STAGE 4 | 235KW

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

The BT50 3.2L Stage‑4 Upgrade begins with our trained technician setting your vehicle up on one of our chassis dynamometers to perform a baseline dyno run. This initial test ensures 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 & transmisson Cooler
With the baseline established, we begin the mechanical enhancements by fitting a Process West TERRATUFF front‑mount intercooler kit. Because 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 has proven its effectiveness time and time again, delivering intake temperature reductions of up to 40 degrees during testing, ensuring consistent performance under sustained load.

Turbo Upgrade
As the standard 3.2L engine’s power and torque fall away sharply after 2900rpm, we fit a GTurbo FR2‑G300 NextGEN turbocharger. This unit provides substantially increased airflow and improved reliability over the factory turbo, while remaining a direct bolt‑on replacement requiring no modifications. Once installed and calibrated, the FR2‑G300 dramatically broadens the engine’s usable powerband, bringing the BT‑50’s performance in line with many modern 3.0L V6 turbo‑diesels.

High Flow Injectors
To further increase the engine’s fuel delivery capability, we install high‑flow injector nozzles into the factory injectors. These nozzles significantly increase the volume of fuel available when demanded, allowing the engine to maintain safe air‑fuel ratios while producing even more power. Because the additional fuel is only commanded when required, the upgrade does not negatively affect fuel economy or everyday drivability. Supporting these airflow and fuel system enhancements is the installation of a high‑flow airbox. The factory airbox becomes a restriction at higher power levels, so the upgraded unit ensures the engine receives the airflow it needs while maintaining excellent filtration and durability.

Exhaust System Upgrade
To complete the mechanical upgrades, we install a Pacemaker turbo‑back exhaust system. This system provides unimpeded exhaust flow from the turbocharger rearwards, improving turbo response, reducing back‑pressure, and enhancing overall engine efficiency. Pacemaker’s long‑standing reputation for quality and performance makes it the ideal choice for this platform.

ECU Recalibration
With all hardware installed, we move on to the calibration phase. Your vehicle’s ECU is custom‑tuned on the dyno using the latest tuning software, allowing us to optimise power, torque, fuel efficiency, and throttle response. At the same time, we recalibrate the Transmission Control Unit (TCU) in real time to ensure the transmission’s shift points and line pressures are matched to the engine’s new powerband. This integrated tuning approach transforms the way the vehicle drives, delivering smoother, more predictable shifts and significantly improved towing performance. Once dyno tuning is complete, 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 gains achieved. The BT‑50 3.2L Stage‑3 eXtreme Upgrade is designed for owners who want the highest level of performance, drivability, and towing capability while maintaining the safety and reliability standards HP‑F is known for. The result is a powerful, responsive, and highly capable vehicle that performs exceptionally well in all conditions.

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.

Note: Manual vehicles will require HD Clutch.

Package Includes

1 x HPD Upgraded Intercooler Kit 
1 x HPD Bar & Plate Transmission oil cooler
1x Gturbo FR-G300 Turbocharger
5x +30% Fuel Injector caps
1x HPF High flow air box
1x Pacemaker 3" Turbo back Exhaust w/cat
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.
** Manual vehicles will require HD Clutch

Key Features

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

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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