STAGE 4 | 230KW

NISSAN PATROL Y61 3.0L | STAGE 4 | 230KW

The Patrol Y61 3.0L Stage-4 is really where we bring the power output of the ZD30 into the current era. The upgrade starts with our trained technician setting your vehicle up on our 4WD dynamometer 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 new high-flowing Gturbo turbocharger to take over from the small factory turbo, then a Process West SEPR8R air oil separator is installed to capture oil mist entering your engine's inlet manifold which can build up in your engine's intake and cause a carbon build which can reduce the engine's reliability and performance over time. Next, we remove the engines standard injectors and replace the standard nozzles with high flow items, we then install a new Cross Country 4x4 Ultimate intercooler to replace the small and prone-to-leak standard intercooler. These top mount intercoolers make a huge difference, especially if towing or Four Wheeling.  Next up we fit a Pacemaker King Brown turbo back exhaust system which removes restrictions and allows the turbo to spool up easier. We then install a HPD VNT wastegate controller to manage the turbochargers boost control and to improve boost stability.

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 and testing your vehicle on the road to make final adjustments, optimizing your vehicle's performance and driveability. 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.

Like all of our upgrade packages the Stage-4 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 maximum performance with high quality components while still maintaining reliability and 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. 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
• Over Pressure relief valve incorporated to prevent system malfunction in the case of blockage
• Drain port incorporated into main housing with optional drain valve available
• Unique metal matrix filtration system that is anti-clog and also washable/reusable with low restriction filtering
• Laser cut bracket specifically designed for each vehicle
• Moulded temperature resistance houses shaped for the engine bay of each vehicle
• High quality clamps and mounting hardware
• Installation instructions included
• A wide range of specific vehicle applications on offer for direct fitment

Turbosmart wastegate actuator - A wastegate is a valve that controls exhaust gas flow from an engine to the turbocharger, it controls exhaust gas flow to the turbocharger’s turbine. Moreover, the wastegate can control the boost pressure provided by the turbocharger to the engine. The wastegate needs to be correctly matched for the engine and turbocharger combination, giving the end-user adequate control over boost pressure. Turbosmart Upgraded Wastegate Actuators have been developed to provide maximum possible boost response for your factory frame turbocharger. The Turbosmart IWG75 Series of upgraded Actuators benefit from an increased ‘Working Ratio’ over the factory equipment resulting in improved boost response, throughout the RPM range. This Improved ‘working ratio’ is achieved through an increase to the effective surface area of the diaphragm & revisions to the actual springs fitted resulting in greater leverage of the forces the actuator is working against (boost and backpressure) while still being super-responsive. Upgrading with the same base pressure as factory, you can expect a broader boost & torque curve through peak boost being achieved earlier in the RPM and being held longer, into higher RPM. These improvements can be amplified with higher base pressures; however tuning & recalibration is likely required.

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 standard 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.

The Cross-Country intercooler starts with the latest light-weight tube and fin PWR Race Series core which monsters the size of the standard intercooler with measurements of 1050 × 859 × 200mm. The huge intercooler is supported by a new full width and sharp looking bonnet scoop and a thermo-fan mounted underneath the cooler to pull air through at low speeds. This is coupled with CNC folded tanks that have been the culmination of years of motorsport fabrication experience, then refined even further using computer flow simulation. This ensures the tanks are highly efficient and provide high, even, unrestricted flow to the whole area of the core with no swirl pockets or restrictions. From our testing, the Cross Country is hands down the best and most efficient Intercooler for the Y61 Patrol platform. Cross Country intercoolers are made in Edwardstown South Australia and they use world renowned PWR intercoolers whom supply teams such as F1, NASCAR, V8 Supercars, DTM, WRC and Moto GP. PWR are based in Ormeau, QLD.

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.

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 turbochargers for diesel engines. Based in Balcatta, WA Gturbo turbochargers are manufactured in-house by an expert team of engineers and their turbos are designed and built in Australia for Australian conditions. HPF have unashamedly leveraged Gturbos unparalleled diesel turbocharger development and we offer two different turbochargers for the ZD30 to suit auto or manual. For manual’s, we typically use the G260-ZD NextGEN turbocharger as it provides towing power, with superior low rpm grunt and efficiency compared to the original turbocharger. For automatic equipped cars we run the larger G300-ZD NextGEN as the automatic transmission’s torque converter helps in getting the engine up and into the turbochargers sweet spot nice and quickly.

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.

Package Includes

1 x Gturbo ZD-G260 turbocharger
1 x Cross Country 4x4 Ultimate intercooler & thermo fan
1 x Painted body colour hood scoop
1 x HPD VNT boost control valve
1 x Set of Gturbo Highflow Injector Caps
1 x 3" Intake pipe & 3" turbo inlet pipe
1 x SEPR8R air oil separator
1 x Pacemaker King Brown turbo back exhaust
1 x HPF Custom ECU reprogram
1 x Before and after dyno graph
1 x Labour to fit, tune and test

Key Features

The Stage 4 package addresses the next level of components that limit power; generally this will be an intercooler and exhaust upgrade and associated hardware upgrade. You will note that the Stage 4 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 Stage 4 package.

Notes

• Power figures listed are estimated kilowatts at the flywheel based on results typically obtained by HPF on HPF’s dynos and are based on a automatic 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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