N70 Toyota Hilux Tuning & Performance guide
In this article we will provide clear information about performance upgrades and the parts required to get there, to help you make an easy choice. We’ll start with some background information then list our performance upgrades and notes on the parts.
N70 Toyota Hilux Tune?
You’ll be hard-pressed to find N70 Toyota Hilux owners who would go back to stock after driving a tuned Hilux, it’s just better.
One of the great benefits of diesel performance upgrades is that you can in some ways have your cake and eat it too, tuned vehicles have more instant torque, which makes for a much better experience and requires less effort to drive around.
With the added bonus of increased efficiency on the highway, tuning your 1KD-powered Hilux is something we recommend doing.
Many of us are building tourers with bigger tyres and lift kits, heavy bull bars or accessories like rooftop tents to travel throughout Queensland right through to laps of Australia.
All of those things mean that a stock engine has to work harder, resulting in more heat, struggling on hills and poor efficiency.
Tuning is the process of increasing a vehicle’s performance, using a dyno as a controlled tool to dial in the air/fuel ratio and stress test, along the way we find and upgrade weak links in the vehicle’s components.
Fortunately, we’ve been through this process hundreds of times so you don’t have to find out the hard way, you can get more power out of your 1KD with a bolt-on package from HD Auto and simply tune the car once to suit.
This article is written on the N70 / KUN26R Toyota Hilux, the more popular model for Australians. But 90% of this information applies to the 2WD variants, KDJ120 KDJ150 Prado and other models of 1KD powered vehicles.
1KD-FTV Engine
They produce about 125HP an 300NM of torque at the wheels stock on our Mainline Dyno here in Brisbane, Queensland.
The engine is a well-designed package capable of over 200HP, they don’t suffer from cooling issues, good maintenance and simple bolt-on upgrades are key.
Early models of Toyota Hilux (05-08) had several differences such as ECU, injectors, injector drivers, smaller flywheel and no EGR cooler. Some information/results will vary.
We didn’t get a DPF variant in Australia, but they were available overseas. They have the same turbocharger but the injector codes, tuning and ECU are different.
N70 Hilux with HD Auto 250HP Package fitted, after the owner recently completed a long trip around the Coast of Western Australia from Broome to Perth.
Basics of Diesel Performance (Oversimplified)
More power is achieved by adding more fuel, via various methods such as rail pressure, increasing boost to fuel factor values, which is then further compensated by adding boost, and altering the start of injection timing.
Tuning your Engine
Before we get into the fun stuff like turbos & intercoolers, it helps to understand how you’re going to tune the vehicle.
There are two practical methods for tuning the Toyota Hilux 1KD Engine; remap or piggyback ECU install.
Sometimes both methods are used together if the factory ECU data needs to be edited.
The factory ECU is integrated into the factory vehicle harness, so it’s not ideal to replace it with a stand alone unit, therefore keeping the factory ECU with a remap, or adding a piggyback ECU is a reliable and simple alternative.
Factory ECU Remap
The ECU software is recalibrated by a tuner to modify and increase limitations on fuel, boost, etc.
A remap by itself costs $1450.
Recalibrating factory ECU Data can be complex.
It is more the job of a talented software engineer than a talented mechanic.
It is quite literally data translated into English language and mapped out in various axis via tuning software such as BitEdit or ECM Titanium.
A more advanced tuner will utilise programs such as WinOLS5 and create their own map areas to calibrate the data correctly, ensuring you have precise and accurate results.
ECU Remap – Pros:
- Can remove functions such as VNT, EGR from ECU or edit other engine codes at the same time.
- It’s simple, no added boxes, wiring or controllers.
- The factory ECU remains fully integrated into the vehicle.
ECU Remap – Cons:
- Single Tune (Generally).
- Should be done on a Dyno by an experienced tuner
Piggyback ECU
A tuning module is installed to take control of injector duration, timing, throttle response, common rail pressure and boost pressure to provide a power increase. Our supported tuning options are UniChip Uni-X and ECU=SHOP ProBoost.
Piggyback ECU – Pros:
- Piggyback module works with the factory system, is easy to install & leaves factory ECU untouched,
- Multiple tune options for power, towing, economy with extra functions such as programmable hard cut limiter,
- Pre-tuned options can be supplied with our turbochargers for DIY install.
- Faster to tune as it can be live tuned as opposed to writing ECU files repeatedly until a desirable result has been achieved.
- Unlocks the limits of the engine/ECU with no hidden ECU limiters, often these units benchmark what is capable for the factory ECU, but is much harder to achieve with a factory ECU.
Piggyback ECU – Cons:
- Wiring is required for install,
- Doesn’t reprogram the factory ECU, so cannot turn off codes or delete VNT system if wanting to switch to a gated turbo.
