Plenum Drain Tube Replacement

WARNING: This page is about a different car, the 2012 Chevrolet Volt. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Plenum Drain Tube

Courtesy of GENERAL MOTORS COMPANY

Callout	Component Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Before working on any high voltage system, be sure to wear the following Personal Protection Equipment: Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors. Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors. Visually and functionally inspect the gloves before use. Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not. Failure to follow the procedures may result in serious injury or death. WARNING: The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions. WARNING: Do not use a service jack in locations other than those specified to lift this vehicle. Lifting the vehicle with a jack in those other locations could cause the vehicle to slip off the jack and roll; this could cause injury or death. Preliminary Procedures Open and suitably support the hood assembly. Remove the front suspension strut housing brace. Refer to Front Suspension Strut Housing Brace Replacement . Remove the heater coolant heater. Refer to Heater Coolant Heater Replacement .
1	Plenum Drain Tube Nut CAUTION: Refer to Fastener Caution . Procedure Remove the nut from the master wiring electrical harness to the plenum drain tube tab and remove the tab from the auxiliary heater stud.
2	Plenum Drain Tube Procedure Disconnect the plenum drain tube from under the dash outer panel insulator. Remove the plenum drain tube from the bottom front side of the dash panel outer insulator. Pull the plenum drain tube upward and outward from the engine compartment side.

Callout

Component Name

WARNING:

Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps:

Identify how to disable high voltage.
Identify how to test for the presence of high voltage.
Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

WARNING:

The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.

WARNING:

Do not use a service jack in locations other than those specified to lift this vehicle. Lifting the vehicle with a jack in those other locations could cause the vehicle to slip off the jack and roll; this could cause injury or death.

Preliminary Procedures

Open and suitably support the hood assembly.
Remove the front suspension strut housing brace. Refer to Front Suspension Strut Housing Brace Replacement .
Remove the heater coolant heater. Refer to Heater Coolant Heater Replacement .

Plenum Drain Tube Nut

CAUTION:

Refer to Fastener Caution .

Procedure
Remove the nut from the master wiring electrical harness to the plenum drain tube tab and remove the tab from the auxiliary heater stud.

Plenum Drain Tube

Procedure

Disconnect the plenum drain tube from under the dash outer panel insulator.
Remove the plenum drain tube from the bottom front side of the dash panel outer insulator.
Pull the plenum drain tube upward and outward from the engine compartment side.