Plenum Chamber Drain Grommets - Every A4 B6 owner is affected by this common fault

[GrayT]

Mines a 2004. Not sure if it's been done but I'm going to take them out as after I wash the car a trail of water is left round every roundabout for the first ten minute drive. Can't think where else that amount of water would come from.

That's exactly how mine was yesterday. Thing is I had checked the chamber when this thread first appeared - no water. So left it. Car wash yesterday and first roundabout I see water spurt out the side of the bonnet and hear it sloshing - I guess all the crud from autumn/winter blocked it up fairly quickly. I know it's in the thread already, but DO NOT INGNORE THIS ISSUE folks! I'm glad I caught mine before damage was caused. I had to nip out and get a long flexi screwdriver with allen head to take the battery out - I can't believe how difficult Audi have made it to remove the battery. I removed the grommets completely. I would be too afraid to drive the car with all that water sloshing about near those components.

 

[subaru swift]

Right i replaced my battery on sun morning & saw some water about 1cm if that so i replaced the battery ( i know silly me ).

& remembered on my old 1.9 tdi ( 51/ 2002 reg ) i had a recall for this problem, so i thought i would let Audi do the recall & guess what.

I rang stoke Audi today & the lad said there is NOT a recall on my 2.5 v6 tdi ( 54 /2004 reg ) !! so they would have to charge me but i said i would do it my self.

However I will just pull out the bungs from under the car if i can get it on my mates ramps, as the battery swap took me a hour .

 

[ocalld]

I had a recall letter sometime last summer.
Unfortunately my servo iced up Dec 09. Anything 3DegC or under the pedal felt like it had a brick under it, stopping you pressing the pedal.
Even had the brakes jam on.
Every time i took it to the garage they couldn't find anything wrong with the brakes. It took three attempts to get it diagnosed.

I think it cost me around £600 to replace the servo in an independent Audi specialist.

 

[ocalld]

I had a recall letter sometime last summer.
Unfortunately my servo iced up Dec 09. Anything 3DegC or under the pedal felt like it had a brick under it, stopping you pressing the pedal.
Even had the brakes jam on.
Every time i took it to the garage they couldn't find anything wrong with the brakes. It took three attempts to get it diagnosed.

I think it cost me around £600 to replace the servo in an independent Audi specialist.

 

[Cabbyfan]

My 2001 B6 2.0 saloon I used to have sufffered with the stuck brake peddle problem, had to have the brake servo replaced. I arfued at the time it was a dsign fault and my local dealer said Audi woudnt foot the bill. I needed the work doing as I needed a car, paid the bill. I then kept asking my local Audi dealer if they would assist with the cost, eventually they paid for half the cost. About 6 months later the plenum chamber recall happened and they all got done..... maybe I should try and get the other 50% refunded !

 

[Cabbyfan]

* note to self..... spell check posts before submitting

 

[AudiLeon]

Cheers for this people!
I popped the battery out today to have a look, it seems who ever has serviced the car before hand (which is odd as it has full audi history) has just got rid of the plug below the battery, the one under the servo was bunged up.

Cleaned it out, much happier now!

 

[Harold]

I'm actually a 51 Passat owner, but would like to comment as 'the poor cousin' whilst I'm pleased that Audi owners are being looked after by their manufacturer and are having repairs covered. I am currently embroilled in a war of words with VW UK, who have not issued a 'recall' but a 'Service Advisory Record' and they refuse to acknowledge that the plenum chamber is a design 'fault' and insist that it is an easily servicable part.
This fault has caused the chamber to flood and caused failure of the brake servo and battery to discharge it's self.

It is interesting to note the stark difference in customer service between the brands.

I have highlighted the class law suite in the states and Audi's handling of this design fault and VW UK insist that the american chasis and EU Audi's are entirely different design.... despite the exact same fault.
I would be interested to hear from any Audi owners that have had to fight / take legal action for compensation.

regards,

haroldofislington@hotmail.com

 

[paul20v]

I have highlighted the class law suite in the states and Audi's handling of this design fault and VW UK insist that the american chasis and EU Audi's are entirely different design.... despite the exact same fault.

Hi
they sound like there trying it on really badly , as for a entirely different design i dont think so there all nearly identical
Passats are based on the B5 range in that age and they also had an issue the B6 also is basically the same design in the bulkhead and scuttle area
there just trying it on and im shocked that one half of the same overall company is trying it on like this
Hope you get some success mate .

