Plenum Chamber Bulkhead, Removing And Installing: Removing

-- Remove the tower brace. Refer to appropriate Repair Information .

Vehicles with High-Voltage System:

-- De-energize the high-voltage system. Refer to appropriate Repair Information .

-- Loosen the high-voltage cable for high-voltage heater (PTC) -arrows-.

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-- Loosen the grommet -3- from the plenum chamber bulkhead.

-- Release the connector for the high-voltage cable for high-voltage heater (PTC) -2- from the high-voltage heater -1- and remove.

-- To do so remove the connector lock -3- in direction of -arrow A-.

Fig 1: High-Voltage Connector, Releasing

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-- Press the release -4- in the direction of -arrow B- and remove the connector -1- approximately 5 mm up to the next release point.

-- Press the release -5- in the direction of -arrow D- and remove the connector from the connector mount -2- in direction of -arrow C-.

• The high-voltage cable set must be replaced if the connector is damaged.

4-Cylinder TDI Engine:

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-- 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.

-- Clamp off the coolant hoses using the Hose Clamps - Up To 25mm:3094  .

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.