OMEX. Ford 2.0L Duratec VVC (MZR) Performance Engine Packages

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1 OMEX Ford 2.0L Duratec VVC (MZR) Performance Engine Packages

2 Ford Duratec 2.0L VVC (MZR) Engine Packages Brochure v /01/15 Our range of OmexPower engines has been developed to be engine package solutions that are truly turn key. We have developed a coherent range of very high quality, fully tested engine packages with varying power outputs to suit your requirements and budget. All our engine packages are built on brand new engines. The engines are all built at Omex, mounted on a special jig and hot run. This means that the cams are run in, the throttle bodies (where applicable) are balanced, the idle speed is set and the emissions are checked for IVA and MOT compliance. The engines are supplied with the new Omex 630 Series ECU and a fully assembled wiring loom as standard. To ensure absolute peace of mind the engine is tested with the actual loom and ECU that are shipped with your engine. As the ECUs are all precalibrated there is no need to run any OmexPower engine on a rolling road or dyno. Simply fit to your car, connect 5 wires (details are of course supplied) and start the engine! The OmexPower range of Ford Duratec VVC (MZR) engines covers power outputs of 195 to 215 bhp. The engines are available as an inline (to suit front engine rear wheel drive) version. The engines use the superb RaceLine lowline fully baffled sump (do not confuse this with cheap inferior copies that are available). These superb engines features variable cam timing (VVC). The inlet camshaft timing is varied by up to 36 degrees under ECU control to give a very wide power band, with excellent bottom end torque and a real rush at the top end of the rev range. The standard specification of these engines is significantly enhanced from the non VVC Duratec engines, allowing a safe and totally reliable 7800RPM rev limit. As standard both specifications are fitted with an uprated crankshaft, forged con rods and forged pistons. They also have uprated valve springs as standard fitment. This makes them ideal as a trackday engine as they are very strong engines. We initially designed this specification for a production run of 60 cars for Morgan Motor Company where many of them have been raced for three seasons with no issues at all. They have since been fitted into all sorts of vehicles including our own raw Striker test car where Autocar magazine described it as the one we could have stayed on track all day with. The 215bhp specification features our own camshaft design that gives an additional 20 bhp and improved midrange torque with no loss at the bottom end of the rev range. There are a wide range of mechanical options and upgrades available to suit your requirements, such as 3 different throttle body lengths and 2 manifolds, different clutches and flywheels, side water rails, a choice of linkages, uprated valve springs etc. The available options for each engine specification are detailed at the end of each section. In addition there are several electronic options available, such as full throttle gearshift, shift lights and more, again detailed at the end of each engine. If you would like advice about which specification fits your vehicle best then please give us a call. If you would like to see any of our engines, we generally have all specifications available for viewing. In addition we have most specifications available in demonstration vehicles. Most of these regularly attend track days and you would be most welcome if you would like a demonstration on track. Selecting your engine Engine shown is D20MZR021 with kit OMEP2110A(F) Duratec Variable Valve Timing (VVC) engine package High specification engine 195 bhp 7800 RPM rev limit Multiple throttle bodies for instant throttle response Inline installation 195 bhp Duratec VVC Engine Engine shown is D20MZR031 with kit OMEP2110A(F) Duratec Variable Valve Timing (VVC) engine package Omex specification inlet and exhaust cams High specification engine 215 bhp 7800 RPM rev limit Multiple throttle bodies for instant throttle response Inline installation 215 bhp Duratec VVC Engine 2

3 Duratec 2.0L VVC (MZR) Engine 195 bhp This superb all alloy, variable valve timing engine makes a fantastic road or track day engine for your vehicle. It offers great power output in a lightweight package with an extended rev range, this engine with its strong torque curve gives great performance and exceptional reliability and driveability. Available as an inline (front engine rear wheel drive) engine, it utilises individual throttle butterflies for each cylinder which gives unrestricted airflow to each cylinder and hence a high power output. In addition, the ability to produce more power and torque at the higher end of the rev range means that the on road and track performance is enhanced. Also the sound of throttle bodies cannot be beaten. The engine is fitted with the superb Raceline lowline wet sump (with a dry sump option) to allow maximum ground clearance and no oil surge. A wide range of options and upgrades to suit your specific requirements are available. Inline Specification 195 bhp Duratec VVC Engine Engine shown is D20MZR021 with kit OMEP2110A(F) Engine 195 BHP Engine (inline) Options D20MZR021 Alternator outputs and positions Dry sump system Alternative inlet system lengths and angles Air filters Throttle linkages Fuel line fitting type Brake servo piping Uprated bigend bolts Side water rail assembly Flywheels and clutches Starter motors Bell housings Uprated wiring harness specifications Electronic controls Engine Specification New Duratec 2.0L VVC (MZR) Engine Ready mapped 630 Series ECU Ready built wiring harness Lowline baffled sump Inlet manifold with multiple throttle bodies Lightweight alloy air horns Fuel rail Fuel pressure regulator Throttle position sensor Air temperature sensor Coolant temperature sensor position sensor Injectors Ignition coil pack and leads Oil filter Gaskets Engine Power Graphs How much power will my engine make? The power and torque graph shows the results obtained from an engine in a Morgan Plus 4, using an Aero Racing exhaust manifold, catalytic convertor, and silencer system. These results are from testing on Omex s Superflow rolling road D20MZR021 BHP / Torque Power Torque RPM Duratec 2.0 VVC (MZR) 195 bhp Engine Power Graph