 

[rjm180]

I have highlighted the class law suite in the states and Audi's handling of this design fault and VW UK insist that the american chasis and EU Audi's are entirely different design.... despite the exact same fault.
I would be interested to hear from any Audi owners that have had to fight / take legal action for compensation.

haroldofislington@hotmail.com

Harold, cant help you myself but Good Luck.

 

[Point_Audi]

Just writing this as I remain suprised that there is not an obvious sticky thread for this design fault and I continue to read posts about people having problems when it rains.

Surely every A4 B6 owner has now removed the grommets in the bottom of the plenum chamber? There are rubber grommets below battery on the left and below the brake servo on the right fill with crap and dont let water escape from the car.

If you haven't removed these it is purely a matter of time before your car fails in an expensive (water in ECU, HVAC, engine) or dangerous (brake servo failure) way.

I dont think this common fault is highlighted enough in this forum as the consequences of not sorting can cost many thousands.

How to fix the problem here
(for a passat but identical problem)
or

Take your car to a dealer and they will fix it for free.

Really hope this saves a few people from disaster.

Paul

Great guide, thank you!

I decided to do this yesterday as I was off work! Took me about one hour start to finish. I was glad I did, as the rubber under the brake servo was full of mud, however there was no rubber under the battery! Looks like it had been removed before!

Few Pictures:

Before:

After:

 

[trevaudi]

Thanks for the guide. Finally forced into doing the job yesterday 'cos I had to fit a new battery. Plenum chamber had plenty of water sloshing around inside but fortunately nothing damaged. Done just in time!

 

[benjie]

Great guide. Did this last weekend. All clear, but the one under the brake servo was full of gunk, so I expect it was all draining through the other one. All nice and cleaned out now, nice simple job.

 

[sinic]

I phoned Wearside Audi in the week to find out if the recall had been done. They entered my registration number into the super computer and stated that my car did not require the upgrade as being an '04 was not affected.
I explained that after a wash I have streams of water following me around roundabouts but they said that it would not be a recall, all they do now is check and clear them out at every service. So I asked why they didn't do it when I recently had the cambelt service done - to which they could not answer but ensure me that I could take it in and they'd sort or I could leave until the next service and they'll do it then (like I'm going to pay someone to minor service it anyway? - Donuts).

Also couldn't be bothered to go all the way there for them to do it and me to dream about a brand new Audi for an hour so I did mine today.

Took the battery out after swearing at the ridiculous design of the battery clamp then to find a huge puddle of water, but no crap or crud anywhere. I was expecting to find a real mess but it's very clean down there, apart from the water. Possibly due to me finidng a clean low mileage car?

At first I was looking for a grommet. Couldn't find one at all in over 2" of water. Was feeling around in that cold water for ages and no luck. Loosened the expansion tank, moved it aside and tried from underneath but still couldn't feel a grommet as I was looking for something protruding to grab hold of and pull out.

Eventually squezed the heater matrix hoses together to release the water which took forever to drain. Then got a torch to continue the search. Finally found a flat rubber insert under the air con hoses

At this point I must add that this is the biggest grommet I've ever experienced, it's almost the size of a packet of 10 cigarettes and resembles nothing like a grommet at all, infact it's more like a black rubber Always Ultra.

Removed it, folded it in half and cut a section out of it with a bread knife.

Daylight was nearly over at this point and trying to find the other under the servo on a black car was hard and didn't manage to get at it.

So can anyone tell me if the one under the servo 'needs' to come out or will my mod be enough?

The puddle was large and long and went under the servo but was gone when I'd finished but I don't like doing things by halves so would rather go back and find the other fanny pad if needed.

Cheers

 

[sinic]

Should also mention, battery off for about 15-20 minutes. Went shopping after the work. Traction light went out after about 200 yards, the radio had kept it's code and by the time I got to Tesco's the remote key had sorted itself so I didn't even have to recode it to the car - apart from the clock & date & having to re calibrate its miles left to empty it all sorted itself!

Happy with that.

 

[GrayT]

That bit you took out doesn't look like my one at all, but then mine is an 03. I can't see anything on the bit you removed that ever would have let water out?! It looks more like a blanking plate of some kind. I would try and locate the one under the servo - I believe there is a ridge in the middle that means some water will more than likely be retained on that side. Also, even with the opening you've made a wet leaf could easily block that side and it would be advantageous to have the other one clear.

Edit: Take a look at the 2nd photo in post 91 above. That's a close up of the part that mine was like.

 

[sinic]

That bit you took out doesn't look like my one at all, but then mine is an 03. I can't see anything on the bit you removed that ever would have let water out?! It looks more like a blanking plate of some kind. I would try and locate the one under the servo - I believe there is a ridge in the middle that means some water will more than likely be retained on that side. Also, even with the opening you've made a wet leaf could easily block that side and it would be advantageous to have the other one clear.

