STAGE 2 | TOW

BT50 UP & UR 3.2L | STAGE 2 | TOW

The BT50 3.2L Stage-2 TOW upgrade begins with our skilled technician positioning your vehicle on a dynamometer for a baseline run. This step ensures everything is functioning correctly and provides initial performance data for comparison after the upgrade. Next, we install a Process West ‘TERRATUFF’ front mount intercooler, an HPD bar-and-plate transmission cooler kit, and address the factory intercooler and transmissiom tempratures, which is crucial for towing applications — whether for trades or caravans. The installation of the Intercooler has demonstrated a 40-degree drop in intake temperatures, significantly enhancing performance, while the transmission cooler helps maintain optimal transmission temperatures to extend its reliablity and lifespan. We also fit a Process West SEPR8R oil separator to prevent oil mist from entering the intake manifold, protecting your engine.

The package is completed with a custom ECU tune and transmission control unit adjustment, performed in real-time on the dyno using advanced tuning software to optimize power, torque, and fuel efficiency. Afterward, we conduct on-road testing to fine-tune the vehicle’s performance, driveability, and shift points. Upon completion, you'll receive a dyno graph showcasing the increased power and torque achieved through the upgrade.

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.

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.
 

Package Includes

1 x Process West Sepr8r Catch Can
1 x Process West front mounted Intercooler
1 x HPD Bar & Plate Transmission oil cooler
1 x Custom ECU - reprogram
1 x Before and after dyno graph
1 x Labour to fit, tune and test

*Intercooler fitment labour may change based on accessories fitted to the vehicle.

Key Features

Elevate towing reliability and potential with the HPF Stage-2 Upgrade! Tailored for heavy-duty towing, this package delivers a commanding 160Nm increase in towing torque. The Process West Heavy Intercooler Kit combuned with the HPF transmisson cooler ensures consistent and reliable power delivery under demanding loads. Professionally installed this upgrade unleashes your BT50's towing prowess!

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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