Unichip X & Monster Max piggyback ECU.
Horsepower and Performance Guide for the 1KD-FTV Toyota Hilux
For the sake of simplicity, we’ve broken it down to having only the required parts you need listed, there are number of parts that can be added to mix and match, they are of course an upgrade but not necessary.
125HP and 300NM – Stock
The Toyota Hilux 1KD is fitted with a VNT Turbo and top mount intercooler. It produces around 125HP on our Mainline Dyno.
160-190HP and 450-520NM – Remap with Supporting Mods
Simply tuning the vehicle gives a very worthwhile power increase from stock, but limited by turbo and intercooler.
- Tuned (ECU Remap or Recalibration)
- Heavy duty clutch
- 3″ Exhaust
We did a whole video on this specific level of upgrade which can be viewed here.
200HP and 550NM – Turbocharger Upgrade – Tow and Tour Upgrade
At this point, we have about 50% more HP. They are much more responsive and efficient but limited by the standard injectors.
- Tuned (ECU Remap or Recalibration)
- Clutch upgrade / Auto valve body upgrade
- Garrett or Flex VNT Turbo upgrade
- Front mount Intercooler
- 3 Inch Exhaust
250HP and 600NM – Ultimate Performance Tourer
The 250HP level is a great result for the 1KD – they have heaps of torque, economical on the highway and we still achieve this using simple bolt on parts for reliability.
- Tuned (ECU Remap or Recalibration)
- 30% High Flow Injectors (+30)
- Heavy Duty Clutch / Auto Valve body upgrade
- Flex Pro VNT or Flex R77 Gated 44MM Turbo Upgrade
- Front mount intercooler
- Airbox upgrade
- High Flow Snorkel
- 3 Inch Exhaust
300+HP and 700NM – High Performance 1KD
300+HP is achievable on the 1KD, but this is the area where custom work is required, such as larger F55 Turbochargers, stroker pumps, +50 or larger injectors and potentially upgraded engine internals. The manual gearbox won’t handle the power long so an automatic or conversion is necessary.
How much do I need to budget
Ranging from just a remap, to a full package – It costs between $3200 and $12,000 in performance parts. A 250HP package fitted is around $16,000 including workshop labour.
Parts Breakdown
Turbo Upgrade
There’s a few options, VNT, Gated, 44MM – We’ve written a complete article on 1KD Turbo upgrades here:
https://hdautomotive.com.au/2024/11/26/trade-secrets-best-turbo-for-n70-hilux-1kd/
Throttle Controller (Optional):
A throttle controller is a cheap simple upgrade that can be done to your Hilux at any level – The factory accelerator pedal sends an electronic signal that’s calibrated for rear linear power delivery. Adjusting that signal makes a huge difference even in a completely stock car, the power feels more responsive and it takes less effort to drive.
It’s true that we can just edit the pedal signal for the same effect when tuning the ECU, but then it wouldn’t be adjustable on the go. For example it’s very hard to hill start in the rain with the pedal response turned up, so we recommend using an Adjustable controller like the ECU=SHOP V2, which can be set back to standard on the fly. It costs $279.
Intercooler
A full size front mount will give the best results every time. The top mount is a compromise that suffers from heat soak, we haven’t seen great results from any of the upgraded top mount options either, they perform the same or only slightly better than the plastic factory intercooler. The PDI Intercooler kit costs $1700 with everything you need to do a front mount upgrade.
What about blocking the radiator? The front mount intercooler far offsets any effect it has on the radiator by providing cooler charge air into the engine. You may need to relocate any wiring/control box, etc mounted in front of the radiator, but there is usually plenty of room for an intercooler and winch behind the bar.
We did a full run down on upgrading the intercooler on your Toyota Hilux which you can watch here.
Common Issues
Intake manifold
The 1KD intake manifold is prone to clogging up with carbon & soot from the EGR system.
This can happen even at very low KM’s, it’s highly recommended to do an intake clean before tuning work.
Removing the manifold and physically scrubbing it clean is the only way, workshops charge around $1100 for this service.
Do not get sucked into paying for an intake clean in a can. This does NOT work on clogged EGR systems.
https://hdautomotive.com.au/product/1kd-ftv-intake-clean-gasket-kit/
The intake clean gasket kit to remove and refit your manifold is $230.00.
Cooling
Factory cooling system is well designed, there’s no fan or radiator upgrades we would recommend. Issues with heat are usually typical 4wd maintenance problems, such as a blocked radiator from mud.
Fuel System Upgrade
For performance, the genuine Denso injectors are upgraded with 30% oversize nozzles.
Unlike some models of direct injection, it is fairly straight forward to swap these nozzles over.
You can buy Genuine Denso nozzles to upgrade yourself, or purchase pre-built brand new injectors for $3200.
