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Thread: Passat B5, B5.5 plenum drain cleaning

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  1. Passat B5, B5.5 plenum drain cleaning UPDATE Pg.2 plenum seal 
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    Aug 2015, plenum re-seal on page 2

    This covers the following cars;

    B5 Passat 1997-2000
    B5.5 Pasat 2000-2005
    C5 Audi A6 1997-2005
    Not sure about the A4 of the same vintage


    A really important job to do, as if these are blocked all sorts of problems can occur; water ingress through the pollen filter housing causing the central convenience module and wiring to fail, rotting out the brake servo which can possibly lead to a very expensive repair bill.

    Anyway, this is how I did it. Please note I thought about taking the pics part way through the job so some may appear to be out of sequence.

    Tools,
    10mm spanner for battery terminals.
    13mm socket with 10" bar for battery clamp.
    13mm spanner for battery cradle.
    Pressue washer (if you have one).

    So;

    1, Pull the rubber seal off at the front edge of the plenum cover.
    2, Ease the plastic plenum cover out.

    Some say that the wiper arms and the scuttle cover that butts up to the screen needs to come off to remove the battery. This isn't the case, you can move the rubber incased loom forwards to provide access to remove the battery but you need to be careful not to damage the very brittle windscreen scutte panel.

    3, Picture below shows the 3 clips securing the loom in place, you need to roll the loom over the bulkhead to release the clips and also release the grommit where the loom pases through the bulkhead. Also shown is the scuttle panel part removed. (Ignore the fact all of the engine covers are also off as I was going on to clean the engine bay as well as doing this, you don't need to remove them to clean the plenum drains).



    4, Undo the battery terminals, 10mm spanner, and set aside.

    5, Undo and remove the battery clamp, 13mm socket on 10" bar. See picture below for location.



    6, Remove battery cradle, x2 13mm nuts and one 13mm bolt, see picture below. Note that the alarm sounder is secured by one of the nuts. Note this was taken on re-assembly so it appears clean!



    7, This is what I was faced with, a dirty but dry plenum! The location of the battery side drain is shown arrowed and the approx location of the drain under the servo is also arrowed. I chose to poke the grommits out. There are two schools of thought on this, one being that they should remian in place as they stop fumes rising into the plenum as thus into the car interior via the pollen filter which is in the plenum. The other is to remove and not worry about fumes unless your exhaust is blowing. Im not worried and so poked them out! You can make your own decision on this.



    8, Cleaned with TFR (traffic film remover) and my pressure washer. I also ran an open hose in there as well to ensure all crud was removed.



    9, With battery back in.



    10, Connect everthing back up, replace plenum cover and rubber seal, job done! Took me about 45 minutes in total.
    Last edited by Col; 30-08-2015 at 09:57 PM.
     
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  2. Re: Passat B5, B5.5 plenum drain cleaning 
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    I had this done under warranty about 4 years ago but not before the rear carpet got soaked the previous year and I unblocked it but left the bung in!. Anyhow, good on you for putting this preventative measure up on the forum.
     
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  3. Re: Passat B5, B5.5 plenum drain cleaning 
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    Have you done it since? I did it twice a year when I had my Passats.
    Nothing to see here, move along..
     
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  4. Re: Passat B5, B5.5 plenum drain cleaning 
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    I think it is something that needs to be checked once a year if not sooner.
     
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  5. Re: Passat B5, B5.5 plenum drain cleaning 
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    What is new on here?

    My last post is showing as requiring moderator approval ?
     
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  6. Re: Passat B5, B5.5 plenum drain cleaning 
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    Good write up. How did you manage to get the battery out? I tried removing it but it fouled on the plastic lower windshield lip.
     
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  7. Re: Passat B5, B5.5 plenum drain cleaning 
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    Quote Originally Posted by BigCol View Post
    What is new on here?

    My last post is showing as requiring moderator approval ?
    I moved the thread to the How To section as it's another one of your damned good posts.

    I've moved it back now and copied the first post only.


    Considering selling my VCDS KEY-USB interface. If you're interested please contact me via PM or email.
     
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  8. Re: Passat B5, B5.5 plenum drain cleaning 
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    Quote Originally Posted by mycarsavw View Post
    I moved the thread to the How To section as it's another one of your damned good posts.

    I've moved it back now and copied the first post only.
    Excellent, cheers Sam.
     
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  9. Re: Passat B5, B5.5 plenum drain cleaning 
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    Quote Originally Posted by attila_tdi View Post
    Good write up. How did you manage to get the battery out? I tried removing it but it fouled on the plastic lower windshield lip.

    Read Nr3. above, you need to roll the loom forwards to create room.
     
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  10. Re: Passat B5, B5.5 plenum drain cleaning 
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    Bump for wet winter and thanks for the guide!

    Shared on A4 B5 forum!
    '11 VW B7 Passat Estate 2.0TDi CFFB (Current)
    '98 VW T4 Transporter 2.5TDi ACV (Previous)
    '99 Audi B5 A4 Avant 1.9TDi AFN (Previous)
     
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