Can I clean plenum holes myself?

[cinman2003]

Is this a job I can do myself, cos I'll have a go this weekend if so?

I ask as I've read that some Passat owners have to take their motors back to dealers to get it sorted - which makes me think it might be a pig to do without specialist knowledge/tools/etc.

I've got a slight dampness to my front passenger footwell and from the excellent information on this great forum, I'm determined to check the plenum chamber drainage - but no point if it's out of my range so to speak.

Thanks once again, and sorry by the way for bombarding this forum with questions but I've only just got my first Passat and am well excited to get the bits sorted.

[Hex69]

Is this a job I can do myself, cos I'll have a go this weekend if so?

I ask as I've read that some Passat owners have to take their motors back to dealers to get it sorted - which makes me think it might be a pig to do without specialist knowledge/tools/etc.

I've got a slight dampness to my front passenger footwell and from the excellent information on this great forum, I'm determined to check the plenum chamber drainage - but no point if it's out of my range so to speak.

Thanks once again, and sorry by the way for bombarding this forum with questions but I've only just got my first Passat and am well excited to get the bits sorted.

YES, there are 2 bungs holes, one under the battery and one under the brake servo.

Remove the battery (as you've got a petrol should be straightforward). The bungs are about an inch or so wide, remove clean and replace, and while you're in there clean out all the crud from the plenum chamber, and before you replace battery, pour a pint of water in to see that it drains ok.

Repeat every 6 months or so. :mad:

[cinman2003]

Hex69 - thanks that's brilliant - will have a go tonight when I get home (as it's due to rain shortly I think!)

[veedub76]

My wife has a 130 TDI and we want to check the plenum ourselves. Is it harder to do on a diesel? Not sure how to remove all the plastic around the scuttle. Do the wipers need to come off?

[RBF]

My wife has a 130 TDI and we want to check the plenum ourselves. Is it harder to do on a diesel? Not sure how to remove all the plastic around the scuttle. Do the wipers need to come off?

It is a PITA on a diesel, because the battery is massive and requires removal of the plastic trim under the wipers. Otherwise, on your own it is impossible to lift the battery clear in such a small gap, due to it being so heavy and far away as you lean over the wings towards the centre of the car. Wipers must be removed with a wiper arm puller tool before removing trim and even then the trim is a pig to remove without breaking it.

It is possible to unblock plenum bungs from underneath vehicle, but you would need it up on a ramp and something long to poke up to unlock them/better still pull the god damn things out!

[veedub76]

Blimey, does sound like a nightmare:(. It's in for a service saturday and the guy at the garage said that he's had loads of them that are full to the brim with water. He said the easiest way is to get it underneath and pull the bungs out. Think this is the way i'll be going!

[RBF]

Blimey, does sound like a nightmare:(. It's in for a service saturday and the guy at the garage said that he's had loads of them that are full to the brim with water. He said the easiest way is to get it underneath and pull the bungs out. Think this is the way i'll be going!

Definitely! :fing02:

The only reason they have a bung is stop road spray entering the plenum chamber. Can't see that could do more damage than the plenum filling with water and flooding the passenger carpets and the servo filling with water, leading to brake problems!

[cinman2003]

Mine will have to wait until the weekend as I can't see a thing (too dark) by the time I get home from work. I was thinking I might use that flexible cord used for holding up net curtains - you know that long flexible stuff that's quite strong along its length ... we'll see.

[MalcQV]

It is a PITA on a diesel, because the battery is massive and requires removal of the plastic trim under the wipers. Otherwise, on your own it is impossible to lift the battery clear in such a small gap, due to it being so heavy and far away as you lean over the wings towards the centre of the car. Wipers must be removed with a wiper arm puller tool before removing trim and even then the trim is a pig to remove without breaking it.

It is possible to unblock plenum bungs from underneath vehicle, but you would need it up on a ramp and something long to poke up to unlock them/better still pull the god damn things out!
Glad mine is petrol, had the thing in and out more times than a groom's todger on his wedding night.

