Plenum Chamber Water Drain

Plenum Chamber Water Drain

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system.

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages.

Risk of unintended engine start

The ignition must be turned off and the ignition key must remain outside of the vehicle when working on vehicles with a high voltage system.

How to handle high voltage cable:

• Do not stand on or place tools on high voltage cables and their components as it may damage the cable insulation.

• Never bend or kink high voltage cables forcefully as it may damage the cable insulation.

• Color-code the round high voltage connector with an external color ring and code them mechanically using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid mechanically damaging the high voltage connector.

There is a risk of electrocution from damaged high voltage components

Observe the following when working around high voltage components and high voltage wires:

• Never work around high voltage components and cables with cutting, deformed, or sharp edged tools, or heat sources such as welding or soldering tools, heated air, and thermal glue.

• Inspect the high voltage components visually before beginning.

• Perform a visual inspection of the electric drive power and control electronics (JX1) , the electro-drive drive motor (V141) , the A/C compressor (V470) and the high voltage lines when working in the engine compartment.

• Perform a visual inspection of the high voltage lines and the cover when working on the underbody.

• Perform a visual inspection of the high voltage lines and the Electrobox with the high voltage system maintenance connector (TW) when working in the luggage compartment.

• Perform a visual inspection on all of the potential equalization cables.

Observe the following items when performing the visual inspection:

• The components do not display any signs of external damage.

• The high voltage cable insulation and the potential equalization cables are not damaged.

• The high voltage cables do not display any abnormal deformations.

• Every high voltage component is marked with a red warning label.

- Turn off the ignition.

- Remove the rubber seal - A - and the plenum chamber cover - B - (there are different versions).






• Inspect the high voltage components - D - (the electric drive power and control electronics (JX1) ) and the high voltage cables - E - after removing the plenum chamber cover - B -. Refer to => [ Visual Inspection of High-Voltage Components and Cables for Damage ] Visual Inspection of High-Voltage Components and Cables For Damage.

• Be careful not to damage any high voltage components - D - or the high voltage cables - E -.

• Inspect the high voltage components - D - and high voltage cables - E - after completing the work procedure and before installing the plenum chamber cover - B -.

• Remove the cowl panel - C - if it is necessary to clean the water drains.

For vehicles without a high voltage system

- Turn off the ignition.

- Remove the plenum chamber cover and/or the cowl panel (there are different versions).

All vehicles

• The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5 etc., the location of the components varies slightly. The description of the components is not different; removing, installing and checking is performed in the same way as on the Audi A5 Coupe.

• The draining of water from plenum chamber may be impaired by deposits (leaves, diverse tree needles etc.) accumulating in plenum chamber water drains - A -. The water level in the plenum chamber then rises if the vehicle is taken to an automatic car wash or in the event of heavy rain, water enters via intake housing into the A/C unit and is blown by the Fresh Air Blower (V2) onto the evaporator together with the air conveyed.






• If both water drain grommets - A - (right and left in plenum chamber) are blocked by leaves and pine needles, it may cause the drains to freeze up in winter and water can no longer drain out. After a short drive, heat emitted from engine and exhaust system melts the ice in the drains again and water may drain off again before vehicle arrives at the workshop.

• The water drain grommets - A - are snapped into the plenum chamber openings from above.

• In addition to the two water drain grommets - A - there is an opening on the right side of the body - C - in which water can drain out behind the wheel housing in case both water drain grommets - A - should become obstructed. Likewise, make sure these openings are not obstructed by dirt.

Checking and cleaning

- Remove the plenum chamber cover, if necessary (there are different versions).

Use a commercially available and illuminated endoscope for example, to check the water drains that are difficult to reach. It is best to use one that has a flexible waterproof head.

• Use a commercially available flexible gripping tool to clean for example, coarse dirt from difficult to reach water drains. Then wash out the any remaining contaminates.

- Clean the left and right water drains - A -.

- Clean the plenum channel from debris (leaves, pine tree needles) and other objects.

- Check the function of the - A - grommets (the valves - B - must not stick or be obstructed with dirt)

Removing

- Remove the grommets - B - by pressing them from the top, out the water drain openings - A -.

Installing

- Install the grommets - A - by pressing them from the top, into the water drain openings.

- Check the function of the - A - grommets after installing them (the valves - B - must not stick and must close)