Why are high flow Injectors the way to go?
Essentially, you have a window of time to inject fuel into the cylinder while the piston is travelling up to it’s combustion event, increasing the size of the injector allows a significantly larger amount of fuel to be injected at the right time of the combustion process, rather than stretching out the injection opening time over a long period with a stock sized injector to increase the fueling. This means you can target better injection timing, and smoke control.
https://hdautomotive.com.au/product/30-1kd-injector-genuine-denso/
Gauges
The factory sensors work well & feed the ECU accurate information about temperature and conditions.
We don’t recommend going over the top with gauges, sometimes there’s just too much information you really don’t need.
But there are a couple of advantages to putting in aftermarket pillar gauges, if for no other reason than they look good on your build.
Boost Gauge: Will give an instant indication if there’s any turbocharger issues such as a boost leak, or an early warning that it’s going over it’s target boost level. (More relevant on a wastegated turbocharger conversion)
EGT Gauge: Exhaust temp (Post Turbo) is useful for monitoring changes in conditions less so than outright temp. For example, your tuned Hilux usually reaches 450°C EGT up a Hill, but today it is reaching 650°C – That could be a sign of a boost leak or mechanical attention needed.
You can check out this gauge kit here.
Driveline
Manual
For manual vehicles, heavy duty clutch is absolutely needed for tuning. The torque increase will slip the factory one straight away. We’ve already posted an article here on best clutch options:
https://hdautomotive.com.au/2024/10/31/the-best-heavy-duty-clutch-upgrade-for-n70-toyota-hilux/
Automatic
Whether you have the 4 speed or 5 speed Auto, converting your valve body to a heavy duty one is highly recommended. Increasing shift pressure reduces wear and helps the auto handle the torque increase from tuning. This can be done by a confident DIYer, by HD Auto in Brisbane, or your local automatic transmission shop.
A340 (4 Speed)
https://hdautomotive.com.au/product/heavy-duty-valve-body-kit-toyota-hil
A750 (5 Speed)
https://hdautomotive.com.au/product/heavy-duty-valve-body-kit-a750-toyota-hilux-5-speed-auto/
Exhaust
The factory exhaust is small, so a 3″ Exhaust is recommended for all levels of performance upgrade. Most of the aftermarket systems will flow quite well so don’t expect there to be a huge difference between brand apart from sound and stainless material options. Premium Manta exhausts start at $1200 & we stock budget options starting at $629 as well. There’s no reason you can’t go for the mild steel option to keep your performance package under budget.
Pictured is the ‘moderate’ option exhaust which has a hotdog resonator and a cat, deeper sounding than factory without going over the top loud.
High Flow Airbox and Snorkel
A high flow air box further contributes to increasing airflow and achieving a ‘safe AFR’, factory style plastic snorkels can become restrictive over 200HP so an upgrade is recommended. (If using a snorkel)
Safari make an “Armax” high flow plastic snorkel if you aren’t into the stainless look.
We recommend using dry, synthetic type high flow filters like in the PSICO Airbox, over the washable / oiled air filters. If too much oil is applied they restrict air flow, oil can also make it’s way down the intake and cause issues with the Air Flow Meter.
Looking a lot better than factory plastic, PSICO Airbox is a good option for 1KD and only costs $1145
Performance Packages
To make it even simpler, we have the N70 dialed and it can all be purchased as a bolt in package.
https://hdautomotive.com.au/product/1kd-ftv-manual-250hp-bolt-on-package/
Bling Parts
There are a number of bling parts to dress up your freshly Tuned Hilux engine bay.
HPD Radiator cover, oil cap and battery bracket pictured.
Maintenance
Injectors
The injectors were updated over the production years from 11 code / 13 code / 18 code injectors. Your ECU has an injector driver to suit that code & they MUST be replaced with the same code. You can easily identify your injectors by removing the intercooler & checking the first two digits printed on top. From around 2010 the injectors were Diamond Coated and may experience very long service life – 300,000+KM is common & we’ve seen over 700,000km on an untouched engine.
Considering it’s only around $200 in parts it’s recommended to at least replace the injector washers at a shorter interval – They can flog the seats out causing low compression, a misfire or numerous other issues. Many customers choose to replace the injectors at the same time while they’re already there, the price has come down a lot, it’s now only $2200 for a set new Denso injectors.
Timing Belt
The 1KD has a timing belt that needs to be replaced every 150KM at least. It’s very important that it should be inspected often for signs of damage or wear.
BASCO service kits combine aftermarket and genuine parts where needed, making it easy and more affordable to maintain your Hilux with quality parts.
HD Auto
For any questions there’s a dedicated HD Auto text line you can message anytime at: 0483906923
We keep all of these parts in stock and they can be found on our website.