**** design and dangerous, great car the Passat but this lets it down so much I won't be buying another.

[cinman2003]

I've got my Haynes manual on its way to me in the post, so I might find these "bungs/holes" easily enough. Does anyone have any piccies in case the manual doesn't arrive this weekend (did you see the Dispatches on the postal system earlier this week - it'll be a miracle if it arrives at all!!)

Is it so obvious where it is once I remove the car battery? Either way I'll take a look and see for myself this weekend and lets see what happens. I've got my heater pointing down to the footwells for now so my commute it the only chance it gets to dry out right now !?!

[MalcQV]

There used to be a URL on weirdlittlebiscuit but it no longer works. Anyone?
http://www.weirdlittlebiscuit.com/passat/leak/

[Hex69]

Is it so obvious where it is once I remove the car battery?

Yes, it is, one under the battery tray (you can remove the tray easily by undoing 3 bolts), and one under the brake servo (big round thing in plenum chamber)

Piccies here (http://images.google.co.uk/imgres?imgurl=http://img.photobucket.com/albums/v22/Turkish/Passat/17102006199.jpg&imgrefurl=http://www.passatworld.com/forums/showthread.php%3Fp%3D1892310&usg=__gDUGNRINJqqPMOyBiJA-pR8SXdw=&h=768&w=1024&sz=148&hl=en&start=51&um=1&itbs=1&tbnid=rSSP6kdWL8FLWM:&tbnh=113&tbnw=150&prev=/images%3Fq%3Dpassat%2Bplenum%2Bchamber%26ndsp%3D18 %26hl%3Den%26client%3Dfirefox-a%26rls%3Dorg.mozilla:en-GB:official%26sa%3DN%26start%3D36%26um%3D1)

[mwvw]

Just done the wifes' 2.0 passat, she was complaining that there was a smell in the car, checked under the passenger carpet and sure enough, wet underneath.
First thing was to check the drain bungs.
You need to remove the windscreen wipers, pullers are the best way to do this.
Remove the plastic valance/weather strip at the bottom of the windscreen.This should be gently levered or pulled up at 90 degrees to the windscreen. Once you can get it started at one end it will easily pull up, all along the windscreen. Battery can then be easily removed. Unbolt the battery tray to get at the bung directly underneath and you can then just about get at the one under the brake servo.
I removed the pollen filter housing, 3 bolts and resealed it with mastic as the foam seal was cracked and full of water.
Inside the passenger compartment, the front seat and rear seat squab were taken out. The side trim along the door was prised up and the centre console removed. This enabled me to raise the carpet up and mop up the water in the well (well being the correct term, as I had out about 1/2 a washing up bowl of water in there). The fan heater has been running constanly at low heat to gently dry out the felt soundproofing - hate to see what my electric bill is going to be.
Fortunately the inside of the CCM housing was dry and its now ready to put back, although will have to reset the airbag fault light.
Not a hard job but why should it necessary if things were designed better.:(
Hope this helps

Also agree with MalcQV, The URL for weirdlittlebiscuit is out.

[cazyp]

You can get the battery out of the diesel without removing the scuttle trim under the wipers by relocating the wiring harness that runs along the front of the bulkhead. The battery will then lift out ;)

[Hex69]

You can get the battery out of the diesel without removing the scuttle trim under the wipers by relocating the wiring harness that runs along the front of the bulkhead. The battery will then lift out ;)

Just what I've said, however the battery will only come out at an angle, so be careful folks!;)

[cazyp]

Just what I've said, however the battery will only come out at an angle, so be careful folks!;)

Good advice - wiggle it, just a little bit.

[MalcQV]

You can get the battery out of the diesel without removing the scuttle trim under the wipers by relocating the wiring harness that runs along the front of the bulkhead. The battery will then lift out ;)
Yes sir you have to do this with the battery in the petrol version too else she won't come out ;)

[cazyp]

Yes sir you have to do this with the battery in the petrol version too else she won't come out ;)

Cool, never owned a petrol passat. Just good old diesel taxis :biglaugh:

[RBF]

The whole, removing the wiring harness thing (that's an odd looking thing in itself) and wiggling the battery out is a two man job if you don't want to be dragging the battery out and bashing all the bodywork. Perhaps I am just too weak, but the battery on the diesel weighs a ton and is not easily removed.

