Hi,

We have a split in an air hose I suspect is connected to the intercooler but can someone please tell me what this pipe is and where is connected.

My wife is complaining that the car gets juddery, almost like wheel balance issue when accelerating around 60 MPH , I also think economy is not very good at the moment and it has never been one for accelerating as a turbo car should.

This pic is not from my car, its one of an identical engine from the net so if it belongs to a poster on this forum .. Thanks.

I have drawns a red line to indicate the split. My car is a 105bhp 1.9 JTD (2000) W Reg.



I am also going to inspect other pipes and connections, clean the MAF sensor with Iso alcohol and follow the EGR cleaning guide, though the drill bit and the springs look worrying and I dont have carb cleaner just brake cleaner ?

Any suggestions on how to repair the hose on a temporary measure, Gaffer tape just seems to bubble after a day or so. Now Thinking of a SOCK and then Gaffer tape but its on a bend so more aukward.

If anyone has this hose for sale anywhere then I would be interested in hearing from them. There are a selection on Ebay but not sure which is the exact hose.

Thanks for your help.

Finding a replacement pipe may be difficult, I would just use self amalgamating silicon tape. This tape is 19mm wide and looks like insulating tape but has no adhesive on it, when you stretch it and wind it over itself it amalgamates and cures into a solid piece. I have seen it used for temporarily stopping leaks in copper plumbing and I once used it as a temporary repair on a high pressure injection pipe on a fiat punto. On that occasion the repair lasted for over three weeks until we could find a replacement pipe.

You can find this tape on ebay, just follow the link below:

http://www.ebay.co.uk/itm/Self-Fusing-Amalgamating-Silicone-Rubber-Tape-Car-Boat-/230407583304

By the way, make sure you get the silicon type, there is also a rubber amalgamating tape but it is not very good at high temperatures.

Good luck

Thanks, that sounds like a great idea. I have put a sock over and then surrounded with Gatter Tape. See how it holds while I get hold of some of that tape.

There looks like a pipe on Ebay that could do the job

While I had the engine cover off I noticed the thin rubber tube had completely severed. I think its from the EGR Solonoid to a small plastic cylindrical device at the back .. Any idea what this device is and the consequence of it not being connected.



Took the car out and it does feel a little more responsive, probably for cleaning the MAF meter but there is still a small vibration at over 60 MPH. Took the car out of gear and its still there so its wheel balance, suspension related I think.

Not sure what the tube does as I have limited knowledge of the JTD, but thin rubber tubes, if they are not carrying fuel etc, are usually vacuum pipes which if split or damaged could affect the running. Many accessory shops carry pipes like that on a roll so you can get a length cut. I would definately replace it.

I replaced it when I spotted the problem. Had some vacuum tub in the toolbox from my old Fiat Coupe days and working with Boost guages and dump valves.

Hi , pretty sure it's a VAC hose, as it connects to zinc plated steel over the engine , then another rubber 90' elbow into the vacuum bellows wotsit . visible in your 1st pic..,


your BIG hose is the cooled air feed in from the intercooler - if memory serves -, so ANY splits in that will REALLY effect performance

Charlie

could get a custom one made up by SAMCO. not that expensive either

Re Economy
i just drove a 110 JTD weekend through france, spain and portugal, got an average of 54.7mpg over 3 tanks fully laden, the best tank full did over 70mpg ( mainly on the flat at a contant 65ish mph ) The worst was climbing up the Pyrenees brought it down to about 48mpg

paullpunto said:

Re Economy
i just drove a 110 JTD weekend through france, spain and portugal, got an average of 54.7mpg over 3 tanks fully laden, the best tank full did over 70mpg ( mainly on the flat at a contant 65ish mph ) The worst was climbing up the Pyrenees brought it down to about 48mpg

Click to expand...

Hi , sounds about right,
our 105 was bought for such a trip and returned 75MPG at a contant 70 with the aircon on.. great for that, but I couldn't get on with it's SOFT power compared to the Tipo's and Tempra's we'd had before - didn't see the point of a diesel that wouldn't lug..bought the factory towbar, but never fitted it - bought another tipo TD for that..!!
Charlie

A scrap yard might be your best bet - or someone breaking a car (bravo/brava/marea) through ebay. That hose, as said above is the pressurised feed from the intercooler to the inlet manifold, so a split will drop your performance to almost N/A. Not sure it could be fixed with tape. I'd imagine a repair from inside is needed, or glue/rubber vulcanising solution into the split?

Thanks Hellcat.

Ill try to get one from a scrap yard at some point but for now I have ordered some of that Silicon based self amalgamating tape. Its advertised to be resistive to high pressure up to 700psi ?? oil high temps etc.....

Got to be better than a sock and gaffa tape that is holding out for now but wont when the sock is saturated with oily stuff.

Disconnected MAF seems to have improved overall performance, no lag but certainly no decent turbo performance but in fairness it never really has been a flying machine, just steady away.

Tempted to order from these guys at 1/2 price of the original BOSCH part and someone on this forum has used and had good results.

http://www.webcon.co.uk/Downloads/Webcon Marelli MAF 2007.pdf

Can you tell me where the EGR is on this model JTD as you can see on my second picture under may hand I would expect to see a long metalic EGR but its a block square plastic cover instead, is it under there ?

I believe this engine is the Euro 2 - and according to the Eper the part you are fixing the thin tube on is part of the EGR system.

Hellcat thats a really useful couple of diagrams. I have a copy of the workshop manual somewhere but think the 110 engine not the 105 is covered.

Anyway. Do you have the key for some of the components.

1 and 7 from the top and 1 from the bottom.

I thought 1 from the bottom is the EGR Solonoid but might be wrong but still no idea what no. 1 is from the first diagram.

If I was to try blanking the EGR what position would it be 6 or 3 of the bottom picture. I will try giving the system a clean.

I also have an ALFA 156 JTD with the same bosch code MAF so I am going to move my working MAF to the Fiat and see if there is an improvement there.

Since I already know them I'll add them here..

1. Electro-valve
7. Vacuum tank

1. Electro-valve

I'd say 6 or 3 would be suitable points to blank the EGR. I don't know if the system demands at least some re-circ so perhaps a blank with a small hole in the center would be better than a straight blank. Perhaps you have a similar issue to the multijets with a clogged (and therefore stuck open) EGR valve?

For anything else.. go to http://eper.fiatforum.com > Fiat > Marea > Marea 1999-2001 > Fuel & Exhaust system > Anti Polution system

http://eper.fiatforum.com/eper/navi...INT_MODE=0&EPER_CAT=SP&GUI_LANG=3&WINDOW_ID=1

and

Exhaust gas control system

http://eper.fiatforum.com/eper/navi...INT_MODE=0&EPER_CAT=SP&GUI_LANG=3&WINDOW_ID=1