Skoda Octavia 1.8T Front Mounting Intercooler Kit

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1 Skoda Octavia 1.8T Front Mounting Intercooler Kit Please read these instructions before starting the installation. Please ensure at all times that you work safely and take suitable precautions to protect yourself from risk of injury. We accept no liability for this installation of this kit or for changes in the vehicle crash deformation characteristics. Tools Required for Installation, Metric Socket Set, Screwdriver set, Torx set, Alan Key Set, Hacksaw, Suitable means of safely supporting the front of the car whilst both front wheels off the ground eg Axle Stands, Trolley Jack. It is good practice to check all components on installation that no foreign bodies are present that may be drawn into the engine on start up as severe damage may result..

2 Raise the car off the ground with suitable jack and support with axle stands. Remove the front plastic wheel arch liner screws with a T25 Torx driver, starting level with the gap between the plastic bumper and front wing. Work from top to bottom of the plastic Wheel arch liner removing 6 six screws per side on the outer edge. (Two screws out of the six per side hold the Air diffusers back edge in position which must be removed.) Working from under the car you now need to remove both of the Plastic air diffusers which slide out from the slots in the underside of the Bumper. Now remove the two T25 Torx Screws that secure the underside of the bumper to the under tray

3 You are now ready to remove both of the front quarter grilles. This is done by gently pulling from the inside lip. Remove the two T25 Torx head screws that are behind each grille. Working from the top of the car with the bonnet open, remove three more T25 Torx screws that are located in the center of the plastic bumper. Moving to the sides of the plastic bumper, remove both sides of the plastic trim by gently edging a flat screwdriver under the trim and then pulling the edges of the trim away to in order to expose the fixings on both sides of the vehicle.

4 The Plastic Bumper is now almost ready to remove, we now suggest one other person is holding the bumper at this stage. Using a 10mm socket remove the two bolts from either side of the bumper, then gently ease the bumper away. With the outer bumper now removed you can begin to remove the inner steel crash bar. This is secured in position with three 13mm bolts per side, they are located one bolt top and bottom per side with one 13mm nut located either end through the hole in the steel crash bar. The steel crash bar is heavy so we recommend another person hold it in position when removing its fixings. Remove the plastic Intercooler Air duct from the front of the O/E side mounted Intercooler. Using a flat screwdriver remove the Jubilee clips that secure both top and bottom boost hoses to the Intercooler. Disconnect the Map sensor plug located on the top of the Intercooler.

5 With a 10mm socket remove the three bolts that secure the original Intercooler in position, these are located two on top and one at the bottom. Gently pull the Intercooler away from the car. Remove the small piece of Silicone pipe from the steel link pipe in the wheel arch. Remove the MAP sensor from the original Intercooler by unscrewing the two self-tapping screws that hold it in position, and then ease the sensor out of the Intercooler being very careful not to damage it. Remove the headlight from the offside by unplugging the wiring harness from both the back of the headlight and Indicator unit. Now while holding the Headlight unit remove the four T25 Torx screws from around the headlight assembly. * Note that these screws should be kept separate from the other T25 Torx screws that have been removed as the thread diameter is bigger on those used to secure the Headlight assembly *

6 With a 10mm socket remove both 10mm fixing bolts from the Activated carbon filter (do not attempt complete removal of unit, it requires movement only in order to gain access to the Washer bottle retaining nuts). With the carbon filter eased backwards now remove the plastic 10mm nut from the top edge of the washer bottle. Now remove the remaining 10mm plastic nut from the base of the washer bottle. Disconnect the wiring connector from the washer motor and lift washer bottle out of position. There is enough washer tube to allow the washer bottle to be placed on top of the engine cover without having to disconnect any washer pipe or tubing.

7 Remove the 2x10mm bolts as indicated in the above picture. This will allow the original Intercooler bracket to be removed as indicated below. This part will not be refitted and is removed to allow adequate routing of the Silicon hose to the new Front Mounted Intercooler.

8 With all the above parts removed from the vehicle you are now ready to install your Forge Motorsport Front Mount Intercooler. The first job to do is to fit the MAP sensor into the silicone hose that is supplied with the kit. It has an alloy boss that is molded in to the hose. Fit the sensor into this boss securing it with the two M4 Cap Heads (supplied) facing the short end of the pipe. Now fit the 60mm Alloy connector into the Silicone hose and secure in position with a 70mm Jubilee clip supplied in the kit. The hose with the MAP sensor fitted should then be pushed through the new crash bar supplied in the kit. With the crash bar on the floor secure the Silicone top hose to the Intercooler with a 70mm Jubilee clip supplied. Now fix the Intercooler top and side mounts to the steel crash bar using the four M6 countersunk screws supplied.

9 Before the crash bar can be re installed to the vehicle it is very important that the M8 Stud ( Left Hand Side Only ) that protrudes from the front panel is cut off flush and all burrs removed, failure to do this will result in damage to the silicone boost hose. At this point you will need to trim away the plastic air deflector that runs down the left hand side of the radiator, this is to allow both of the new boost hoses access across the front of the car and can be done with a sharp Knife or Snips. * Remove all sharp edges * Now the crash bar can be re fitted to the car and secured. Connect the Silicone top boost hose to the manifold inlet hose with the Alloy 60mm connector that you fitted in earlier. Secure the hoses with the other 70mm Jubilee clip supplied in the kit. Re connect the map sensor plug to the sensor, now re install the headlight assembly into the car and secure with Torx screws, re connect all wiring. Attach the second Silicone boost hose out of the kit to the steel boost pipe that runs alongside the wheel arch. Connect the large diameter of this pipe to the steel pipe and secure it with the last 70mm Jubilee clip supplied in the kit, then secure the other end of this pipe to the bottom pipe on the front mounted Intercooler using a 60mm Jubilee clip supplied in the kit.

10 After checking all hose connections are tight you can now re install the outer plastic bumper / Grilles and Air diffusers The bumper will need minor trimming around the bottom hose and can be done with a sharp Knife. It is now good practice to check that all the hose connectors are secure Re-assembly of the front panel and wheel arch liner is the reverse of the dismantling procedure, not forgetting to reconnect the fog lights if fitted Where a component is secured by a number fixings it is good practice to leave each fixing loose before aligning the component and tightening the fixings. Once satisfied that all tools have been removed and the vehicle is safe to use you may enjoy the benefits of your new purchase. Skoda FMIC Parts Checklist 1 x Silicone hose Pt no. SP285 1 x Silicone hose Pt No. FMSKOINT 1 x intercooler 1 x replacement crash bumper 4 x 45-60mm (No.2) hose clamps 2 x 60-80mm (No.3) hose clamps 1 x Alloy hose joiner 1 x MAP sensor blanking plate 1 x MAP sensor adaptor 2 x M5 x 16 screws 4 x M6x16mm countersunk screws 1 x instruction manual