Edit: Take a look at the 2nd photo in post 91 above. That's a close up of the part that mine was like.

Thanks, I had seen that photo but was thinking it was on the bulkhead from that photo rather than underneath it but I'll look again.
The large thing I removed & cut was the lowest point removeable rubber of any kind and it would never have let anything.

There's plenty of other rubber things that are more like grometts but again they are also along the bulkhead and under that rear battery mount that has been removed and sitting on top of the engine. Point taken about a leaf covering it but they are bio degradeable lol. At least now I know exactly where it is and can just put my hand under neath and have a prod around, so after finding the servo one I'll be able to do it all without having to remove anything....hopefully.

Cheers

 

[aitch]

Hi simon2004,have had the same prob with my 1.8 Turbo,Phoned Audi,they said it was a recall for that and also from today there is also a product recall on the coil pack problems that has been known.

 

[a4 cabrio]

will audi still fix this for free under a recall??? i have only just bought mine and not sure if its been done or not

 

[sinic]

will audi still fix this for free under a recall??? i have only just bought mine and not sure if its been done or not

One of my local Audi dealers said 'your model isn't affected' then when you challenge them they'll say that all they do now is clear them out when you take it for a service.

Phone your dealers service department and see what they say

 

[audigeezA4]

hi guys

drove my car just literally round the corner today and as soon as i turned the corner i heard a lot of water sloshing about..... so opened up the bonnet and hey presto, lots of water under the battery area. Just contacted my local Audi dealer and after checking my reg nos they state that there is no "outstanding recall" on my vehicle!!! I then explianed surely this is a fault with these models but the woman was adamant that i would have to pay for diagnosis and then whatever it costs to fix the problem. Having read this thread i really have not got the skills to diy....... just a bit annoying if some have had this issued resolved by audi foc. Is it worth trying another audi dealer instead??

 

[Mike B]

hi guys

drove my car just literally round the corner today and as soon as i turned the corner i heard a lot of water sloshing about..... so opened up the bonnet and hey presto, lots of water under the battery area. Just contacted my local Audi dealer and after checking my reg nos they state that there is no "outstanding recall" on my vehicle!!! I then explianed surely this is a fault with these models but the woman was adamant that i would have to pay for diagnosis and then whatever it costs to fix the problem. Having read this thread i really have not got the skills to diy....... just a bit annoying if some have had this issued resolved by audi foc. Is it worth trying another audi dealer instead??

You need to get the water out asap,If you cant push the grommets out use a piece of pipe to syphon as much as poss out of the chamber

 

[audigeezA4]

You need to get the water out asap,If you cant push the grommets out use a piece of pipe to syphon as much as poss out of the chamber

yes it looks like i'm not gonna get any joy with audi so will try to syphon the water using the old pipe in the mouth system and see if i can clear as much as possible although i guess this will be a temp fix. i suppose i will ask audi to clear it properly as part of the next service even though they did an oil change in dec just gone, but as there was no inspection can't really blame them for not checking it.

thanks.

 

[Pabs]

Mine had supposedly been done 3 years ago by audi, this weekend when changing the coolant flange on the back of the cylinder head i noticed water dripping down on to the floor, at first i thought i had another coolant leak. Took off my battery cover and servo cover to find almost 4" of water. Got the battery out straight away and removed the gromets, they were completely silted up, i wont be putting them back in and i'll be checking now every month or so. My gromets looked like they had been cut/slit to allow more water to flow but had still silted up...

 

[fourcircle]

why don't you find someone from this forum in your area who's handy with a socket set, make him a good brew and offer him a couple of hobnobs and make a new friend at the same time? I've made some excellent friends by getting complete strangers to come and help me with minor tasks such as transplanting a new engine

 

[audigeezA4]

why don't you find someone from this forum in your area who's handy with a socket set, make him a good brew and offer him a couple of hobnobs and make a new friend at the same time? I've made some excellent friends by getting complete strangers to come and help me with minor tasks such as transplanting a new engine

That's a great idea, any offers of help would me most welcome, I will even provide chocolate hob nobs if requested. Lol. On a serious note though, any one wishing to help a fellow 2.5tdi Q S owner in time of need would become a friend indeed. I'm not too far from Preston in lancashire.
Cheers.

 

[fourcircle]

sadly i'm slightly too far to be of assistance on this occasion mate but hopefully someone will be along. Maybe try a new post asking for help in Preston area in exchange for choccie hobnobs? Also worth mentioning any hot young ladies in your street if I know this lot at all

 

[iyrix]

It should flow through like a hose! So if it drips out that is blocked. I did mine and now i can run the hose through it with no water collecting.

