr4&list=PLD3_GkY1HOeh76Y-OeWRSKgRwUZUWQ8pB&index=2 << shows the basics, LDV Pilot is a slightly different fixing on the cylinder.
http://www.youtube.com/watch?v=g4HqLoDjVRA << bit slow but shows basic start to process

- Brake cleaner (spray) brake fluid EVERYWHERE> this really helped
- phillips screwdriver for drum retainer screw
- Pliers for spring removal
- axel stands x2 (and chocks for the front wheels)
- spanner (11?) to loosen the pipe fixing to the back of cylinder
- spanner for (8/10) loosening the bleed nipple
- new wheel cylinder, possibly brake shoes if they are soaked compromised through the brake fluid
- bleeding kit / bottle and pipe (see here at 5:37: http://youtu.be/V5O_pbC8R2E?t=5m37s )

1. Loosen the wheel nuts on the offending wheel, Chock the front wheels, jack up, stick the stands under the rear axel, one each side.
2. Take the wheel nuts off, then the wheel, then the handbrake.
3. Spin the drum - it should turn freely
4. find the retainer screw, take it out

The retainer screw half out of the drum

5. Either the drum slides off (not very likely) or you have to just keep hitting the drum with a hammer and turning it... it will eventually crack and begin to come off... like so;

Under the drum... this sight awaits...

6. Basically, I tool the springs out of their holes with a pair of pliers on my leatherman (thanks Ludo) but you can use long nose pliers or something else suitable... I didn't do it in any particular order, but laid the springs between the new shoes to note what went where...

 7. The handbrake is attached to the base of the right brake shoe - simply pull the metal outer cable spring back to expose the cable and slip from the fixture

handbrake cable end location 

8. With the cable and shoes removed, you can start taking the cylinder off> undo the brake pipe nut from the back of the cylinder- there will be some brake fluid leak from the pipe, you can find a way to stop the leak, such as the rubber cap for the bleed nipple.

9. Get the circlip off; slide the old cylinder away from the hub.

 10. Clean up the hub with brake cleaner, then time to fit the new cylinder; get the circlip on first as the pipe screws in easy.

New cylinder pipe and circlip on

 11. Thats the cylinder done really!

 12. Use some copper grease (I only had lithium here) just where the shoes rub on the hub to help prevent squealing - some on the back of the drum also (no pic) so its less likely to be a sod to get off the next time...

13. Get your shoes on!

14. Bleed the brakes (see video above in 'research')

As you can see here, I gave the old shoes a good clean, a brief very very fine sand, as I couldn't work out how to get this handbrake fixture off on of the shoes:

Its the next job:::

Hope this helps - let me know any questions/ advice!

LDV Pilot van - full specs DW8 engine

Link to full specs of DW8 engine

LDV Pilot van - UK regulations

Bills paid.
Road tax duty stamp at £215.00.
MOT coming up in March.

I need to fix the defectuous rear bumper which fell this morning as I lightly hit a tree while manoeuvring. Had to fix it for ages now really have to do it.
The fan belt still haven't been changed (!)
need a new extra tyre.
Need to fix the rear light better then the gaffer tape the previous owner fixed it with.

Need a look into the electrics for start up troubles.
And do the imminent address change.

Finally I'd love to take the time to properly seal the body for water leak and carry on with rust treatment as well as body repair (very appealing job for a sculptor like I).
Pics later.

LDV Pilot van - under the snow

That wasn't its favourite season. Despite a lot of Pilot's owners who claim this van always starts up, mine found it difficult under cold and wet conditions. I changed the battery to a new one but it still had troubles. I guess it's got to do with the heads not heating up properly. Something in the electrics?
Needs to be investigated further...

DW8 engine - Alternator belt

206 DW8 ENGINE

REMOVAL - REFITTING ANCILLARY DRIVE BELT

Conversion - Insulation

Ideas from people's experience on the net:

• Bubble wrap

• FOIL/ LOFT-ROOF INSULATION / WALL INSULATION / DAMP PROOF 

• Space Blanket Loft Roll Insulation 

   
  "Things to think about are weight, will it catch fire easily, how easy would it be to remove if working on body panels at a later date, will it hold moisture and also will it absorb smell, ie cooking etc if using in a camper conversion."

biofuel book

I'm not happy to promote the book here but it can be useful I guess. It's more like I'm archiving the info. Why. I do realise it is a lot of work to gather the infos and put a book together, I've done some of it myself as a graphic designer. The book can be paid for. However this information has more potential than just make us save on our fuel budget. In my opinion it could be made available for free online. That's what the WWW is meant for. (Oh yea but we live in a capitalist world). Anyways it's titled "run your diesel vehicle on bio fuels".

