hi i fitted a bigger intercooler and done the k&n at the same time, i have just removed the egr system and blancked it off,YES YES I KNOW SHOULD HAVE DONE IT AGES AGO! i got the intecooler of ebay from a company called bell autos its the same size fits in the same place and has a larger flow rate i paid £126.00 including p&p but that was exchange on my old unit,i got a standard one due to having air con,i was considering fitting a td5 intercooler but the capacity is actually smaller i know hard to believe but the td5 was also harder to fit in a 300 tdi although it might have run cooler,another idea i might try out is water cooling,basically having a couple of washer jets to spray the intercooler with cold water to give coolder air and more boost,the k&n i got off ebay for £5.00 another bargain,i have just replaced the intercooler hoses purchased from allard turbo,nice blue ones holds the pressure a lot better,just had car MOTd on tuesday emissons on 1.17 overall so really pleased on a 120k engine and nothing to repair,the electric fan i still think is the first thing to do you really can feel the difference straight away,i would only sugest a normal size intercooler if you dont tow a lot and go off road a lot,its only then that you will notice a great difference,my car has so much low down grunt now im like a boy racer again,or so my wife tells me.