[Qman5]

I put a new battery on my TDCI 130 yesterday.
I started at 3.00pm and finished at 7.00pm. What a rotten job this was. I read the Haynes manual, it looked easy!
Whatever anyone says the battery will NOT come out until you remove the cowling below the windscreen, if you move the wiring loom some pipes are still in the way.
Haynes says carefully lift the cowling and pull. This didn't work, so I used a small screwdriver to lever it a little. Now the windscreen has a large crack and the cowling broke so I rang a friendly mechanic to shift it. He struggled for quite a time before moving it and fitting the new battery.

So a broken windscreen and cowling, a few pints for friendly mechanic, very cold hands all to fit a battery!!! What a daft design, thanks VW.

[cinman2003]

Sorry to hear you've had a sh*t time of it dude, that's rough.

I poured an egg-cup full of water down there and looked underneat the car ... lo'n'behold there it was dripping straight out ... so it looks like I don't have to bother ... YEE HAA :biglaugh:

It does look like the batter would come out with just removing the + and - cables though, perhaps at an angle (I've a 1.8 S/99 petrol) at worst maybe haveing to remove the plastic filter cover. Maybe I'll attempt that in Summer.

Thanks all for the excellent advice - I've learnt loads which I simply couldn't of gotten elsewhere, nice one.:beerchug:

[salmonhunter]

after you remove the battery do you need to get your radio coded.

[mwvw]

I think it depends on model/year, as just having cleaned the drain plugs and sealed the pollen filter housing on my 02, the radio set itself up after reconnecting the battery

[dickturpin]

My radio was fine after battery disconnected. 2004 Tdi Sport.

[Chipped2]

Battery is easy to remove even on diesel as you can thread a 4-5ft length of 3"x1" timber through the battery 'handles' and two can easily lift and place on engine for lifting to floor. Leave the battery clamp in place after removing screw.

Remove the 2 nuts and one screw from the battery box and remove. The first bung is beneath the two air-con pipes. Clean it out with a toothbrush and water. Compost will fall through. I prefer to leave my bungs which prevent fimes from entering plenum chamber and into car via the pollen filter.

Second bung is beneath brake servo. you cannot see it but if you feel under the now loose alarm you will be able to crook your finger into it and push the 'composted crud' through.

Before you replace all, clean all the other leaves/compost/crud from the following areas. Behind and around pollen filter, wiper motor, ECU and anywhere else you can see it. Use wire and whatever brushes you can find. Then pour a couple of jugs of water into the plenum chamber and ensure it all disappears through your clean drainage holed. replace all as before. The worst part of the whole job can be removing the wipers as they can corrode onto the spindles, loosen the centre nuts and spray with WD40 the night before. Rmove the full width plastic trim from being clipped into the channel if the windscreen as follows;

Using a half a wooden clothes peg minus its spring, push the thin end between the windscreen and trim on the passenger side. Keem the peg flat on the cleaned windsceen to prevent scratching and push it towards the drivers side. It will lift the plastic trim from its attachment to the windscreen. \it may be brittle and crack but they are approx £10 and it may be best to get one prior to starting. If it does crack you could still refit and either glue or tape over until one is available.

If yours is a B5.5 you will also replace the larger plenum chamber cover which helps to keep out some of the leaves that cause the problem in the first place!! Try not to park beneath trees with small leaves and ESPECIALLY small berries.;)

PS. Dry your carpets ASAP.

[cinman2003]

Nice and concise - pretty much covers it all off in one hit - thanks for your detailed and helpful notes. I have printed it off and will have a go when the weather cheers up a bit :beerchug:

[Qman5]

I got a new windscreen from Autoglass yesterday, a very good firm using identical glass to the original. The fitter used a special tool to run along the base of the windscreen to loosen it, like the clothes peg idea. This advice is not in the Haynes manual, which seems to be a bit useless (oil recommendations wrong, tyre pressures wrong)

I looked again and the battery will not come out on a Passat 5.5 TDI without removing the cowl at the base of the windscreen, even if you jiggle it!

