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Stilo JTD Boost Solenoid Valve -resite it!
Failed boost solenoid - resite it & keep it dry
Published by Hydrocw49
26-01-2010
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Stilo JTD Boost Solenoid Valve -resite it!

Boost Solenoid valve symptoms

Failure of the boost solenoid valve is a common occurrence on Stilo JTD's, indicated by spurious lack of power - mines normally been when going uphill and was quickly restored by dipping the clutch. Diagnosis (by Examiner or FiatECUscan) will often reveal a P0235 boost fault code.

Whats caused the failure?

My Stilo's suffered 2 failures in the last 2 years, both caused by driving through largish puddles. On early Stilo's the boost solenoid is hidden under the nearside headlight, just in front of the wheel - almost impossible to see. The early ones (Part No 55188059) had a square body housing a mesh type filter, later ones (part No 55203202) have a round body containing a small foam filter fitted. Both have a solenoid fitted which I believe are controlled by a variable frequency input. Neither likes getting wet! Once they get wet, they dont seem to respond to being dried out. At about 50 from Fiat, replacement doesn't hit the wallet too hard, but if all you do is simply replace it, you're likely to need to replace it more than once.

What's the solution?

Within the forum, there are many references to moving the solenoid, some as Fiat dealership modifications - the question is exactly where? Whilst collecting my new solenoid from Pewsham Fiat, Chippenham; I asked whether Fiat had recommended a modification. The answer was that there have been 4 different locations for the solenoid:

Under the NS headlight,
Under the battery tray,
On the side of the battery tray, and
Behind the turbo!

Personally, the only sensible place to resite the solenoid is on the side of the battery box. The following may help you to resite your boost solenoid and hopefully avoid further failure.

Start here

Remove battery cover.

Reaching down behind the NS headlight, remove the 2 10mm bolts that hold the solenoid bracket to the front panel. Access is tight, but is possible with only a few scraped knuckles. Dont worry about disconnecting the electrical plug or vacuum pipes, they're easier to disconnect later.

Pull the solenoid and bracket up between the battery tray and headlight, then disconnect the 2 vacuum pipes and electrical connector (push the metal clip in and pull connector up)

Now unbolt the solenoid from the bracket. Remove the sleeves from the rubber grommets and prise one of the grommets from the bracket.
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Cut the grommet in half to form 2 rubber washers.

Using the solenoid as a template, position it on the side of the battery tray as shown in the photo - 2 vacuum pipes at top, electrical connector at bottom and drill 2 6mm holes - being careful not to drill through the battery cables inside!
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Using 5 or 6mm bolts mount the solenoid on the battery box, sandwiching the rubber washers between the two.
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Reconnect the electrical connector and 2 vacuum pipes, large connector to turbo actuator, small to vacuum pipework under EGR valve. Secure pipes with cable ties to prevent rubbing.

Refit battery cover - dependant on solenoid position, the cover may need trimming - easily trimmed with a hacksaw.

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Close bonnett, job done
Thanks gerardh66, custard thanked for this post
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Old 07-02-2010   #1
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Thanks for useful pics - I was wondering what one looked like I was getting a few "engine faults" popup and Yani's ecu software showed P0235 and P0236 - these were cleared ok and I've have now repositioned valve to see how it goes. However, on a 115 JTD I've gotta say scraped knuckles was the least of the pain - skin removal on the fore arms is much worse Not sure what car yours is and i'm no salad dodger, but the lack of clearance on the JTD made it impossible to get to the bottom mount bolt from above/side, so ended up undoing the front half of the wheel arch liner to at least be able to turn the rachet past the intercooler from the back. I left the cable and pipes connected all the time as it repositioned ok once unmounted and fitted it lower down the battery case as in original horizontal position (looks like your red tube is a replacement one and possibly longer than the fiat one?). That said, drilling the holes lower means there no clearence for a normal drill to get in so you need a right angle one Thanks for the guide
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Old 09-02-2010   #2
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Mines a 115 JTD as well - I found that I was also getting cramp in the arm, trying to get the bottom bolt - i was using a shortened 10mm ring spanner. The valve was replaced previously by a local garage, who fitted the red pipe - the original hard plastic pipe had started to rub. Guess mounting the valve lower on the battery box, makes accessing the bolts interesting, unless you took the battery off first. Glad you found the guide useful.
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Old 10-07-2010   #3
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Thanks a million for the guide, had terrible trouble getting up hills,
and could often hear a "whoosh" and had lack of power.
Today, I did 5 things for my wife's Stilo.
1) resited the Boost Solenoid Valve as suggested.
2) cleaned the mass air flow meter/sensor with contact cleaner
3) changed air filter
4) reconnected hose to the oil collection thingy under the air filter housing (2nd hand from a breaker)
5) found a hole in bottom hose from intercooler, and cut it down by 1cm

