Hi all I'm new to the forum and just bought a defender 90td5 after having numerous landys I plan on deleting the egr valve removing the cat and getting her re-mapped but not for speed I want more mpg! Has anyone out there done any of these things? Had problems? Or got the desired result? Please post any info here for me before I start taking bits off as I don't want to kill my new Landy!
Thanks

ditch the center silencer for a straight through pipe , did mine on my 110 it has upped my miles per tank full of fuel by an average of 45/50 miles .
couple of tank fulls should almost pay for the pipe

I have done most of the things you suggest... my 90 is pre-cat so I didn't need to do that.
Stage 1 re-map for economy... also removed the low rev flat spot, so better pulling away.
Egr removal made quite a difference...probably the best value for money change I've done.
I have a straight through mid pipe.... tried a cherry bomb type, as well as the standard cheap type, both equally noisy - sweet if your outside the vehicle, but booms alot inside... so I'm planning to put the silencer back on... I understand this is more noticeable in 90's as opposed to 110's
Early on I fitted a Disco transfer box, which reduces engine revs when cruising - hopefully good for economy, as well as comfort.
In the winter I run on 265 AT's, and still have the original 205's for the rest of the year... this does also vary the gearing and odometer readings... but I think I get about 34mpg...

Thanks for the replies, I was wondering if the ecu will show a fault when I remove the egr valve??? Or is it a straight forward remove and forget about it?

Oh and what sort of BHP is safe I don't want it eating tubines or oil I was thinking about 180BHP rather than some I have seen around at 230bhp+???

I get about 30-32mpg in my 110 crew cab and about 24-26 while towing

ECU remap
Bigger intercooler
Silicone hoses
EGR delete
Decat
Center box replacement pipe
Disco transfer box.

Have a stainless manifold being made to fit next and a Varible Geometry turbo so will be interesting to see how they effect it when re-mapped again.

I probably could get more in fuel ecomony but I've a roof-rack, exmoor hood and 33x12.5 MTs so all of those woul knock a good few mpg off.


The disco transfer box makes the biggest difference if you do any sort of decent mileage I think but a re-map compliments it very well to get abit more low down torque to pull the longer ratio.

EGR delete should be done no matter what though even if your looking for better performance or not and there's no need for a cat in it

TD5s with 230bhp plus would need all of the bits I mentioned mine has plus a different turbo and more than likely a stainless manifold.

You'd be doing well to have 180-200bhp with the simple stuff like the EGR, decat, remap and maybe a bigger intercooler.