[dieselbundy@aol]

yes it will you have to unclip the wiring harness on the firewall and lift out at an angle:Blush:

[Qman5]

I unclipped the wiring and it still would not come out because 2 other pipes were in the way.
I got a mechanic friend to help, he said the battery wouldn't come out without taking the cowl off, whatever you did.
Is your car a diesel? because I think the petrol ones have a smaller battery.

[cazyp]

I got a new windscreen from Autoglass yesterday, a very good firm using identical glass to the original. The fitter used a special tool to run along the base of the windscreen to loosen it, like the clothes peg idea. This advice is not in the Haynes manual, which seems to be a bit useless (oil recommendations wrong, tyre pressures wrong)

I looked again and the battery will not come out on a Passat 5.5 TDI without removing the cowl at the base of the windscreen, even if you jiggle it!

It will. Done mine 3 times so far. The angle is important.

[djmx5]

Following this thread keenly......dieselbundy and cazyp...... I too cannot see how the battery can be removed without lifting off the cowling. On my 2005 tdi I cannot even see the battery, only the terminals are visible by sliding a small plastic flap to one side before removing. You guys must have differant setups on your diesels.

[Qman5]

The cowling you are talking about is easy to take off. There is another cowling which has to be removed under the first one. It's the one which is at the bottom of the windscreen, you have to take the window wiper arms off as well. Do not prise with a screwdriver!!!
My mechanic pal definitely said that the battery would not come out without removing the horrible plastic cowl thing. Some cars must be different.

[cazyp]

The cowling you are talking about is easy to take off. There is another cowling which has to be removed under the first one. It's the one which is at the bottom of the windscreen, you have to take the window wiper arms off as well. Do not prise with a screwdriver!!!
My mechanic pal definitely said that the battery would not come out without removing the horrible plastic cowl thing. Some cars must be different.


There all the same. It can be done. Just not 'easy.'
I'll take some pics next time I do mine.

[djmx5]

cazyp...that is a great offer, and would no doubt go a long way to properly explain how to do this essential maintainance issue.

Do you know if there is a 'how to' link on the forum regarding posting photo's?

Thanks

D

[djmx5]

derrr....just seen a link.........going to experiment with an unrelated photo7974

[cazyp]

There all the same. It can be done. Just not 'easy.'
I'll take some pics next time I do mine.


cazyp...that is a great offer, and would no doubt go a long way to properly explain how to do this essential maintainance issue.

Do you know if there is a 'how to' link on the forum regarding posting photo's?

Thanks

D

There you go - a rubbish how to lol:

http://www.vwaudiforum.co.uk/forum/showthread.php?p=485226#post485226

HTH.

[N_CURTIS]

Hi all,

Had this saved in my favourites list and it still works.

http://www.weirdlittlebiscuit.com/passat/leak/index.htm

[dpmorgan]

Hex69 - thanks that's brilliant - will have a go tonight when I get home (as it's due to rain shortly I think!)
Try this site

http://weirdlittlebiscuit.com/passat/leak/

[cazyp]

Hi all,

Had this saved in my favourites list and it still works.

http://www.weirdlittlebiscuit.com/passat/leak/index.htm


Try this site

http://weirdlittlebiscuit.com/passat/leak/

Great thread unless you have a TDi - the battery on a TDi doesn't just 'lift' out. No room. Hence: ;)



There you go - a rubbish how to lol:

http://www.vwaudiforum.co.uk/forum/showthread.php?p=485226#post485226

HTH.

