Plenum Chamber Bulkhead, Removing And Installing

Special tools and workshop equipment required

Removing

-- Remove the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

4-cylinder TDI engine:

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-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

-- Push the coolant hoses using the hose opening through the plenum chamber bulkhead into the engine compartment.

Continuation:

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-- Lift the clamp -2- and remove the coolant bleeder line -1-.

-- Release the catches -arrows- and free up the coolant bleeder line -3- on the plenum chamber bulkhead -4-.

-- Remove the lock washer -3- and free up the heat shield near the nut.

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-- Remove the nut -2-.

-- Free up the wires.

-- Pull the plenum chamber bulkhead -1- upward and remove.

Installing

Install in reverse order of removal and note the following:

-- Remove the foam seal and remove any adhesive residue.

-- Clean the plenum chamber bulkhead with Cleaning Solution:D 009 401 04 .

-- Push on the new plenum chamber bulkhead seal and shorten if necessary. Refer to Parts Information.

Make sure the seal between the plenum chamber bulkhead and the body is seated correctly.

Tightening Specifications