 

[audigeezA4]

sadly i'm slightly too far to be of assistance on this occasion mate but hopefully someone will be along. Maybe try a new post asking for help in Preston area in exchange for choccie hobnobs? Also worth mentioning any hot young ladies in your street if I know this lot at all

Cheers pal. Think I will get a little pipe in their today and try to syphon out. Shame I won't pass as a hot young lady as I'm sure the guys would all be queuing up!

 

[audigeezA4]

It should flow through like a hose! So if it drips out that is blocked. I did mine and now i can run the hose through it with no water collecting.

Yes mine only drips out so defo blocked.
Cheers.

 

[fourcircle]

Shame I won't pass as a hot young lady as I'm sure the guys would all be queuing up!

depends what your knight in shining armour is into. each to their own

 

[audigeezA4]

After several sucks on a clear plastic pipe and quite a mouthful of greasy water i've managed to syphon most of the water out, there was a good couple of inches in there, it even ran down the side of the drivers footwell whilst driving. however, i would not recommend this method!!! So, i have decided i will attempt to remove the battery, yes i am hopeless at diy but i am not gonna let this defeat me.

I reckon if i can do this myself then there's still hope for me

. Only worry is it will probably end up taking me more than 2 hours.........

. I will follow the step by step guide posted in this thread so fingers crossed, or maybe i should keep them straight in this case!!

 

[Mike B]

This is awkward cos the battery is heavy .Suggest you loosen the clamp so the battery will move slightly sideways and using a short wire or as I did a bottle brush you can feel for the grommets and push through.I managed to cleanout the muck and flush through with clean water and the blockage did not recur

 

[fourcircle]

The only way to learn is by starting with the low risk jobs like this and having a bash. Then you can steadily progress to the "aw ****, I really wish I hadn't started this" stuff It's amazing how much you'll accomplish with good advice from the collective mind of a few good web forums. I bought a rear ended S2 and reshelled it with a lot of forum advice and a few days when people called round to help. Before that the most adventurous task i'd tackled was brake pads. get stuck in!!

 

[audigeezA4]

This is awkward cos the battery is heavy .Suggest you loosen the clamp so the battery will move slightly sideways and using a short wire or as I did a bottle brush you can feel for the grommets and push through.I managed to cleanout the muck and flush through with clean water and the blockage did not recur

will do-cheers pal.

 

[audigeezA4]

The only way to learn is by starting with the low risk jobs like this and having a bash. Then you can steadily progress to the "aw ****, I really wish I hadn't started this" stuff It's amazing how much you'll accomplish with good advice from the collective mind of a few good web forums. I bought a rear ended S2 and reshelled it with a lot of forum advice and a few days when people called round to help. Before that the most adventurous task i'd tackled was brake pads. get stuck in!!

yeah your right- thanks buddy. tomorrow i plan to don my boiler suit, miners hat with torchlight, hammer, chisel and i'm ready to go- actually thats sounds a lot like my local garages...lol. now, just to locate that battery......lol!!
will let you know when and if mission was successful!!!
hey, if this goes well, i might have a go at: broken glove box, interior led's, door/puddle lights, chrome door mirror housing..... i might even turn pro yet.... or it will all go t**ts up!!!!lol.

ta laa.

 

[fourcircle]

I think that's the standard process. and it needs to go tits up now and again or we'd just get *****

 

[audigeezA4]

just thought i would let you guys know i FINALLY got round to fixing this issue- (with a lotta help from my teen nephew and friends), was actually straightforward apart from having to buy a long alan key to remove the darn battery, which then fell into one of the holes.....ooops!!

but rescued it eventually. there was no rubbers in the holes so guess they had been removed before so can only think gunge was blocking them- anyhow fixed for now so thanks for all your input fella's as i would neva had known where to start if i had not joined this forum......salutes!!!

ps, i'm still hopeless at anything technical so if anyone is prepared to help with any of the mods i wish to do i would be an able assistant and perhaps even make it WORTH your while.....

cheers all.

 

[fourcircle]

well done mate. this will be the start of a beautiful obsessive compulsive disorder, ending eventually in a desire to change your own timing belt

 

[Mike B]

Good news but some gunge do you get a lot of Guano where you live?Mines mainly due to the neighbours trees overhanging the drive so I have started using a windscreen cover in autumn to shield the intake grill and made some mesh covers for the big openings round the battery chamber which seem to suck the rubbish in