DIY - 1.9 TDI PD basic service, and PROVENT INSTALL

[gldgti]

After owning our new 2007 Skoda Octavia 1.9TDI for nearly 3 weeks, I thought I would do a bit of a service on her to make sure everything was ok and to familiarise myself with the car a bit more. I've always been hands on with all my cars and this is no different, only its the newest car I've owned by far.

So, the lineup of jobs to do was:

> Oil and filter change
> Air filter inspection/change
> Fuel filter inspection/change
> General look around
> Install Mann&Hummel PROVENT 200

Things you'll need when working on your 1z octavia, or indeed mk5 golf, 9n polo, etc....

> 1/2" and 1/4" socket set
> torx screwdrivers or torx bit, all sizes
> basic screwdriver set
> decent trolley jack
> axel stands
> oil drop pan
> various "garage supplies" like rags, newspaper, beer.

Oil and filter change

You can use ramps, but because I was doing more of a general inspection (and I wanted to look over the suspension, etc) I supported the car on axle stands, with the car supported under the rear wishbone bushings on the front subframe.

1) Use torx drivers to remove the smaller screws (4 on each side) holding the plastic undertray to the bodywork.
2) Support the weight of the undertray and remove the 3 larger torx bolts towards the rear of the tray. Slide the tray rearward so that it is released from the front splitter and remove the tray from under the car.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010403-1.jpg
3) Now we can see the underside of the engine bay and access the oil sump.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010410-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010407-1.jpg
We can see that the octavia has a front mounted intercooler, which resides in between the radiator and a/c condensor. Its HUGE - and a good thing to, its a pretty big car for this engine, and a tiny turbo!
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010412-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010411-1.jpg
Heres a pic of the tiny little VNT-15. This turbo really is small, I kinda want it to fail so I can put a proper turbo in there and get some real power.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010405-1.jpg
and the cat integrated into the downpipe.... not a DPF, but you can see they put it nice and close to the turbo so that it gets hot fast and burns out any soot.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010406-1.jpg
the O2A gearbox that we know and love - this is actually exactly the same gearbox I had in my mk3
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010408-1.jpg
4) Drain the oil
5) Use a 32mm socket, long extension and ratchet to remove the oil filter housing. Be careful with it, it can be broken if you are too enthusiastic.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010418-1.jpg
6) Replace the filter with a new one. It just unclips (pulls) out. The new filter will just clip in place.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010419-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010420-1.jpg
7) Replace the big O-ring seal. Prise it out with a small, blunt flat bladed screwdriver. Before you put the new one in, lubricate it with some clean engine oil.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010422-1.jpg

[gldgti]

9) Replace the new oil filter and housing. Don't do it up too tight!
10) Top up the oil to the mark 'a' as stated in the user manual....use the right oil -
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010425-1.jpg
Enviro+ is Volkswagen Approved oil. I find it easier to fill the oil by first decanting it into a 2L, gradiented jug. This is much easier to pour from and minimises risk of spillage. It should take 4L.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010426-1.jpg


Air Filter

1) Use a phillips head screwdriver to release the upper airbox cover. Lots of screws, but they are easy to undo...
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010415-1.jpg
2) I'm pretty sure the filter had never been changed - a Sydney car, but it just looks OLD. see the discolouration. Not very dusty, but in need of replacement.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010416-1.jpg
3) Clean any bugs from the bottom of the airbox then replace the air filter, and then the airbox top cover.

Fuel Filter....

I was going to change the filter but discovered upon removal of the element that I had been supplied with the wrong part.... anyway, I did determine that mine needs replacing.
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010427-1.jpg
If you just use a torx driver, you can simply remove the 5 screws on the top of the filter housing, and lever the housing out. You need not even remove the hoses from the top. Once the top is removed, its a simple matter of swapping the element inside the housing. Put a rag around to prevent any spillage of diesel into the engine bay....

[gldgti]

I decided it would be easiest to stick the provent up the front of the bay near the dipstick.

I used a couple of bits of "make a bracket" and 2 existing screws in the front upper crossmember.... Its pretty rough actually but I want to make a decent bracket in stainless at work so this will do for now...
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010429-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010430-1.jpg
I've used here 19mm black silicone tube. Its pretty stretchy, but a little vaseline on the ends where you are trying to push it onto the 25mm fittings on the provent makes it a lot easier...

only 2 90 degree elbows needed to rout the "exit" pipe
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010431-1.jpg

...and a few notches (ok cutouts) made in the engine cover to facilitate the hoses and the provent itself. I did these cutouts with my 5" angle grinder, using a 1mm cutoff wheel to "sideways grind" the plastic away. Its very effective but most people should probably use an abrasive bit on a dremel to do this job...
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010433-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2011/07/P1010434-1.jpg

Looks almost stock!

[ope126]

Nice write up there mate.
Great to see some practical DIY's here in the Diesel section!

[Greg Roles]

Yeah, well done, and wash down that dusty engine mate!

[Preen59]

Wow! Very nice, mate! Your engine looks damn near identical to the Caddy, in terms of where everything is.

The fuel filter is a pain... There's 3 different ones for the 1.9TDI. First time it took me 2 goes to get the correct one.

If you lower it and subsequently decimate the sump, i've got a couple of spares here for you.. :)

[Transporter]

The most common one is this one; MAHLE KX228, MANN PU936/1 or the one from VW dealer p/n 1KO 127 177 B

[Evaded Motorsport]

Very nice guide!

You may also need to replace the oil filter plug, it is supposed to be replaced at every service to prevent the leakage you have around there.

The other thing is the turbo may in fact be a KP39, I think most of the later PD100 engines ended up with it rather than the VNT 15 and if that is the case good luck killing it.

[gldgti]

interesting info about the turbo - thanks!

Gave the car a really good run today on the cruise - pushed it quite hard and now the car is going MUCH better. I reckon the vanes were sticking a bit but now its much faster to get on boost, and consequently has the knd of midrange i thought the car should have but didn't.

I think the old air filter was pretty bad too!

The sump plug/washer looked fine to me, the leakage that was evident around the plug actually was coming from a bit higher up, but I didnt find the source of it.... I would guess its coming from around the valve cover somewhere, but its pretty minor from what was evident on the undertray.

[PranK]

Great write up - i know this is an old thread but trying to work out where to put my Provent and your bay looks the same as my Passat.

The three torx screws at the rear of the splash guard feel like they are welded in place! I couldn't get them undone when I was under there last time.

I'm happy to see you using the Penrite - thats what I bought and was nervous that it wasn't right.

[Buller_Scott]

Wow, GLD - thanks very much for this write-up! I'm going to be doing my fuel filter change when i get back (oil might be due, too) and i'd been interested in a provent somewhere down the line. This guide, like pretty much every guide in the diesel section, is valuable info.

On a side note, Evaded - when you say "most of the later pd100's came with kp39", would that include the polos, per chance? Sweet, if so...