4 What comes with the engine? Electronics 195 bhp Duratec VVC Engine Omex s new 630 Series ECU controls the fuel injection, standard Ford distributorless ignition coil pack, and optionally, many other functions around the vehicle. The ECU is connected to the hardware with a complete, ready built wiring harness, which is fully tagged and with the correct connections made for the Duratec engine, ensuring easy clipon fitment, optimum performance and absolute reliability. The ECU, wiring harness and sensors are kept with each engine build throughout assembly and testing work, ensuring that the engine package you receive has been tested as a whole package. Inlet System Standard fitment long throttle bodies with long port angled inlet manifold and 40mm air horns Proven, reliable, Jenvey throttle bodies are used on these specification engines. Individual throttle plates give the air an unrestricted route to the engine giving maximum power. There are three options of throttle body lengths and two manifold designs to suit all applications. Sump Inline wet sump in parts and assembled on the engine. The engines are fitted with a new low line increased ground clearance sump with internal baffling designed to keep the oil on the pickup. This sump has been tested in vehicles up to single seaters with slicks and wings generating very high cornering forces. 4

5 What comes with the engine? Ignition System 195 bhp Duratec VVC Engine DIS coil pack, ignition leads, and spark plugs are all included. Temperature Sensors Air and coolant temperature sensors are supplied and fitted. & Throttle Position Sensors Injectors and throttle position sensors are supplied and fitted to all engines. Bosch injectors are used giving excellent spray patterns to optimise power outputs and reduce emissions. Gaskets & Oil Filter Fuel Pressure Regulator All gaskets and an oil filter are included and fitted. The engine utilises an aluminium billet fuel pressure regulator. 5

6 Engine Dimensions (Inline Version) All dimensions are approximate, if you need any other dimensions please ask. Ignition coil pack can be removed and mounted remotely Optional side water rail reduces the size of the water housing (see options list) Oil filter can be changed for a shorter filter Engines shown with optional kit OMEP2110A(F) and standard inlet system arrangement. Front of pulleys 630mm Back of Water housing 195 bhp Duratec VVC Engine 510mm cam cover Bottom of sump 150mm 440mm 250mm 175mm 260mm 570mm 590mm 330mm 160mm Side Rear of block 120mm Rear of coil End of Throttle bodies throttle bodies Bottom of throttle bodies oil cap & cam cover Bottom of sump Side 420mm 490mm End of Throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 6

7 Options and Upgrades Alternators Inlet side kits For chassis clearance there is the option of mounting on either the inlet or the exhaust side of the engine. Racecars with minimal electrical requirements can use the smaller 50A. Road cars and rally cars with higher electrical requirements will require the larger 130A. All kits are fitted to the engine and include;, pulley, billet brackets (or direct mount), idler pullies and drive belt. 195 bhp Duratec VVC Engine OMEP2110A(F) 130A inlet side 270mm cam cover 160mm 80mm Bottom of 180mm 110mm Engine shown with standard length throttle bodies and low line sump Side of engine Side of OMEP2114A(F) 50A inlet side 355mm cam cover 85mm 70mm Bottom of 200mm 80mm Engine shown with standard length throttle bodies and low line sump Side of Side of engine 7

8 Options and Upgrades Alternators Exhaust side kits OMEP2112A(F) 130A exhaust side cam cover 260mm 195 bhp Duratec VVC Engine Bottom of 190mm 60mm Engine shown with standard length throttle bodies and low line sump 115mm 130mm Side of Side of engine OMEP2116A(F) 50A exhaust side 190mm cam cover Bottom of 260mm 60mm Engine shown with standard length throttle bodies and low line sump Side of 85mm Side of engine 130mm 8

