Originally Posted by SubyDrewski
jayman is trying to say (I think) that you need to use a BRAND NEW gasket, as in, fresh out of the box, rip the plastic off first. The new one will get molded and formed to the parts as you tighten it down, making a good seal. Using old one means that it's already molded and formed, and may not seal the gap between the BPV and intercooler. Hope that helps.
Correct. You need a BRAND NEW GASKET EACH TIME!!! lol
Chances are you caused the probelm, if the problem started after you changes a part. Put the stock one on with a new gasket from the dealer, check that the hose going from the bpv to the inlet is connected all the way to the back of the bpv, and go from there.