[blown the case]

Hi Fellas, still in negotiations with my VW garage and VW UK, seems it may be done by them yet ? However if not, for clarity, am I correct in thinking on the 2.0 petrol you just have to take the battery out to clear out the drainage holes, I had read that the wipers had to be removed, the plastic cowle at the base of windscreen removed etc, to access the drain holes ?
Now we are getting a few sunny days my car is like a bloody sauna & the passenger side front carpets are only damp ?
Cheers

[cazyp]

Hi Fellas, still in negotiations with my VW garage and VW UK, seems it may be done by them yet ? However if not, for clarity, am I correct in thinking on the 2.0 petrol you just have to take the battery out to clear out the drainage holes, I had read that the wipers had to be removed, the plastic cowle at the base of windscreen removed etc, to access the drain holes ?
Now we are getting a few sunny days my car is like a bloody sauna & the passenger side front carpets are only damp ?
Cheers

Depends how big the battery is.
ALL can be removed withour taking the wipers etc off.
See http://www.vwaudiforum.co.uk/forum/s...226#post485226 (http://www.vwaudiforum.co.uk/forum/showthread.php?p=485226#post485226)

[MalcQV]

Hi Fellas, still in negotiations with my VW garage and VW UK, seems it may be done by them yet ? However if not, for clarity, am I correct in thinking on the 2.0 petrol you just have to take the battery out to clear out the drainage holes, I had read that the wipers had to be removed, the plastic cowle at the base of windscreen removed etc, to access the drain holes ?
Now we are getting a few sunny days my car is like a bloody sauna & the passenger side front carpets are only damp ?
Cheers
Mine came out no problem a 75Ah battery. I just had to pull back the cable trunking on the front edge of the plenum.

[cinman2003]

I poured some water down there and it dully ran out the bottom (looking underneath the car) however my passenger footwell is still soaked. Thought I might take my battery out too this weekend, weather permitting, and see what's going on down there. Perhaps there's a leak somewhere. From what I can gather the smaller petrol engined models should get the battery out no probs. Might take piccies in case it helps others, etc.

[MalcQV]

I poured some water down there and it dully ran out the bottom (looking underneath the car) however my passenger footwell is still soaked. Thought I might take my battery out too this weekend, weather permitting, and see what's going on down there. Perhaps there's a leak somewhere. From what I can gather the smaller petrol engined models should get the battery out no probs. Might take piccies in case it helps others, etc.

I had similar problems the first time even after cleaning out. I found even though the water flowed out it still (given enough) created enough build-up to seep through the A/C duct seal. I used panel seal as it was all I had at the time, on the joint.

[cazyp]

I poured some water down there and it dully ran out the bottom (looking underneath the car) however my passenger footwell is still soaked. Thought I might take my battery out too this weekend, weather permitting, and see what's going on down there. Perhaps there's a leak somewhere. From what I can gather the smaller petrol engined models should get the battery out no probs. Might take piccies in case it helps others, etc.

In your case it will probably be the pollen filter seal needing replacement.

[bigchazmo]

Have been sorting out the water in mine this weekend and sealing off the pollen filter properly. It's quite straight forward, i would strongly advise you get a wiper arm puller as they are a git to get off!

Found this link really good - http://www.weirdlittlebiscuit.com/passat/leak/index.htm

[djmx5]

Hi all,

Well, have just spent 40 mins with the aid of a second pair of hands to help with the battery removal and the job is done! Not too bunged up but enough to warrant a clean out.

I am not 'handy' with spanners but I found this very easy by following the step by step guide found elsewhere in this forum, so go on..... give it a try.

Cheers
D

[Trillock]

Had the same problem with my Passat (51 plate) 1.9Tdi with water dripping down the side of the front passenger footwell.
I did manage to take out the battery by myself (yep they are big and heavy)........a bit of a struggle, but moving the wiring loom off its clips and a wiggle here and there, it came out.
Lifted the carpet and removed the water that was sitting there by the black box of magic tricks.
Cleaned the chamber and cleaned out the bungs....there wasn't any water in the chamber but the bungs were blocked with dirt/mud.
Replaced the battery and replaced all the bits I moved/took off, and checked that car started and no problems with radio.....all back as it was.
It still leaked after rain.....pah!.

Was not feeling very good about attempting to remove the pollen filter housing, so gave in and took it to my local VW garage where they removed/replaced the housing with the mastic seal.......not foam seal, for £75.
No leaks at all now so problem solved, nice and dry inside.
Just as well with the cold, snowy and icy winter we have just had, so I am glad I forked out good money to have it fixed.

