How to remove plenum chamber bulkhead from a Polo 6R

Firstly you need to:

Components that are fastened to the plenum chamber bulkhead must be detached.

So remove ECU, ECU bracket, soundproofing and now black metal plate (aka cover plate for plenum chamber / plenum chamber bulkhead) 😉

Remove engine control unit and retainer for control unit

It’s different depending on your engine. In Polo cars with a gasoline engine 1.4 and 1.6 there is engine control unit (ECU) -J623- with anti-theft secure, so firstly protection must be removed, and then ECU can be disconnected.

  • Open line guide -1- and raise catch -2-.
  • Remove engine control unit from its bracket.
  • Unscrew shear bolt -1- using pliers.
  • Turn engine control unit -2- around and also unscrew second shear-head bolt using a pair of pliers.
  • Pull bracket -1- and protective housing -2- off engine control unit -3- in -direction of arrow-. –
  • Release connectors from engine control unit and pull off.

ECU location

Removing

  • Remove clamping washers -6-
  • Remove sound absorber for water box -5-
  • Remove bolts -2-
  • Twist plenum chamber bulkhead upwards out of the plenum chamber -4-.

1 – Plenum chamber bulkhead (cover plate for plenum chamber)

2 – Bolt

  • Qty. 8 or 10, depending on the type
  • Specified torque: 8 Nm

3 – Plenum chamber

4 – Seal

5 – Insulation (sound absorber for water box)
Secured to bulkhead plenum chamber with clamping washers.

6 – Retainer (clamping washer)
For securing insulation to bulkhead plenum chamber.

Photos, pictures, part numbers

  • photo from Madwarlock

Plenum chamber bulkhead (cover plate for plenum chamber)

cover plate for plenum chamber (plenum chamber bulkhead)
Oval hexagon socket head bolt, M6X14

4 – 6R0805275A (6R0 805 275 A)

31 – N91166401 (N 911 664 01)

Sound absorber for water box (insulation)

In versions with a turbine, there is additional thermal insulation.

sound absorber for water box (insulation)

13 – sound absorber for water box ( Insulation)

  • 6RF863993A (6RF 863 993 A)
    PR-TF3, TL0, TK0, TS4
  • 6RF863993B (6RF 863 993 B)
    PR-TF3, TL0, TK0, TS4, T1S “IND”
  • 6R6863993C (6R6 863 993 C)
    PR-TF0, TF3, TK0, TL0, TS4, TT0, TT1 ,TW0, T70
  • 6R6863993D (6R6 863 993 D)
    D – 15.02.2014>> – 03.11.2014
  • 6R6863993E (6R6 863 993 E)
    D – 04.11.2014>>

27 – clamping washer, 5X30 (retainer)

Clamping washers (retainers)

There are many types of clamp washers for VAG cars, sometimes newer parts vary in shape or color.

N90796501 (N 907 965 01)
B5 X 30 X 0,4
N90796502 (N 907 965 02)
5 x 30
N90335004 (N 903 350 04)
5 X 30
N90335005 (N 903 350 05)
5 x 30 x 0.4
N90335005 (N 903 350 05) – black version, e.g. from Porsche Cayenne
N90335004 (N 903 350 04)
N90796502 (N 907 965 02)

Car workshops usually have a special tool for removing clamping washers, but you can easily unscrew it with your fingers 😉

If you plan to unscrew them often, you can consider buying the LASER 7347 Clamping Washer Tool – it costs about 25 EUR.

LASER 7347 Clamping Washer Tool

Below is a video showing how this tool works: