Update - got the intercooler pipe from Roadside in Coleraine - the store man had set the part aside so that the sales guys could transact it for me. The pipe itself is a Fiat part 51709470 (they are also a Fiat franchise). I assume that the front end of 147/156/GT and Bravo 1.9 JTDs are the same under the skin. The pipe length,diameter and location notches are exactly the same. The part was £60 including VAT
Now the bad news I removed the undertray - some of the low profile machine screws attaching the leading edge were missing (vibrated out or slapdash services). One rear attachment bolt came off easily, but the other appears to have corroded onto the captive nut inside the chassis rail. Despite having been prepped with WD40 the captive nut has detached
I got the undertray off, but I'll have to grind that bolt off and drill a pilot hole for self tapper instead.
That was a bit of bad news, but there was worse to come. When I removed the undertray there was a pile of corroded steel lying in it
. This turned out to be the lower half of the attachment bracket for the intercooler.
The intercooler has a couple of spigots that locate in a couple of rubber grommets in the bottom of that bracket. This bracket attaches to an alloy bracket. I assume that the mild steel bracket was not painted/had poor corrosion resistance applied and that no hylomar or whatever had been smeared as an interfay between the two parts. Since the windscreen drains into this area and sits in warm airflow (radiator and intercooler), the warm wet condition hasn't helped it!
I think that I should be able to access the bracket by removing the battery/tray etc. I'll post a couple of piccies when I can. I had a good check around the underside of the engine bay and this appears to be the only corrosion. Anyone else had this problem?