DW8 engine euro 3 rating

The DW8 is for all intents and purposes an evolution of the XUD9 and is the only Diesel engine in the family not to feature a turbocharger or common-rail direct injection. It has a bore of 82.2 mm and a stroke of 88 mm for a displacement of 1868 cc. It is mainly used in vans such as the Citroën Berlingo and Peugeot Partner but can also be found in more affordable versions of the Peugeot 206 and 306. The DW8 was phased out in 2007 as it does not pass Euro IV emissions regulations (it is an Euro III engine[1]). DW8 69 PS (68 hp/51 kW) Dieselcatalyst DW8 B 69 PS (72 hp/53 kW) Dieselcatalyst

From http://en.m.wikipedia.org/wiki/PSA_EW/DW_engine#section_4

DW8 on 206
read more - images

French breathalyser news

Car breathalyser fine enforcement delayed in France until March 2013

LDV Pilot van - spare, Replacement Key

http://www.autolocksmithstockport.co.uk/cars/ldv
http://www.bancroftlocksmiths.co.uk/

LDV - random knowledge on common faults and more

Help! I have an ex Post Office LDV Pilot with an immobiliser.

kingpins!!!!!!! new or pack with grease

History

LDV

LDV is a famous UK van manufacturer, located in the Drews lane area of Wolseley, Birmingham, England. It was a part of the British Leyland/Rover Group empire and was the latter's Freight Rover arm of the Land Rover Group division. It was officially known as LDV Limited after its merger with Leyland Trucks and DAF Trucks in 1987. The company manufactures various panel vans, pick-ups and minibuses. These vehicles are available with various modifications and specifications. The Convoy and Pilot panel vans were amongst the first modified versions of Leyland DAF 400 Series of vehicles. They were produced between 1997 and 2006. The convoy was available as 2.8 tonne, 3.1 tonne and 3.5 tonne variants with load volume capacities of up to 12.9 cubic metres. The pilot was made available in capacities ranging from 2.2 to 2.6 tonnes in a 5.7 cubic metre load area. Both these vans were immensely popular as a minibus and would come as pick-up and fleet based vans. These vans were replaced by an LDV van, the Maxus. Maxus van was launched in 2005 and was awarded the Professional Van and Light Truck Magazine ''Van of the Year 2005'' title. It is available in two wheelbases, three roof heights and a choice of 2.8t, 3.2t and 3.5t GVW. It is being used on fleet basis by companies such as Transco, Royal Mail and various UK police services. The company had also produced a small van named LDV Cub that was produced from 1996 until 2001. It was popular with small businesses such as plumbers, gardeners and electricians. The company also provides services and insurance for LDV Maxus and other LDV cars. 

Big Brother Maxus:

http://dudleyinvestigatesldv.wordpress.com/

(on LDV Pilot vans) "Rads block, if they overheat it normally wrecks the cylinder head, Rad fan switches fail, kingpins wear out quickly, shock bushes are always wearing out, steering boxes wear and leak, gearboxes can give problems with crunchy gears etc, diff seals leak, wiper linkages wear out and leak water into cab and your forever banging your elbow on the door."

kingpins!

 

 

 

LDV Pilot van - UK miles per gallon calculator

http://www.mdocuk.co.uk/mpg_calculator.htm

LDV Pilot van - logbook - Rust treatment

The MOT document which came with the van mentioned a bit of rust on the front left but I hadn't been able to spot it til I started to treat the rusty areas of the van's body. It's located by the driver's door on the round of the wheel and it looks like it'll need that chemical I used to change rust into metal on the outside areas (mainly around the gutter and the worse being above the windscreen and doors edges) plus a fair quantity of resin to get it back as it was and stop the damage for good. There is also a worrying amount of humidity under the cabin's floor mat which I presume is the result of rust damages and cracks in dried joints. There's a good post on this forum about water leaks (but you'll need to join the forum to read it. Here's the link This, from the same forum, speaks about water leaking through the windscreen rubber joints. Common bug.

LDV Pilot - logbook

Apparently having a speed restricter on the engine makes it last longer.

LDV PIlot - logbook

The left rear bumper need to be fixed to the body.
The left rear light needs to be fixed to its support.

LDV Pilot Van - logbook

I offered to help carry a friend's giant puppets for a Latin American festival with the van last sunday. All went well until on the way back, my (only) key got stuck in the side door's lock. I managed to get it out but the lock is not functioning with the key anymore. I need to open it from the inside.
Not a big deal. It's more worrying that I only have one key for this van.

LDV Pilot Break down number 1- logbook

About a week ago, there was a heavy load in the back and the alternator belt and water pump belt snapped as I was driving.
The engine kept running and pulling the van so I could drive to a parking place.
Luckily it wasn't the timing belt but without those belts the cam/timing belt could get damages too.
With friends' help the belts were replaced. I was sold the wrong alternator belt but although it is too short it did the job (It doesn't fit the diagram and misses going around one of the tensioner but the tension is good). I'm not totally sure the water pump belt is the correct one either but it works.

I still have to find the right alternator belt, replace it with the right tension and I need to check the timing belt before any long distance trip.

LDV Pilot disel 1.9 DW8 engine manual

Link to forum

and to downloadable manual in a zip file

LDV Pilot DW8 and XUD9 engines

Peugeot DW8 engine
Lots of technical infos

Peugeot forum

Berlingo (DW8 engine) forum

Zip file for DW8 digital manual

Forum talk
"I have heard several times that the DW8 engine (1868cc) looks identical to the XUD9 engine (1905cc). They differ in the intake manifolds, that is one way to tell them apart.

Peugeot did not make a turbo version of the DW8, but it is availabel on the XUD9.
I am guessing that IF IF IF the intake manifold of a XUD9 diesel engine would fit on a DW8 engine block, then you would have the option to add a turbo as well."

LDV Pilot Alternator belt diagram