STAGE 2 TOWING | 180KW

BT50 UP & UR 3.2L | STAGE 2 TOWING | 180KW

The BT50 3.2L Stage-2 upgrade starts with our trained technician setting your vehicle up on one of our dynamometers and performing a baseline dyno run. This allows us to firstly make sure everything is working A-OK and secondly it gives us standard figure from your car to compare to once the upgrade is completed. We then commence the upgrades by fitting a Process West – ‘TERRATUFF’ front mount intercooler kit. With the Mazda BT50 used by many owners to tow, either tradie style or caravans, the factory intercooler is one of the first things we address and to prove its worth, we have seen a 40 degree drop in intake temperatures after installation!! Next up we fit a Process West ‘SEPR8R’ air oil separator to capture oil mist before it enters your engine's inlet manifold where it can build up in your engine's intake.

We complete the package by custom tuning your vehicle's ECU on the dyno in real time utilizing the latest ECU tuning software to maximize power, torque and fuel efficiency. We follow that up with testing your vehicle on the road to make final adjustments, optimizing your vehicle's performance and driveability. At the end of the upgrade, we provide you with a dyno graph comparing the before and after power & torque increase the upgrade has made to your vehicle

Like all of our upgrade packages the Stage-2 package is modular in that it allows the customer to add to the package minimising the requirement to spend money twice when and if further upgrades are desired. We also always strive to bring you the maximum safe performance with high quality components while maintaining reliability and improving driveability.

Catch Can – Process West, Diesel - Internal combustion engines like the engine in your 4WD will in normal use have some combustion pressure leak past its piston rings. This pressure if not released, will build up inside the engine’s crankcase leading to engine oil leaks and a negative effect on engine power. To control this pressure build-up, the manufacturer has installed a vent on the top cover of your engine that plumbs this pressure into the inlet of your turbocharger, however that pressure takes with it vapour that contains an engine oil mist.

The heart of the Process West SEPR8R system is a uniquely designed Catch Can with an internal filtration system that scrubs the oil mist before plumbing the vapour back into the turbocharger as per the OEM routeing. From the factory this 'air cleaning' doesn't take place, so the oil that comes out of the top engine cover ends up lining the insides of your intercooler and inlet system resulting in both reduced performance and economy over time.

Manufactured from Billet Aluminium with removable lid and filtration assembly of 650ml capacity, the ‘Sepr8r’ features an over pressure relief valve incorporated to prevent system malfunction in the case of blockage. It also features a drain port incorporated into main housing with optional drain valve available. The filter features a unique metal matrix filtration system that is anti-clog and also washable/reusable with low restriction filtering. The laser cut bracket and moulded temperature resistance houses are shaped for the engine bay of each vehicle.

Diesel Tuning - For the most part, diesel 4×4’s are bought and employed to do a job, it may be towing, regularly carting heavy loads or used as daily transport with the odd trip off-road. Whatever is it, chances are that the vehicle may struggle to do that job in one area or another, maybe the vehicle struggles to pull the van or it uses too much fuel or it has annoying flat spots or a delay in the throttle response, no car is perfect. But by reprogramming the vehicles factory ECU, we can iron out those flat spots, increase the vehicle’s torque output and increase the general enjoyment of driving your diesel to get your car closer to perfect and help it to do the job you originally employed it to do.

Safety First - We at HPF have a set of tuning guidelines in place that ensures we do not exceed predetermined SAFE air / fuel ratio & boost level parameters; in some cases, the air / fuel ratio is the same as standard. This guideline is in place to provide you with the safest and most reliable result and instead of chasing a maximum power figure, we tune your engine to these SAFE parameters and the increased power is a result of that. As each car is individually tuned on the dyno, the final outcome has been scrutinized and road tested prior to being returned to the customer.

Intercooler, Diesel – Basically, the intercooler’s purpose is to remove the heat made by the turbocharger when it compresses the intake air to make boost. Cool, dense air is the best for performance and the engine’s ECU monitors the boosted air temperature via a sensor positioned after the intercooler, the ECU then alters engine power based on that temperature signal in order to maintain safe and reliable operation. Sustained hard driving like towing or four-wheel driving where the turbo is constantly working, will result in the intercooler reaching a state of ‘Heat Soak’, meaning it cannot pull any more heat out of the boosted air. Heat soaking of the intercooler will result in the engines ECU lowering the power output of the engine when the power is needed the most.

Designed not only with market leading performance in mind, OEM level durability is also part of the Process West TERRATUFF arsenal, offering OEM style design and fitment, followed through with industry leading testing and validation. The heart of the Process West TERRATUFF Intercooler system is a durable front mounted Bar and Plate intercooler core. All TERRATUFF intercoolers use Bar and Plate construction due to not only its effective cooling and heat-sink capability, but also because it is the most durable and impact resistant of all intercooler types. Measuring in at 700m x 247mm x 75mm the Ranger/BT50 TERRATUFF core also offers a massive increase in cooling surface area as well as overall thickness. Process West was established in 2003 and run out of a purpose-built facility in Berkeley, NSW.

Package Includes

1 x Process West intercooler 700 x 247 x 75mm upgrade
1 x Process West CNC mandrel bent intercooler piping
1 x SEPR8R Air oil separator Catch Can
1 x Custom ECU - reprogram
1 x Before and after dyno graph
1 x Labour to fit, tune and test

Key Features

The Stage 2 Towing package addresses the next level of components that limit power; generally this will be a Intercooler and associated hardware upgrade. The Intercooler upgrade is aimed at maintaining our ‘reliability first protocol’ which maintains safe air fuel ratios and low EGT’s. You will note that the Stage 2 Tow package may not include what is traditionally thought to be ‘essential diesel upgrades’ but rest assured, if it’s needed, it will be in the Stage2 Tow package.

Notes

• Power figures listed are estimated kilowatts at the flywheel based on results typically obtained by HPF on HPF’s dynos. Typically these are based of a manual vehicle with standard driveline and standard wheels and tyres. Actual power can vary based on each specific vehicle.
• We advise against increasing the power output substantially on high kilometer engines, if your engine has in excessive of 150,000kms please contact us to discuss options.
• Whilst every attempt is made to ensure prices listed online are correct, they are subject to change at any time.
• Additional parts may be required in some cases depending on the condition of the vehicle. Cost of these parts and additional labor required may incur additional cost.
• Images are for illustration purposes only.

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