Hi all, just thought I'd share my solution to my intercooler issue.

As is common with high mileage Fabia vRS's (mine's the original variant - 2006), my intercooler pipes were blowing off at high revs. The bottom elbow was a straightforward replacement from Skoda (how much £££!!!)...but the top was a little more tricky.

The plastic socket had partly broken away, which meant that one of the lugs was not making (hence why it was blowing off), so even purchasing a new pipe was pointless.

Removal of the intercooler entirely wasn't really an option given the time I had available...firstly I installed two jubilee clips (one on the socket, one on the pipe - I'll come back to that later). Next I drilled two holes through the outer intercooler plastic socket, and through the metal end of the right angled pipe...then I simply installed two self-tapping screws through...

Unfortunately I couldn't access the underside of the socket, I imagine a better job would have been to remove the intercooler and fit four equidistant screws...unfortunately I just didn't have the time...

The end of the pipe has a rubber 'o' ring installed as standard, so this theoretically seals the internal join (in case anyone is wondering about potential leaks through the screw holes / broken intercooler socket!).

Beacuse the only screws I had managed to get in were at the top I wrapped four strong cable ties around the jubilee clips, and tightened the clips...

The jubilee clip around the socket was situated tight up to the standard retaining clip. The jubliee clip around the pipe was situated as close to the metal lip.

Then, I simply tightened up the jubilee clips, and pulled the cable ties tight (making sure that the join of the cable ties was as far to the right as you look overhead as possible, as the headlamp sits very close to this assembly)...I ensured that one of the cable ties was on the bottom, having identified this as the week point...

I snipped the residual part of the cable ties away to tidy up and...

...saved myself best part of £1000...200 miles down so far (within the national speed limits of course) and still holding strong.

The job took around three hours in total, the main headache being partially removing the bumper to enable headlamp removal. The cost was <£5 (cable ties and jubilee clips).

One note to add is that when drilling the screw holes, I did put cloth down the intercooler and up the pipe so that no dust or metal/plastic shards crept into the system. I also thoroughly cleaned the area before re-attaching.

I am be no means a professional so couldn't for one second recommend anyone does this (and if you do, it's at your own risk!)...and no doubt Skoda would always recommend a new intercooler...but all I can say is it worked for me!

Edited 29 July, 201213 yr by bickie

Hi and welcome aboard.

Hi and welcome aboard.

Thank you! Been long overdue for me to get in here!!

Hello bickie and welcome along

Hello bickie and welcome along

Cheers Briskodian!

Cheers alkip!

1000 miles and still good!

2500 miles and still good!!!

Good, good

Bickie - Can you remember what sized jubilee clips you used?

On 19/04/2018 at 23:12, robj1969 said:

Bickie - Can you remember what sized jubilee clips you used?

Any idea? 

18 hours ago, vrsfabia-mk1 said:

Any idea? 

That person hasn't been online for over 2 years, probably moved on.