STAGE 3 | 215KW

BT50 UP & UR 3.2L | STAGE 3 | 215KW

The BT‑50 3.2L Stage 3 Upgrade begins with our trained technician setting your vehicle up on one of our chassis dynamometers to complete a baseline dyno run. This initial test allows us to confirm that the vehicle is operating correctly before any modifications are carried out, while also providing a factory reference point to compare against once the upgrade is complete. 

Intercooler Upgrade
With the baseline established, we commence the mechanical enhancements by fitting a Process West TERRATUFF front‑mount intercooler kit. Given that many BT‑50 owners use their vehicles for towing—whether for work or caravanning—the factory intercooler is one of the first limitations we address. The TERRATUFF intercooler delivers a dramatic improvement in cooling efficiency, with intake temperatures dropping by as much as 40 degrees during testing, ensuring consistent performance under sustained load.

Transmission Cooler
To further improve the vehicle’s capability and reliability, we install a HPD Bar & Plate Transmission Cooler. This heavy‑duty cooler is designed to stabilise transmission temperatures during towing, off‑road driving, and long climbs—situations where the BT‑50’s transmission can otherwise experience heat‑soak and reduced shift quality. The HPD cooler provides significantly improved thermal control, helping to protect the transmission fluid from breakdown, maintain consistent line pressure, and extend the overall service life of the transmission. This upgrade is especially valuable once additional power and torque are introduced through tuning and turbocharger enhancements.

Turbo Upgrade
As the factory 3.2L engine’s power and torque fall away sharply after 2900rpm, we address this limitation by fitting a GTurbo FR2‑G300 NextGEN turbocharger. This turbocharger offers substantially increased airflow and improved reliability compared to the standard unit, while still being a direct bolt‑on replacement requiring no modifications to install. Once fitted and calibrated, the FR2‑G300 transforms the engine’s performance characteristics, broadening the usable powerband and allowing the 3.2L to deliver strong, sustained power all the way to 3500rpm and beyond. With this turbocharger installed, the BT‑50 typically produces around 215kW and 650Nm—representing gains of approximately 45% at 3500rpm and bringing the vehicle’s performance in line with many modern 3.0L V6 turbo‑diesels.

ECU Recalibration
We complete the package by custom tuning both the engine control unit (ECU) and the transmission control unit (TCU) in real time on the dyno. Using the latest tuning software, we optimise power, torque, fuel efficiency, and drivability while ensuring the transmission shift points and line pressures are recalibrated to suit the engine’s new powerband. This integrated tuning approach results in a smoother, more responsive driving experience with improved towing performance and better throttle control. Following the dyno calibration, the vehicle is road‑tested to validate performance under real‑world conditions and to make any final refinements required.

At the completion of the upgrade, you will receive a detailed dyno graph comparing the before‑and‑after power and torque figures, clearly illustrating the improvements achieved. The BT‑50 3.2L Stage 2 Upgrade delivers a substantial increase in performance, cooling efficiency, and towing capability, while maintaining the safety and reliability standards HP‑F is known for. The result is a more powerful, more durable, and more enjoyable vehicle—engineered to handle the demands of work, towing, and touring with confidence.

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.

Package Includes

1 x G-Turbo FR-G300 Turbocharger upgrade
1 x Process West front mount 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*

*Please note: Additional labour may need to be charged for Intercooler fitment if aftermarket accessories are fitted.

Key Features

The Stage 3 package addresses the next level of components that limit power; generally this will be a turbocharger and associated hardware upgrade. The turbocharger upgrade is aimed at increasing air flow into the engine; this allows extra fuel to be added for more power and torque throughout the rev range. We still maintain our ‘reliability first protocol’ which maintains safe air fuel ratios and low EGT’s. You will note that the Stage 3 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 3 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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