Removal and installation the lower intake manifold (BGU) (VW Caddy 3)

Removal

1. Remove the engine cover.

2. Disconnect the connector (1) from the secondary air pump electric motor.

3. Disconnect the air hoses (2) and (3) from the secondary air pump motor.

4. Remove the secondary air pump motor.



5. Remove the upper part of the guide tube together with the dipstick from the lower part of the guide tube and the secondary air pump motor bracket.

6. Unscrew the screws (1) and (2) and the nut (3) of the secondary air motor bracket.

7. Loosen the poly V-belt and secure the tensioner by installing the lock.



8. Remove the shield (arrows).



9. Remove both pull-out rivets (1).



10. Unscrew both screws (2).

11. Loosen the remaining screws (3) securing the lower part of the intake manifold to the cylinder head.

12. Loosen the screws (4) securing the fuel rail.

13. Remove the pop rivets securing the wiring harness to the fuel rail.

14. Carefully spread the clips on the top of the intake manifold and remove the lower part of the intake manifold forward.

15. Disconnect the fuel manifold with injectors from the lower part of the intake manifold.



16. Without jerking, separate the upper and lower parts of the intake manifold. Place the lower part with the fuel manifold and injectors (arrows) in the engine compartment on a clean rag.

Installation

Installation is carried out in reverse order. when doing this, the following remarks must be taken into account.

• Replace the sealing rings between the intake manifold and the cylinder head.
• Replace the injector sealing rings; lightly moisten the new ones with clean engine oil.
• Install the fuel manifold with the injectors inserted into it onto the intake manifold and carefully and smoothly press it so that the injectors enter the seats.
• Ensure that the O-rings are properly installed between the upper and lower parts of the intake manifold.

Attention! To secure all hoses to the fittings, use clamps of the appropriate series.

Intake manifold to cylinder head: 25 Nm.

Intake manifold lower to upper mounting screws: 3 Nm.

Fuel manifold to intake manifold: 8 Nm.