2.5 TDI Transporter BPC 2009 info thread

[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!!

[Syncrotek]

Quite the ride it's been Greg, good on you for sharing the info, keeping up a thread like this one also takes a lot of time and effort,
Many Thanks.

[Dave BPC]

Hi Greg.
I’m the UK and very much appreciate your efforts to detail your engine build/work/diagnostics and links.
I’ve had mine since new and now with 270k miles on it.
I felt obligated to post my thanks for your detailed post.
It’s given me much more confidence in my engine.

[Greg Roles]

Hi Greg.
I’m the UK and very much appreciate your efforts to detail your engine build/work/diagnostics and links.
I’ve had mine since new and now with 270k miles on it.
I felt obligated to post my thanks for your detailed post.
It’s given me much more confidence in my engine.

Welcome Dave, wish I had a resource like this from the start, glad to help others. They are a solid machine overly engineered in a few areas, with a few fatal flaws you need to keep an eye on. Knowing what I know now, I could run one forever with preventative maintenance, but the process of getting that knowledge has left me a bit PTSD when it comes to the 2.5!