STAGE 4 | 235KW

BT50 UP & UR 3.2L | STAGE 4 | 235KW

The BT50 3.2L Stage-4 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!! To capture oil mist entering your engine's inlet manifold which can build up in your engine's intake we then fit a Process West SEPR8R air oil separator. Next, as the power and torque of the 3.2L engine falls over after 2900rpm we fit up a GTurbo FR2-G300 NextGEN Turbocharger. The Gturbo FR2-G300 turbocharger offers much increased air flow and additional reliability over the standard turbocharger it’s also a direct fit and requires no modifications to install. The fitment and tune of the FR2-G300 turbocharger vastly broadens the power and torque of the 3.2L engine aligning it with most modern 3L V6 turbo diesels. Next, we install high flow fuel injector nozzles to the factory injectors, these bad boys vastly increase the amount of fuel that can be added when demanded from your right foot. The result is a safe air / fuel ratio and even more power! To support the injector nozzle and turbocharger upgrade, we next install a high flow air box from PSICO as the standard item begins to hamper flow. To round out the mechanical upgrades, we install a turbo-back exhaust system from Pacemaker for unimpeded exhaust flow and increase turbo response.

We complete the package by custom tuning your vehicle's ECU on the dyno and Transmission Control Unit (TCU) in real time utilizing the latest tuning software to maximize power, torque and fuel efficiency. We test your vehicle on the road to make final adjustments, optimizing your vehicle's performance, driveability and transmission shift points. At the end of this upgrade, we will provide you with a dyno graph comparing the before and after power & torque increase the upgrade has made to your vehicle.

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 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.

TCU, Transmission recalibration - Late model AT (Automatic Transmissions) are all computer controlled via a Transmission Control Unit (TCU), some TCUs are built in to the PCM (Powertrain Control Module), while others are separate computers. By optimizing the AT shift points and line pressures we are able to match the AT’s shift strategies with the engines new powerband. This can transform the way the car drives and for many models it’s a mandatory requirement when parts like superchargers, large turbochargers, camshaft upgrades, high stall torque converters, etc, are Installed. TCU tuning can also assist when larger tyres and or alternate diff gear ratios are fitted.

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.

Gturbo Turbochargers – Since 2012, GTurbo have been constantly innovating, designing and testing to deliver their customers unrivalled vehicle performance with every upgrade. GTurbo is now one of Australia’s leading manufacturers in high performance diesel turbos. Based in Balcatta, WA Gturbo turbochargers are manufactured in-house by an expert team of engineers. The FR2-G300 NextGEN Gold turbo for the 3.2L Ranger, Everest and BT50 provides ample towing grunt, with power that extends to 4000rpm! It’s designed for 34psi and can be operated efficiently via ECU control from 16 – 37psi. 1-Year Warranty included.

High flow Injector Nozzles – Performance upgrades for just about any engine is about removing restrictions and allowing the engine the breath in more air, however at some point the fuel system runs out of the ability to keep up. In most common rail diesels, the limitation in the fuel system is the actual fuel injector nozzle. Each nozzle has a number of holes that the fuel flows through into the combustion chamber and the size of these holes will ultimately dictate how much power the engine can make. Enter the high flow injector nozzle. We again leverage GTurbo’s extensive diesel experience and option to install their range of high flow nozzles. The nozzles are available in sizes much larger than the standard items however the extra fuel is only commanded when required, meaning that larger nozzles will not affect economy or effect the way the engine runs in regular use.

Turbo-back Exhaust system – A ‘Turbo back’ exhaust system is as the name suggests from the engines turbocharger, back. A good turbo diesel exhaust system features a well-designed 3” ‘dump pipe’ at the back of the turbocharger to promote turbocharger boost response - which in turn improves engine response. It then features a high-quality catalytic converter to keep the smell and law enforcement away and an adequate pipe size to provide unrestricted gas flow. After that, muffler design is largely a personal preference so we can provide a number of muffler options. HPF chooses Pacemaker Exhausts for most of our 4WD diesel platforms. Made in Richmond, South Australia for almost half a century, Pacemaker are synonymous with performance and quality.

High Flow air box, PSICO - The all-Australian Fabricated Air Box (pronounced ‘Psycho’) is packed with features ensuring it is your first choice when you a looking to upgrade your vehicles intake system. Fabricated from 2.5-mm Aluminium sheet metal ensuring high strength and no rust ever, all PSICO® Performance Air Boxes feature a 10-mm thick acrylic lid engraved with PSICO® Performance logo. This lid allows easy inspection and maintenance of your air filter. It is also simple to tell if any water has ingress into the system requiring drainage. The Air Box mounts into the factory location and is mounted on robust mounts and comes standard with a 4“inlet allowing easy connection to 4"stainless steel snorkels and can be adapted to suit most factory style plastic snorkels. The Air Box comes standard in a durable satin black powder coat finish and features an easy to access billet drain port fitted with a quarter turn drain valve. This valve can be left open during normal conditions or easily closed to completely seal your air box when travelling through water crossings. The PSICO® brand was established in 2015 and they are based in Bundaberg QLD.

Package Includes

1 x G-Turbo FR-G300 Turbocharger (Changeover)
1 x Process West Intercooler 700 x 247 x 75mm upgrade
1 x Process West CNC mandrel bent intercooler piping
5 x +30% Fuel injector caps
1 x High flow airbox
1 x SEPR8R Air oil separator catch can
1 x Pacemaker 3" turbo back exhaust (With cat)
1 x Custom ECU - reprogram
1 x Before and after dyno graph
1 x Labour to fit, tune and test

Key Features

The Stage 4 Extreme upgrade is for the BT50 owner looking for the ULTIMATE performance upgrade!

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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