Seat Ibiza MK4 FR 1.

8T Front Mount
Intercooler Instructions

Tools Required:
T30 Screwdriver Flat headed Screwdriver
T25 Screwdriver Trim removal tool
7mm hose clamp driver 16mm drill bit
4mm allen key Drill
10mm socket and rachet and swivel extension seen in part 17 Hack saw/dremil
13mm spanner Philips screwdriver
1. Under the front of the car, remove all of the torx bolts holding the undertray in place
including the two through the bumper with a T25 screwdriver, as shown in the pic
below.

2. Remove the 5 torx bolts holding the arch liner to the bumper, using a T25 screwdriver.
3. Open bonnet and remove the four torx bolts using a T30 screwdriver.

4. Now remove the two torx bolts using a T30 screwdriver situated in the grill on each side
of the bumper as seen below.
5. Bumper is now ready for removal. As you do this you will need to unclip the 2 plugs on
each of the front fog lights and the air temp sender.
6. Now the bumper has been removed, undo the plastic clip holding the plastic/rubber
wind deflector in place situated just under the crash bar on the intercooler side of the
vechile, using a trim removal tool.
7. Now the plastic/rubber wind deflector can be removed by simply pulling it off from the
plastic locaters on the top of the intercooler. Once this is removed undo the plug on the
map sensor by pulling back on the tag, and remove the 2 philips screws.

8. Remove the two 10mm bolts of the intercooler using a 10mm spanner or socket.
9. Now remove the 10mm bolt situated at the front of the intercooler using a 10mm
spanner or socket.

10. Remove both pipes going to the intercooler, and remove the intercooler.
11. Using a 13mm spanner/socket and a 10mm spanner/rachet remove the three 13mm
bolts and two 10mm bolt situated on each side of the crash bar and remove.

12. Now using a 16mm drill bit, drill out the exsiting holes to remove theT30 torx bolts
behind.Tak extra care not to drill into the torx bolts. You will have to make your own
holes on the drivers side using the same spacing used on the opposing side.
13. Using a hacksaw or dremil cut the plastic tag on the passenger side radiator cowling as
shown below.
14. Fit the new brackets supplied by sliding them between the radiator and radiator cowling
and bolting them up with the T30 torx bolts removed previous through the 16mm holes
drilled.
15. Fit the new intercooler to the brackets using the M6 and M8 bolts supplied, but do not
fit the bottom passenger side bolt in just yet.
16. Fit the air temp sensor to the bracket supplied, and then using the 13mm bolt.
17. Now replace the crash bar back onto the car using exsisting 10mm and 13mm bolts.
18. Now remove the boost hose going into the turbo outlet pipe using a flat bladed
screwdriver putting it into the arched part of the clip and levering outwards making sure
you don’t damage the pipe.

19. Carefully remove the rubber seal on the end of the coupler and replace it onto the new
coupler provided.

20. Fit the 90 degree bend and the S shape hose together using the 51mm short alloy joiner
, then place the new bayonet coupler provided onto one end and the 60mm long
straight pipe onto the other in the same orientation as below and re fit back into the
turbo pipe making sure it fits correct using the clip.
21. Fit the 45 degree silicone hose to the intercooler, the 90 degree alloy bend to that and
then the silicon hose joiner to connect the bottom pipe work together as previously
installed with jubilee clips provided.
22. Now remove the standard boost hose situated on top of the engine that connects to the
throttle body.

23. Fit the new Throttle body hose .

24. Now fit the silicone 60mm coupler hose to the intercooler, and fit the upper intercooler
pipe (with the map sensor flange)
25. Fit the map sensor to the alloy pipe using the sensor plate and the two M5 bolts
provided, then attach the plug onto the sensor.

26. Now cut the locator pin out on the driverside of the bumper as seen in the pictures
below this may take a few attepts to get the alignment perfect.
27. Now refit the bumper using steps 1, 2, 3 and 4 in reverse.
Installation is now complete.
Check all hose clamps are tight and road test
Thank you for using Forge Motorsport products

ENGINEERED FOR PERFORMANCE