Cdti 120 EGR Fiat gasket - Details required

[alcutler]

HI changed my EGR, cleaned the boost valve, and replaced the vacuum pipes on my 1.9 cdti 120, in an attempt to cure hesitation / stutter when accelerating hard in 1st and second gear - big improvement but still a bit of a flat spot. This morning disconnected the plug to the egr and ran it like that - was like driving a different car with great acceleration throughout the whole range of speeds and no hesitation. Got the 'spanner' light to start with and after a couple of starts this changed to the eml light, but car ran fine. Re connected the EGR plug and cleared the fault and its now running well. I don't want to blank the EGR but am interested in trying the fiat gasket. I have made a copper blanking gasket but could do with seeing a fiat type gasket so that I can make the necessary hole or holes in my gasket to suit. Can anyone help with this please

[tommytonguedj]

Hi there, i fitted the fiat gasket with 3 holes in i've got the part numbers somewhere if you want them but fiat have them in stock usually, At the time of removing my egr i removed the throttle body and resoldered the dry joints,

P.S. theres a diagram somewhere on the fiat forum showing where it goes

[alcutler]

Hi there, i fitted the fiat gasket with 3 holes in i've got the part numbers somewhere if you want them but fiat have them in stock usually, At the time of removing my egr i removed the throttle body and resoldered the dry joints,

P.S. theres a diagram somewhere on the fiat forum showing where it goes

Thanks for that I never gave the fiat forum a thought - I'll have a look

[zafira]

You can also make a plate of 2 m steel and drill a 6 mm hole. The spanner light dont come on then. Fiat gasget has 3 x 5 mm hole (if I remember right) so a self-made plate make less exhaust go into the manifiold.

[alcutler]

You can also make a plate of 2 m steel and drill a 6 mm hole. The spanner light dont come on then. Fiat gasget has 3 x 5 mm hole (if I remember right) so a self-made plate make less exhaust go into the manifiold.

Hi Thanks for that - did a bit of rooting around and managed to get a nice picture of the Fiat modified gasket on the Saab owners site - its the one with 3 holes in it - I've managed to put it in a graphics programme and got it to actual size and taken measurements and I am in the process of making one from copper plate. If it works I may do a How 2 - a lot of trouble I appreciate to save a couple of bob but my reason is if I make it from copper I can anneal it to make it soft and it will seal itself without the need for any further gaskets.
Ps The gasket with one 6mm hole is sold on Ebay actually blanks the EGR off but fools the sensors into thinking it is still working and does not activate the warning lights. The 3 hole version allows the EGR to operate as normal but restricts the flow of gases and hopefully prevent the hesitation that some owners have encountered.