[vwnige]

I did mine myself but it was a real struggle as the battery is so heavy..

If i clean it again i would definatly find someone to help me lift the battery as it would be much easier...

[trevtherev]

It is a PITA on a diesel, because the battery is massive and requires removal of the plastic trim under the wipers. Otherwise, on your own it is impossible to lift the battery clear in such a small gap, due to it being so heavy and far away as you lean over the wings towards the centre of the car. Wipers must be removed with a wiper arm puller tool before removing trim and even then the trim is a pig to remove without breaking it.

It is possible to unblock plenum bungs from underneath vehicle, but you would need it up on a ramp and something long to poke up to unlock them/better still pull the god damn things out!


Needing a battery during a 4 day power cut last week, I took mine out in the middle of the night - Passat 1.9 TDi 2001 - and didn't remove wipers or plastic trim. I had to unclip what looked like a wiring harness clipped to the bulkhead in front of the battery then lift the battery out at an angle. Putting it in was more difficult than getting it out, but it went in eventually.

I did notice a hole without a bung under the battery - would this have been done during the half hour the garage had it in under the recall?

[cazyp]

Needing a battery during a 4 day power cut last week, I took mine out in the middle of the night - Passat 1.9 TDi 2001 - and didn't remove wipers or plastic trim. I had to unclip what looked like a wiring harness clipped to the bulkhead in front of the battery then lift the battery out at an angle. Putting it in was more difficult than getting it out, but it went in eventually.

I did notice a hole without a bung under the battery - would this have been done during the half hour the garage had it in under the recall?


;) I guess so.

[trevtherev]

;) I guess so.

I should have read to the end of the thread before posting that - I feel I know a bit more about the drain holes now - will look more closely next chance - and interesting to see there is so much controversy about the battery. Just to add a bit more info for anyone wondering if theirs would come out without removing the plastic trim - my 1.9 TDi 130PS PD estate is AVF engine FRK transmission and I presume the battery is original. Battery details are: DZO 915 105D 80AH 380 Amps Appx dimensions 31 X 17 X 18 cms

[Lex_Andrews]

Hi all,
I have a '99 V Estate 1.8T. Everytime I wash the car I notice that I get a "leak" coming from the from passenger side running from the washer bottle or so I thought, till looking at the battery water covering bottom 1/4cm of the battery, not only that the alarm siren doesn't sound. But no water in footwells. Hard brakes though.

Ummmmm. Still not bad though, cars' got 190106miles on clock, and behaves like the 59 Octavia responce car we have at work. Battery out this weekend, here's to a "easy"? job.

[dib]

The trick is to slide the battery towards the pollen filter before attempting to lift out, so I have read.

[Trillock]

I am a complete novice, but it took me something like 15 mins or so to get to the drain holes.
Removed the rubber seal.
Then the big plastic cover.
Then disconnected battery and shoved the battery leads out of the way.
Undid the battery clamp.
Unclipped the wiring harness.
Then put hands under battery, pulled it towards pollen filter housing.....the bonnect strut gets in the way a bit........and then wiggle it up and out, gently pushing the two pipes by the wiring harness out of the way.
It does come out easy enough if done gently.......and yes, the battery is heavy, but using two hands under it helps.
Then undo nuts to remove battery plate and remove.
Now the plenum chamber is clear of obstructions.
I found no need to complicate things by removing wipers and plastic scuttle thingy.....makes extra work, and more than likely I would have broken something doing it :D
Then put it back together again in reverse order............maybe takes about an hour if you have to clean out the plenum chamber......if not maybe half and hour.
Everything worked ok once battery was re-connected........radio etc.

[ad777]

My wife has a 130 TDI and we want to check the plenum ourselves. Is it harder to do on a diesel? Not sure how to remove all the plastic around the scuttle. Do the wipers need to come off?

http://www.vwaudiforum.co.uk/forum/showthread.php?t=92813&highlight=battery+removal
i followed this link to remove myself,took 20 mins and a bit of swearing, but saved a small fortune getting garage to do it. this is a great forum!!