9 Options and Upgrades Dry Sump Although not required for most applications, we offer the Raceline dry sump option for pure competition applications (inline only, not suitable for transverse applications). It gives the advantage of an even lower sump line (approximately 25 mm lower than the lowline wetsump) so the engine can be mounted even lower in the chassis. Also available as a no cost option are mounting lugs on the front of the dry sump for engine mounting directly to the chassis tub in single seaters or via stiff silentblocks in seven type vehicles. Inline dry sump in parts and assembled. 195 bhp Duratec VVC Engine Internal oil pump drive Our dry sump oil pump is built into the engine in the place of the standard oil pump, without any external drive belts that are so prone to damage and subsequent failure causing destruction of the engine. As well as being much more reliable it is lighter in weight than other dry sump systems. With a scavenge to pressure ratio of 2:1 the sump is kept empty of the oil mist that drags down power output. The sump also includes twin crank scraper plates and an additional trough baffle. Installation in your vehicle is really simple, with a single pipe from the sump to the oil cooler, a pipe from the cooler to the oil tank and a feed pipe to the sump. As part of your engine build if you choose this option, plates to seal the engine block are included and fitted. This sump is incredibly well proven, being used on the Palmersport Formula 4 single seaters, the Radical SR3 SL, MCR Sports 2000 and hundreds of Caterhams. 9

10 Options and Upgrades Inlet System Standard kit fitment The engine as standard comes with a set of long throttle on the long port angled inlet manifold, pushon 8mm fuel pipe connections, the injectors fitted in the throttle bodies and with 40mm long air horns. These parts can be changed to allow for the space available in your vehicle; 195 bhp Duratec VVC Engine 2 different inlet manifolds 3 different lengths of throttle bodies 4 lengths of air horns Injector placement in either the throttle bodies or the cylinder head Air filters of different lengths Filter back plates centred or lowered 15mm Throttle Bodies Long Throttle Bodies (Standard fitment) 118mm Medium Throttle Bodies 91mm Short Throttle Bodies 30mm Inlet Manifold Long Port Angled Inlet Manifold (Standard fitment) 17 degree angle Short Inlet Manifold 0 degree angle with 15mm offset Air Horns 90mm Air Horn 60mm Air Horn 40mm Air Horn (standard fitment) 19mm Air Horn 10

11 Options and Upgrades Inlet System Inlet System Selection The ideal inlet is as long as possible, feeds the air to the head at port angle to minimize turbulence, injects the fuel upstream of the head to allow fuel mixing time, and uses a large single air filter for minimum restriction. Long Throttle Bodies with Long Inlet Manifold (standard kit fitment) 229mm 195 bhp Duratec VVC Engine 17 o Medium Throttle Bodies with Long Inlet Manifold 202mm 17 o Short Throttle Bodies with Long Inlet Manifold 141mm 17 o 11

12 Options and Upgrades Inlet System Long Throttle Bodies with Short Inlet Manifold 193mm 195 bhp Duratec VVC Engine Port centre to throttle body centre 15mm offset 0 o Medium Throttle Bodies with Short Inlet Manifold 166mm Port centre to throttle body centre 15mm offset 0 o Short Throttle Bodies with Short Inlet Manifold 105mm Port centre to throttle body centre 15mm offset 0 o 12

13 Options and Upgrades Inlet System Injector Position Bosch injectors are used giving excellent spray patterns to maximise power outputs and minimise emissions. Ideally they are fitted in the throttle bodies (standard fitment), but can also be fitted in the head when space is restricted. Injectors in the throttle bodies (standard fitment) Injectors in the cylinder head 195 bhp Duratec VVC Engine Air Filters The long throttle bodies will accept DCOE / DHLA pattern back plate air filters which can be supplied with a centralised back plate or a 15mm lowered back plate. Sock filters can be used where space is tight but they can affect airflow so should be avoided if possible. The short throttle bodies cannot accept the back plate style airfilter, so the sock style filters must be used with these throttle bodies. Different Depth One Piece Air Filters (Fits onto Back Plate) Central and Lowered Air Filter Back Plates (Fits Ones Piece Air Filter Only) Air Filter Socks One Piece Air Filter with Central Back Plate (Long throttle body use only) One Piece Air Filter with 15mm Lowered Back Plate (Long throttle body use only) Air Filter Socks 13

