I reckon an upgraded intercooler might make life easier for your 2.4.
To be honest i'm not sure which tune i run. When i bought it BAS only had 1 tune for the 2.4 and it was quoted as 440nm which is their 165 bhp tune now. I might have the 165, i might have the 150 tune. I have a 3" exhaust with an oversized free flowing centre muffler. I don't have over heating problems and my intake temps are not rude. Of course an IC will help but the figures don't suggest it is necessary. As for a hybrid turbo, CAL415 (Mick) went this route on his Puma and is not happy. Stefan had a hybrid on his TD5 and it produced lots of power with corresponding black smoke. But it was either all or nothing. I'm not looking for that type of power delivery. I appreciate that i'm asking a lot of the 2.4. In low range the 2.4 is more than adequate, it's just on the hwy that it struggles especially on long hills.
I reckon an upgraded intercooler might make life easier for your 2.4.
Intercooler isn't about overheating, cooler is better and if your pushing it, which it sounds like you are given the tune, exhaust, bigger tyres etc. an upgrade will certainly be beneficial.
That's more likely a tuning issue, I and many others run VGT's on our TD5's and certainly don't have that. When I ran my previous owners Td5Inside tune which was focused on maximum power with no thought about fuel economy it was black smoke out the back, that was quickly resolved with updates to the tune. The VGT upgrade just increased the torque throughout the rev range - makes such a difference Offroad and on the street! I'd highly recommend looking into it further.
OR 1.4 gear set and 40in tyres..
(You knew I was coming along eventually)
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