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Re: Audi S8 Airconditioning
The water is probably condensing on the outer pipe, and then following a pipe and dripping inside the car from some bad insulated gasket. There is also a drain hose for the AC that must be checked. You must individuate where water comes from and re insulate gasket or clean drain hose.
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I'm assuming for now that these are two separate problems:
1. Overheating and emptying expansion tank.
2. Leak into front passenger footwell.
Solution to 1. is likely to be a crack in the expansion tank. This happens often with these tanks. Look under the cap and you'll find two necks. The narrow one is the pressure tube that the lid seals in to. Check the narrow neck for any cracks and check the pressure cap o-ring for condition. Replace both if suspect. They're cheap from FCP Euro or ECS tuning.
The wider neck is the overflow. This drains into a small tube under the lid area of the tank. You could connect a hose to this if you were so inclined, but it normally it just drains into the engine bay (onto the left hand exhaust manifold normally on V6's!). If yours is losing the coolant from here its a classic sign of a cracked filler neck.
Make sure the cooling system gets bled properly as well - top bleeder is the right hand heater hose (factory hose if still on the car will have a hole marked by a white circle - pull the hose off the heater core connection tube to expose this hole to the coolant, undo and raise the expansion tank above the heater hose level to bleed).
On V6's the lower bleed is on the engine cross flow pipe on the rear of the engine on the opposite end to the engine temp sensor - 6mm allen key undoes from memory. Not sure where lower bleed is on 4 cyl models - possibly the coolant pipe in the vicinity of the inlet manifold.
The other possibility for 1. is a failed cylinder head gasket, but I'd be suspecting the expansion tnk ahead of this. Seek professional help if the expansion tank isn't the issue.
2. I would suggest is a blocked plenum chamber drain. You can check by pouring some water down the windscreen with the bonnet (hood) open and seeing if the plenum area fills up without draining or draining slowly. Main drain is in the middle I think and It gets clogged by leaves and debris. Cleaning is difficult, but you can try a shop vac with some heater hose taped to the nozzle to try and get in there, or some compressed air with an air gun or something to try and blow it through.
Search something like "Audi B5 plenum drains" on Google and you may find some other suggestions.
2. may also be blocked HVAC drains for the airconditioning...
Most likly the drain hose for the aircon is dislocated or is blocked up. If upon inspection you find hose still connected then a low preasure air inject into hose may unblock. If you can get a venturi suction on the hose that will extract. some form of vacume pump will do the same. Best to extract any blockage if you can as it will only re-occour
If your car has a sunroof, one if the sunroof drains runs down through windshield post down through to bottom of the car. If it gets plugged it will back up into car.
If it's coolant you're finding (sticky and smelling like coolant) your heater core is leaking
In the dashboard,set down low is a driptray.It collects water that comes off the aircon.It has a hose (sometimes 2) that drains the water out of the car via the firewall so it drips onto the road.This is blocked or the tray has a buildup of gunk.The hose is about 1/2 inch thick.If you lay on the floor where it leaks with a torch you should find it.Or look in the engine bay,just to the left or right of centre(which side leaks?)and backtrace it into the car.You may find the inside hose has fallen off allowing the water to drip inside.Hope this helps you
There are drains under the battery box and under the ECU module. When they plug with dirt, pine needles, whatever, the water fills up the space and backs into the vents or wherever it can leak through the firewall and usually ends up in the rear footwell, drivers side. If you don't get on it and maintain those drain holes, it will start to take out the electrical. Gets very expensive for a simple design flaw. The carpet has to come up and thoroughly dried as well. Not much fun and a lot of work.
does the footwell of passenger side get wet? the hose disconnects under the carpet there, pull carpet up and simple to fix, if not then hose will have disconnected in ducting on right near back of the engine.