Remove battery without removing windscreen cowling & drain plenum, inc TDi

[cazyp]

First, sorry about the pics. Done this today in the rain and as promised on another thread took some pics to show how to remove battery without removing wipers or window cowling. 53 plate 1.9TDi

You'll need a 10mm spanner for the battery connections and a 13mm socket with an extention bar for the battery tray.

I do all the battery removal from the near/passenger side of the car.

Pic of plenum cover: (Yawn..)
Pic 1:
http://i21.photobucket.com/albums/b294/corallus123/p1start.jpg

Pics showing the rubber seal being removed from the bulkhed/plenum cover and the location of the metal clips in red for the big fat rubber 'loom.'
Remove the plenum cover.
Pic2:
http://i21.photobucket.com/albums/b294/corallus123/p2.jpg

Disconnect the battery using the 10mm spanner. Negative first and keep the leads away from the teminals. Pic of the 13mm nut which secures the battery. Remove completely inc bracket:
Pic3:
http://i21.photobucket.com/albums/b294/corallus123/p3a.jpg

Pic of the battery vent pipe in red - gently pull apart. Also pics of the 2 'problems' in green to navigate.
Pic4:
http://i21.photobucket.com/albums/b294/corallus123/p5.jpg

Red circled is the rubber 'loom' which must be gently removed via the metal clips on the bulk head and pulled forwards over the top of the bulk head. Also pull the end of the loom up and out of the cut out in the bulk head in front of the pollen filter (far right red circle.)
Now push the battery towards the drivers side, lift it from underneath about 1cm and pull towards the passenger side above the battery tray lip.
Now lift slightly and tilt the battery forwards and pull towards you until you are clear of the pollen filter and above the alloy pipes that go through the bulkhead.
Pic5:
http://i21.photobucket.com/albums/b294/corallus123/p6.jpg

Keep sliding the battery towards you with the front end against the bulkhead. Use the front handle if you need to/have one.
Pic6:
http://i21.photobucket.com/albums/b294/corallus123/p7.jpg

As you can see the battery will now lift and slide over the wing and give you access to the gromet under the battery tray - rough location marked with the green spot. (Can't beat MS Paint of high tech graphics!)
Pic7:
http://i21.photobucket.com/albums/b294/corallus123/p9.jpg

Take the 13mm socket off the extension bar and use the bar to push the gromet through. Feel satisfied as you hear that water flood out! There is also one under the brake servo if you're feeling sassy.

Refit is exactly the same in reverse. Connect the battery positive first.

HTH.

[djmx5]

Superb write up and photos mate.....well done, this post will no doubt be viewed many times, not least by me!

Thanks again

D

[passat 130 tdi]

thats how i do mine -- except its easier now with a slightly smaller battery . the oem battery was huge and some lump to slug about in the bulkhead.

[N_CURTIS]

Just out of interest, can that cover (obviously what they came up with to keep leaves out of the plenum) from the B5.5 be retrofitted to a B5?

[Richie Preston]

Hi , will the ECU be affected by the loss of power .

[martin1810]

No but early cars might lose the radio code. Most don't.

[MrG]

Great post.
I remember doing this about 3 year ago was easier than I thought it would be but you have to be patient.:beerchug:

[GRAHAM.C]

Good write-up for those who have never removed the battery on a B5.5.
Done mine the same way last year to check the drain holes,and again since to renew the battery last summer.It is a bit of a squeeze,but should be better the next time if needed as the new battery is a little smaller.

[monkgti]

thats how i did mine a few months back aswell to clear the drain holes!! is there another way that people remove the battery?

[caldirun]

Great How To, just like to add, cover the wing with a thick soft cloth to prevent scratches if the heavy battery slips when you lift and slide it out.

[Irri_Tant]

Time to do mine as I've found a swimming pool under the battery. :zx11:

[caldirun]

Time to do mine as I've found a swimming pool under the battery. :zx11:
Dont forget to bin the duckbill valves or you will be doing the same next Autumn