The modern trend of engine downsizing for CO₂ reduction coupled with stringent emission norms compel the engine air inlet system to outperform the conventional designs. Modern turbo diesel engine air inlet system handles higher & higher air flow, boost pressure and temperature.Air inlet system ducting designs have become complex due to oil particles (received through PCV system), engine movement and isolation for NVH.Air inlet ducting failures; like oil mist leakage through joints and seepage through hose wall cause high engine oil consumption and most predominantly environment damage. Also to some extent boost leakage in certain operating conditions. These failures reduce the reliability and performance of engine in certain conditions.This paper discusses design and development of cost-effective non-permeable and leak-proof hose-piping system for turbocharged diesel engine where PCV system was connected to air inlet system. Different materials of hose, different types of clamp and oil mist separators were selected to make various configurations for testing. The configurations were made to pass through static and dynamic tests. At the end final configuration was determined which met cost, performance & reliability targets.