Complete EGR removal kit for Td5 (1999 – 2007)


IRB developments designed Td5 EGR removal kit
– Fits Defender and Discovery (kits available for RHD and LHD)

Very easy to fit, and requires no physical modifications to the vehicle. It is a very easy nut and bolt job to fit!!!

We believe this is the most comprehensive kit on the market!

Contents of the kit:

– New billet Aluminium intake section for the inlet manifold designed as per the original to prevent
the intake pipe ‘blowing off’ under boost pressure. Our intake section is made from one piece
of Aluminium, not a badly welded two piece affair.

– New Gasket/seal for above

– Exhaust Manifold blanking plate

– Blanks for heat exchanger as fitted to post 2002 Td5’s (including new bolts)

– Blanking plug for Air Filter Box

– New Vacuum pump to Servo pipe (we do not believe in just blanking the vacuum pipe – if the blank
comes loose, you will lose servo assistance to the brakes – this is not safe!!)

What is the EGR and what does it do??
EGR or Exhaust Gas Recirculation.
As its name suggests, the Exhaust Gas Recirculation (EGR) system allows a controlled amount of spent exhaust gas back into the air intake of the engine. On both Td5 and 300Tdi this is controlled by the vehicle ECU (Tdi has a standalone ECU for the EGR).
The purpose of recirculating a percentage of the exhaust gas is to reduce nitrous oxide emissions and combustion noise, recirculating a percentage of exhaust gas reduces the combustion temperature and slows down the fuel burn rate – which leads to reduced emissions, but also reduces performance. Although the EGR only works at certain part load conditions, removing it completely makes a marked difference in performance, and will possibly also lead to improved mpg.

Why should I remove it??
As mentioned above, removing the EGR system completely will usually make a difference to performance, and can lead to improved mpg – however that is only part of the story.
When the EGR system works correctly, then it should only operate at part load, part throttle conditions – i.e. the times when you, as the driver, shouldn’t notice its operation. But this isn’t always the case. On both 300Tdi and Td5’s it is very common for the solenoid valve to become clogged internally, which prevents it from sealing correctly. When this happens, performance and MPG will be substantially impaired… it is also very bad for the engine. If the percentage of EGR is too high, rapid engine wear (bore wear) will occur.
The EGR gas will also soot/clog up the inlet manifold as shown in the pictures below. On Td5’s this can cause problems with the MAP (Manifold Absolute Pressure) sensor.

Looking at it from another point of view, removing the EGR basically means there is one less thing to go wrong!! You should also remove the EGR if you regularly use high Sulpher diesel (in the UK, all diesel is low Sulpher)

Does it cause any problems at MOT time??
The current 2008 MOT system for Diesel (i.e. compression ignition) vehicles only requires an Opacity test, (i.e. smoke) and not an actual emissions test as per petrol (spark ignition engine).
The EGR system (and the catalytic converter for that matter) does not actively affect smoke…. This differs from a diesel particulate filter (which is also exempt from testing at the current time). The only requirement is that the max smoke value for a turbo charged diesel is a mean (of the last 3 smoke tests) not exceeding 3.00m-1. For an initial ‘fast pass’ the smoke value must be below 1.50m-1.

In simple terms…. the only reason a modern diesel have CATs and EGR (along with other things) is to enable a manufacturer to meet the current EU legislation (for example EU4/5), but once a vehicle model has been type approved, and sold to the customer… the customer is technically free to do what they like regarding emissions, as long as they meet the requirements of their country, which in the UK is just the MOT test.

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