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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old November 21st, 2010, 17:40   #1
DezlDan
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Default Beware of the Plenum Leak!

Just an FYI to everyone re: Passat plenum leaking. I had heard about this issue, but thought it would never happen to me. Why would it, my car only has 34,000 original miles on it and spends 2/3 of the year indoors? Wrong! Went outside a few weeks ago and she had filled up like a bath tub on the passenger side front and rear.

I dug into it and could clearly see water rushing past the pathetic foam seal on the passenger side fresh air vent in the plenum (where the pollen filter sits). This foam turns to dust from age and heat exposure. If you have foam bits coming in through your air vents inside the car, you should be particularly concerned. As it turns out, there is a recall for this, but as I gather, it was not noted as active on my car, and I was never notified. Perhaps it was a complaint based goodwill recall; either way, I was never notified.

The long and short of it is that the dealer had my car for a full week, and dried it all out, and cleaned it. They did a great job. They were going to replace the TCM but found that it was still completely dry in its housing, so that was not replaced. The total bill has yet to be tabulated, but the rough number is $700. If the TCM had been damaged, the bill would have been far more. The bill was paid in full by my extended VW warranty, which I will more than get my money out of by the time it expires in mid 2012.

The fix is to remove the crap foam seal and replace it with a polybutyl seal. Everything in my car was removed: all seats, all carpets, and center consul. Please save yourself the aggravation and get the upgrade done under the recall or spend the few dollars to get the new seal put in. Once it leaks, you will be sorry that you weren't pro-active about fixing it. I am hoping that this info saves a few of you some grief.
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Old November 21st, 2010, 17:57   #2
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Do you have the TSB or recall number for this warranty repair?
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Old November 21st, 2010, 18:02   #3
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Quote:
Originally Posted by Biodezl View Post
Do you have the TSB or recall number for this warranty repair?
And or the part number?
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Old November 21st, 2010, 18:10   #4
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Guys, I have neither the part number, nor the TSB. I don't even have my bill/ receipt as yet. I picked up the car today from reception (Sunday), as the service department was closed. I will be talking to service tomorrow to get my copy of the paperwork, etc. When I get more info I will post it.
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Old November 22nd, 2010, 20:29   #5
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I found this TSB. Since it's a TSB I assume VW will not cover this outside of the warranty period ?



  • Date Announced: JUNE 01 2008
    TSB #P 9-66C8

    NHTSA ID #10025923
Summary: VOLKSWAGEN: 2001-2005 MODELS: SERVICE AIR PLENUM AREA TO IMPROVE DRAINAGE AND INSTALL IMPROVED POLLEN FILTER SEAL. WATER COULD LEAK INTO THE PASSENGER COMPARTMENT. 2002 MODELS COULD HAVE LEAKS INTO THE BRAKE BOOSTER. *PE
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Old November 23rd, 2010, 07:01   #6
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I remember seeing that TSB, but perhaps it has been updated???? The one I remember seeing covered early B5, perhaps up to 2002. Is there a PDF copy of this around that we could print out? I have a Service Appointment coming up very soon, and I would like that plenum inspected (if it needs to be?), even though I am out of warranty...
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Old November 23rd, 2010, 07:05   #7
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I have a pdf copy and will be willing to e-mail it to anyone who wants a copy. It covers the sunroof drain issue as well. If I post the file in my photo album and link it here, will that work too?

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Old November 23rd, 2010, 07:21   #8
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Aha, sunroof drains too! Yes please, I'd like to see that.

How come the sunroof drain recall was done this summer but only for Jetta/Golf platform?
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Old November 23rd, 2010, 07:32   #9
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Default Here it is

It's in my photo album (aja8888). I can't seem to figure out how to link it here.

it's labeled TAB Cowl.
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Old November 23rd, 2010, 08:17   #10
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Anyone seen this problems in Jettas?
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Old November 23rd, 2010, 08:43   #11
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Quote:
Originally Posted by aja8888 View Post
It's in my photo album (aja8888). I can't seem to figure out how to link it here.

it's labeled TAB Cowl.

Thanks for posting that, looks like it's covered even if we are out warranty.

Here's a direct link to the information (aja8888's Tab Cowl PDF) ----> http://pics.tdiclub.com/data/500/Cow...n_Circular.pdf



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Old November 23rd, 2010, 08:47   #12
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It should have been part of the sunroof drain recall. Funny, the A3s had the same issue (the few sold here that actually had a pollen filter).

Although I think if the drains under the battery are kept clean, the water should not get up that high to get into the HVAC intake area anyways, but perhaps if it was parked nose-up on a hill?
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Old November 23rd, 2010, 09:26   #13
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Quote:
Originally Posted by oilhammer View Post
I...
Although I think if the drains under the battery are kept clean, the water should not get up that high to get into the HVAC intake area anyways, but perhaps if it was parked nose-up on a hill?
Do you have to remove the Battery to get at the drain?

I was cleaning out the leaves and crap in that firewall area with compressed air and a vacuum. Didn't remove the battery. I pour a cup or so of water under the battery to find out where it would go, it looks like it was draining out on to the driver side CV half shaft. Should the water drain on the other side as well?



BTW - I don't see how a foam gasket in the plenum keeps water out in the first place.?.?



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Old November 23rd, 2010, 09:58   #14
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Quote:
Originally Posted by oilhammer View Post
It should have been part of the sunroof drain recall. Funny, the A3s had the same issue (the few sold here that actually had a pollen filter).

Although I think if the drains under the battery are kept clean, the water should not get up that high to get into the HVAC intake area anyways, but perhaps if it was parked nose-up on a hill?
No, that is not the case. My car was on a flat surface. Water was running down the windshield and draining at the base of the passenger side A pillar. As the water poured into the plenum it ran beside the fresh air vent seal on it's way to the bottom of the plenum and then out the drain. At one time, the seal was solid enough to keep the passing water out, but as it deteriorated it allowed water in. Please understand that this has nothing to do with
pooling of water and everything to do with the path that the water travels as it rolls off the windshield and rushes past the fresh air housing.

As an added argument for doing this pro-actively, I am now trying to get satisfaction from the dealership over all the little things they broke when they tore the car apart. I thought
they did a great job, but I have since learned that they broke and scratched many parts of the center consul. I still have no paperwork as they are awaiting payment from my VW
extended warranty. Be pro-active folks. This is an extremely ugly mess to clean up once Ernie and his Rubber Ducky have moved into the new neighborhood bath tub.
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Last edited by DezlDan; November 23rd, 2010 at 10:12.
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Old November 23rd, 2010, 20:14   #15
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Pardon my ignorance, but whats a TCM?
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