2.5 TDI Transporter BPC 2009 info thread

[Greg Roles]

They’re next on my seemingly never ending list. Though the catch can seems easy enough to fit. After some brief research the EGR delete/reduce seems there’s more to it with regard to the ECU…

Anyone on here that’s on the Gold Coast that can help?


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Get a blanking plate with at least a 7mm hole in it. That lets enough through to not throw an EGR error, but significantly reduces the amount ingested. If it throws a light remove it, disconnect the battery for at least half, and redrill it out to 8mm, then 9mm. 7mm was the minimum on my old GT TDI at 2.0 L, and I know you can buy 7-10mm hole ones on eBay, or even just make one yourself. Matters not what end of EGR inlet pipe you fit it. The EGR has to be happy for it to do regens of the DPF, so it needs to be error free.

[JimmyFingerz]

This is just a note to say a massive thanks to Greg!
After 9 months + of my Multivan being up on jack stands, several $$$$ having been spent at Darkside and 07eins amongst others and most importantly of all, Greg's meticulous details and information in this entire thread ... I can now confirm that my Multivan has been roady'd, rego'd and back on the road. Man-o-man, the kids love this vehicle.
Best of all, she fired up first time thanks to all of Gregs great instructions!
For a 360K Km vehicle, she runs strong and smooth and is an absolute pleasure to drive.
As she's a 4 Motion, I've decided I'm going to go with a light UK Swamper style setup. I've fitted 245/65/17 on Amarok alloys and I'll be ordering a lift kit from Transport HQ in the next month or so.
So, as I currently stand, in order to get her running again, I've done the following::
- New head gasket, cylinder head bolts, cam replacement set + bolts , injector seal kit (Darkside)
- New injector Bridge (07eins - what a magnificent piece of engineering)
- New VITON injector seal kit (07eins)
To say this BPC engine has tested my knowledge, patience and amateur mechanical skills would be an absolute under statement ... but I can say I know it a little bit better now .
Thanks Greg!

[Greg Roles]

This is just a note to say a massive thanks to Greg!
After 9 months + of my Multivan being up on jack stands, several $$$$ having been spent at Darkside and 07eins amongst others and most importantly of all, Greg's meticulous details and information in this entire thread ... I can now confirm that my Multivan has been roady'd, rego'd and back on the road. Man-o-man, the kids love this vehicle.
Best of all, she fired up first time thanks to all of Gregs great instructions!
For a 360K Km vehicle, she runs strong and smooth and is an absolute pleasure to drive.
As she's a 4 Motion, I've decided I'm going to go with a light UK Swamper style setup. I've fitted 245/65/17 on Amarok alloys and I'll be ordering a lift kit from Transport HQ in the next month or so.
So, as I currently stand, in order to get her running again, I've done the following::
- New head gasket, cylinder head bolts, cam replacement set + bolts , injector seal kit (Darkside)
- New injector Bridge (07eins - what a magnificent piece of engineering)
- New VITON injector seal kit (07eins)
To say this BPC engine has tested my knowledge, patience and amateur mechanical skills would be an absolute under statement ... but I can say I know it a little bit better now .
Thanks Greg!

Glad I could help, and that my often frustrating misadventure could help someone else along the way, the whole point of the thread. My engine has been perfect since, and it runs like clockwork. I'm now trying to get the notorious auto to the same point, and no doubt will be a bit of a windy path, but I am persistent if not overly smart!

Thanks for the post, and sorry to be so slow to reply, I should bloody log in here more often!

[Greg Roles]

Finally into a bit more my scene when it comes to engines....time for some fun stuff!


Used two x 2.25" 90 degree alloy elbows, two silicon joiners and clamps, and just cut the VW swaged end off the factory pipes. Had to trim the elbows, but talk about a perfect fit. The intercooler dimensions are 2.25" ( 57mm ) in / out, 550 x 230 x 55mm core. Just needs a bracket. All up cost about $400! I'm changing the current trans cooler to a wider, less tall one, as this fat intercooler takes up a lot of room towards the top, and the trans cooler pictured fouls the top edge of the bumper below the grill.

Replaced my dodgey looking radiator while in there with a quality China one, again about $300.

[JimmyFingerz]

Looks good Greg. ��
I'd be interested to know if you find the find the new intercooler makes a noticeable difference, in which case, I'll be sending you a PM for more details .

I reckon I'll need to pull my front bumper off again anyway as I think my aircon radiator might be leaking.

[Greg Roles]

Hey mate, an intercooler won't be felt, beyond a really hot day anyway, it just helps keep the intake charge more dense overall. I've no doubt it flows better, but this was just part of a plan to upgrade the inlet and exhaust path in a bang for buck style, and maximise the standard setup. I took to the front bumper with a hacksaw after fitting my smaller but wider trans cooler, and have some grill stuff to put over it, I'm sure it will keep the trans far cooler now. It also looks more Fast and Furious, even though it isn't.



I'm replacing the middle massive muffler with a straight through Magnaflow, and an running 2.5" all the way to the back axle for now. When I have the time I'll fab up the remainder to the back bumper in 2.5" rather than the very odd sized 2.3" stock.

[Greg Roles]

If ever a car deserved this....my favourite mod to date.

[JimmyFingerz]

Hey Greg. I reckon having that much extra air flowing through should keep her running really cool. ��

[Greg Roles]

On trying to adapt my gearbox yesterday I drove around an industrial estate endlessly for near 50kms, and my peak auto temps were 83 degrees!

[Greg Roles]

Well to close this thread, after a year of having the van running quite well ( around gearbox issues - now also fixed ) I've only driven it a tiny amount and only been on two proper long weekend camping trips with wifey. As much as I love it, I'm just not using it enough to justify the third car, and with other home plans requiring $$ have sadly decided to sell her off. The back fitout is almost as involved as the engine, and is a thread in itself, but someone is sure going to get a fully overhauled van!

So this ends my 5 cylinder chapter, and am glad that at least my time and expense has helped others with their own 5 cylinder journey!!