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.
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
Plenum chamber bulkhead (cover plate for plenum chamber)
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.
13 – sound absorber for water box ( Insulation)
6RF863993A(6RF 863 993 A)
PR-TF3, TL0, TK0, TS46RF863993B(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, T706R6863993D(6R6 863 993 D)
D – 15.02.2014>> – 03.11.20146R6863993E(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.
Below is a video showing how this tool works:
