Technical Stilo JTD Turbo/Intercooler Hose Problem and Silicon Solution

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Technical Stilo JTD Turbo/Intercooler Hose Problem and Silicon Solution

bigfella6969

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I have a solution to the ever present failure issue of the intercooler hose on the Stilo JTD model.

I've sourced a reliable local manufacturer to me who is prepared to manufacture the intercooler end of the turbo/intercooler pipe for this forum's members. The complete pipe (OEM 51718041) costs £87.95 plus VAT from a Fiat dealer, but you don’t need the whole pipe. The OEM kit comprises of a very weighty metal middle section with rubber hoses attaching to both the turbo end and the intercooler end via t bolt clips, you can't buy the rubber end hoses separately from Fiat.

JTD owners will be more than aware that the intercooler end of the pipe passes through an aperture in the inner wheel arch the inner edge of which has a sharpish edge, this coupled with the sawing action via the heavy weight of the whole pipe that eventually creates a cut in the hose through the up and down movement as the car travels and the intercooler end and the rubber hose eventually fails. This results in loss of pressure causing a whistling or rushing sound as the pressure escapes. Both MPG and performance is affected but it’s the more annoying whistling/rushing noise that is the problem especially as it bounces back off high roadside walls etc. You can get four fingers through the hole I've found worn in mine.

The solution I've discovered is a hard wearing polyester reinforced silicon hose intercooler end hose manufactured to sport performance standard,(with a 4.5mm wall thickness). You simply remove the old t bolt clip and push the new hose on to the metal middle section and reconnect to the intercooler again with a t bolt clip available from a Fiat dealer. OEM no's are clip 71714116 50mm £2.97 and Clip 71714117 65mm £2.25 Plus VAT.

I can get these hoses manufactured for £46.95 inc VAT. Available in black blue or red, all come in a high gloss finish. Shipping (UK Mainland) is £4.95. Minimum production run is 6 off to get to this price for me.

I have visited the premises/workshop and this guy really knows his onions. He specialises in manufacturing sports/racing and high performance hoses and pipes and kit to an extremely high standard indeed. Please note these hoses are not cheap Chinese imports they are to be manufactured to order for members of this forum here in the UK. He already manufactures hoses/pipes on behalf of many more non Fiat forums.

If there are any interested Stilo JTD owners out there who wish to take up this offer of a solution to this intercooler hose failure problem please contact me. It is worth noting he will manufacture any hose or pipe in polyester reinforced silicon for any Fiat model, all he requires is a supplied pattern. Non reinforced silicon Vacuum hoses are also available off the roll. Price will always depend on production run quantities [email protected] or mob 07799 127776 and I will provide details for ordering procedure etc.
 
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so this is a pipe that uses the stock airbox and replaces the pipe that fouls just behind the wheel arch.

Sounds like a good price to me but i just put a new one on a few months ago.
 
i bought about 3 meters worth of 50mm bore reinforced silicon pipe a couple of years back, came to around £30 if memory serves and i have enough to replace it a couple of times, im hunting around to see if i can find where i got it.
The only thing i had an issue with was the slight kink in the pipe as its not a straight connection and i didnt want to fork out for angled joints at nearly twice the cost to put a kink in the pipe, this i thought would be a problem but when the turbo kicks in and inflates it there is no issues at all - although this probo does cause some turbulance in the pipe but were not driving racing cars so it really shouldnt be an issue.

ive just found this on the fleabay site, and seems to me a better option

http://www.ebay.co.uk/itm/2-TURBO-INTERCOOLER-PIPE-PIPING-KIT-50MM-SILICONE-BLUE-/310251694005?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item483c7127b5

replacing all the rubber or most of it will metal will give better results, it will probo be a fiddly job but once done i think it will give better results than our current rubber pipe inflation job. has anyone put this kit on the car?
 
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I've done the research on this before posting and had already spotted the kit on ebay as highlighted by Roy at 74.99 plus 9.50 shipping total 84.49GBP That brings you back almost to the cost of the OEM pipe @ 87.95 plus the VAT. And there is more than just a little kink in the original pipe, it is a very odd shape indeed with a couple of bends and then goes off at a curve. I have looked at putting a straight silicon pipe on but it will not suffice.

Shadeyman pointed out that an induction kit would do the job, why an induction kit?, on a diesel? The STILO JTD is not a petrol engine. Show me one that will do a better job on a diesel engine cheaper than my manufacturer's 46.95! This is made to fit the the middle metal section of the pipe in a polyester reinforced silicon material and is more than capable of withstanding the pressure in that pipe.

I've attached some images, the wire you see in the images are a welding rod I shaped to get the correct length bends contours and kinks to make the alternative silcon end fitting. As I said I've done the research!

I am not trying to turn my Stilo JTD into a boy racer machine, just offering a much cheaper alternative to JTD owners who may be considering buying the full OEM pipe at Fiat prices. It is totally unnecessary to buy the whole pipe when an alternative is available at less than half the price when you add in the VAT on the 87.95.
 

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