Car now goes like stink!! No more "whooshing" sound and we can get uphill!!
All in great part thanks to you guys and the threads I have been reading.
Looking forward to filling up and checking mpg.
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Old 23-08-2010   #4
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Sweet, but how the bloody hell do you reconnect the vacuum hoses??? It's so tight
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Old 14-09-2010   #5
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Quote Originally Posted by gtaboyz View Post
Sweet, but how the bloody hell do you reconnect the vacuum hoses??? It's so tight
With great difficulty!!
I gently heated the tubeand used the end of a Philips screwdriver to open up the tube slightly. Worked for me,.

good luck
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Old 08-01-2011   #6
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Re: Stilo JTD Boost Solenoid Valve -resite it!

I gave up and replaced plastic tube with a rubber one. Seems fine will keep my eye on it on weekly checks.
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Old 20-04-2011   #7
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Pig of a job,

but access to the original solenoid is made easier of you take off the nsf wheel and the black plastic inner wheel arch liner (six screws and very easy). You can then get to the solenoid pretty easily .... if you have long arms and small hands (apparently, a prerequisite of any Italian mechanic !)

I'ts also how you also get accesss to change the nsf headlight bulb - if anyone's interested !
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Old 16-02-2012   #8
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Re: Stilo JTD Boost Solenoid Valve -resite it!

i re-positioned mine when i was doing the clutch, as i had to remove the air-box and all the other stuff around the boost control valve, plus because i was doing it this way, i managed to also keep all the pipework connected so it was a 2 min job to bolt it onto the battery tray
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Old 08-07-2012   #9
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Re: Stilo JTD Boost Solenoid Valve -resite it!

i have re-sited my turbo booster valve, worked well for a couple of weeks, but now showing an electrical fault 0n the engine management system and faulty code reader showing a circuit malfunction, now booster stopped working , has anyone have any ideas please ? would be very grateful , thanks Alan Stilo 1.9 jtd
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Old 08-09-2013   #10
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Im going to be re-siting mine and probably ultimately replacing the valve. Car drives normally til you get to 3000rpm (typically when overtaking) and then eml comes on, im getting code P0236 boost signal low, so im guessing the valve isnt working correctly. Once i have it resited ill get the part number and new one ordered, but do these symptoms sound familiar of a faulty valve?
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Old 08-09-2013   #11
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Re: Stilo JTD Boost Solenoid Valve -resite it!

I just resited mine, i found if u remove the plastic air feed pipe (pictured) access is a lot easier, it just clips out, use a big screwdriver to lever it out of the plastic surround. I then used my ratchet and socket. Ive cable tied it temporarily to the rigid plastic air feed to the inlet. I assume theres no way to clean or service the valve? Just replace? Click image for larger version

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Old 31-12-2016   #12
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Re: Stilo JTD Boost Solenoid Valve -resite it!

Thanks for this guide!

My Stilo had the same issue when I drove without the plastic guard underneath the engine. One puddle was enough to lose all engine power.
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