Overview - Bulkhead

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Fig 1: Identifying Plenum Chamber Bulkhead Assembly

Courtesy of AUDI OF AMERICA, LLC

Seal
- Install the seal from underneath.
Lock Washer
- When installing, simply press the plenum chamber bulkhead onto the threaded pins.
Nut
- Tightening specification: 4 Nm
Bolt
- Tightening specification: 7 Nm
Plenum Chamber Bulkhead
High Voltage System Vehicles (Hybrid Vehicles):
CAUTION:
Hazardous high voltage

Severe bodily injury or death by electrocution.
- The high voltage system may only be turned off by a qualified person (Audi high voltage technician).
- It must be certain that the voltage for the high voltage system is turned off. The voltage is guaranteed to be off exclusively with the Vehicle Diagnostic Tester via the "Guided fault finding ".
- The qualified technician (Audi high voltage technician) will make sure the voltage is turned off and that the system cannot turn back on again using a Service Disconnect Lock T40262. The qualified technician should make sure the system cannot turn on again by keeping the key and the High Voltage System Maintenance Connector -TW- in a safe place.
- The qualified personnel (Audi high voltage technicians) mark the vehicle with a label.
NOTE:
De-energizing the high voltage system:

Connect the Vehicle Diagnostic Tester

Select the "Guided fault finding " mode

Using the Go To button, move through the following menu points

Function/component selection

Body

Electrical Equipment

OBD-capable system

8C - hybrid battery management -J840

8C - hybrid battery management, functions

51 - De-energize the high voltage

Read all warning messages for the vehicle when working on a vehicle with the high voltage system.

NOTE:
When removing, remember there are different versions.
- Before removing:
  -- Remove the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .
  
  -- Disconnect the vacuum line to the brake booster at the connection to the plenum chamber bulkhead.
  
  -- Unclip the vacuum line from the plenum chamber bulkhead.
  
  -- Disconnect the Terminal 30 Wire Junction 2 - TV22- from the plenum chamber bulkhead and free up the wires.
  
  -- Drain the coolant. Refer to COOLANT SYSTEM/COOLANT .
  
  -- Disconnect the coolant hoses to the heater core.
  
  -- Press the coolant hoses with hose guide in the plenum chamber.
  
  Vehicles with High Voltage System (Hybrid Vehicle)
  
  -- Disconnect the high voltage cables at the Electric Drive Power and Control Electronics - JX1-. Refer to HIGH VOLTAGE CABLES .
  
  Continuation for all vehicles:
- To remove, remove the bolts -4- and nut -3-.
- Install in reverse order of removal.
  CAUTION:
  Hazardous high voltage
  
  Severe bodily injury or death by electrocution
  - The high voltage system may only be restarted by a qualified person (Audi high voltage technician).
  - Use only the Vehicle Diagnostic Tester in "Guided Fault Finding " to ensure the system has been re-energized.
  - Qualified personnel (Audi high voltage technician) restart the vehicle.
  - The qualified personnel (Audi high voltage technicians) mark the vehicle with a label.
  NOTE:
  Energizing the high voltage system:
  
  Connect the Vehicle Diagnostic Tester
  
  Select the "Guided fault finding " mode
  
  Using the Go To button, move through the following menu points
  
  Function/component selection
  
  Body
  
  Electrical Equipment
  
  OBD-capable system
  
  8C - hybrid battery management -J840
  
  8C - hybrid battery management, functions
  
  51 - Energizing the high voltage system (Rep.Gr. 93)
Plenum Chamber