Clean out your inlet - even on an engine making good standard power , cleaning the inlet manifold & intake ports ( what you can access of them anyway ) liberates (free !) power & economy… works especially well on Mk6 Models but applies to all diesel transits from year 2000 to date…
Its a filthy process though with all the goo from the crankase breather & egr systems feeding into it & you will ideally need a set of (manifold to head), gaskets , they come as 6 blue oblong shaped seals on Mk6′s…
EGR Blanking – replacing the flange gasket from egr feed pipe to egr valve with a blank ( unholed ) plate effectively stops the funtion of the egr valve.. blanking plates are available on ebay for £3 or so or just make one yourself. Not from a beer can though, you need something a little thicker ! this works great on Euro 3 Transits & Transit Connects but on Euro 4 vans of either flavour it will ruin low engine speed performance & throttle response & /or throw up an engine check light / MIL (malfunction indicator lamp) on the dash.. the odd van runs ok, depending on your ECU’s particular software version, but all will currently light the MIL… a software solution is half done for these models (runs great , lights MIL l!!) – i will make a proper song & dance about it if i ever solve it properly so just do a search for “Mk7 Transit EGR delete” here or in google for news of the finished solution…
Fit an intercooler – to 75ps 2.0 litre TDDI Transit ? unless your upgrading the turbo itself, i wouldnt bother .Of the few i have tested , it doesnt seem to be a limiting factor & is a pain as you ideally need a complete donor set of complete pipes to & from it due to differing MAP ( manifold absolute pressure) sensor & EGR valve ( exhaust gas recirculation ) positions…
Manual boost controllers - its easy to get these to show appreciably more boost via a gauge but there seems to be very little extra gains be had so its a subtle power upgrade at best.. save your money & spend it on a really good remap instead !