14 Options and Upgrades Mechanical Throttle Linkages As standard, the throttle bodies have a lever blade to which you can connect the inner throttle cable pulling from above or below between throttles 2 and 3. A more complete cable solution is available by fitting one of the optional throttle linkage kits. These can be specified for single or twin cables, fitting above or below the throttle bodies (above is the preference for ease of adjustment if space is available), and with the cable pulling from the left or the right. The linkages are supplied fitted, adjusted for best throttle action and complete with new throttle cables. Note that dependent on and inlet system choice, it may not be possible to build all options 195 bhp Duratec VVC Engine Single cable throttle linkage kit (top mounting, left pull) Twin cable throttle linkage kit (top mounting, right pull) Fuel Pipe Connections The fuel rail can be built with either pushon pipe or 6 screw fitting pipe fittings. The fuel pressure is regulated by a constant pressure billet aluminium housed regulator (included). The regulator will also have either pushon (standard) or 6 screw fittings (optional) to suit. Pushon pipe fittings 6 pipe fittings Brake Servo If your vehicle requires a brake servo vacuum, the manifold can be fitted with a vacuum takeoff. This can be specified to exit to the either side of the engine. A pushin adaptor to suit 8mm ID pipe is supplied. 14

15 Options and Upgrades Mechanical Uprated Bigend Bolts For engines that are expected to spend a lot of time at high engine speeds, such as those which are intended for competition use or extended trackday use, extra safety can be inbuilt through the upgrade to ARP bigend bolts. 195 bhp Duratec VVC Engine Uprated ARP Bigend bolts Water Housing The standard fitment water housing is mounted on the back of the cylinder head and also acts as a mounting for the ignition coil pack. This points the main 32mm water outlet towards the inlet side of the engine. It also has takeoffs for a heater if required. We offer an alternative aluminium water rail that runs over the top of the exhaust and brings the water outlet to the front of the engine. It also has mountings for the supplied ignition coil pack. It can be supplied with heater takeoffs as well or they can be supplied blocked off to suit your application. If space at the rear of the engine near the bulkhead is an issue we can machine the coil mountings off the side water rail to increase clearance and in that instance we can either relocate the coil with longer HT leads or we would recommend our coil on plug option that includes 4 plug top coils and an expander box for the ECU. Standard Water Housing Side Water Rail Housing 15

16 Options and Upgrades Mechanical Flywheel and Clutch There are a bewildering range of flywheels and clutches available for the Duratec engine so at Omex we have sorted out the sensible combinations that cover nearly all applications. We offer flywheels and clutches that are suitable for road use right to full competition versions. As there are such a large range of choices please call to speak to one of our powertrain engineers if you have any queries. All of these clutches and flywheels are suitable for front engine/rear wheel drive, if you are specifying a transverse application please call. FLYWHEELS OMEP5100 OMEP5102 OMEP5104 OMEP5106 Lightweight (4.7Kg) steel flywheel to suit Ford Type 9 or MT75 offset Medium weight cast flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed) Lightweight (4.7Kg) steel flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed) Lightweight steel flywheel to suit the Raceline narrow bellhousing only (Ford offset) 195 bhp Duratec VVC Engine CLUTCHES All our clutch kits include both pressure and driven plate and are designed to fit specific flywheels and gearboxes. We offer a range to cover both the Ford Type 9/MT75 gearboxes (1 x25 spline) and the Mazda MX5 Mk3 gearboxes that are fitted in so many niche vehicles now such as Morgan Plus 4. OMEP5200 OMEP5200A OMEP5202 OMEP5202A OMEP5204 OMEP5204A AP Racing sprung organic clutch assembly to suit OMEP5100/5106 flywheel. This clutch assembly is ideal for road and trackday use and has a great feel to it and is suitable for mild competition use. It has the Ford 1 x25 spline arrangement so is ideal for the Ford type 9 and MT75 gearboxes. As the OMEP5200 but with a solid driven plate which is more suitable for full competition use or essential with a sequential gearbox that is either driven on track or has a flat shift or paddle shift fitted. Suits the Ford 1 x25 spline input shaft as used on many competition gearboxes. This is suitable for the OMEP5102 cast Mazda offset flywheel and is a completely standard Mazda clutch assembly. It fits the Mazda MX5 Mk3 gearbox (5 speed) and although is a road clutch it has proven totally reliable in 200bhp race cars. We specified this assembly for the 60 off Morgan Supersports, many of which have raced for 3 years now without a clutch change. As OMEP5202 but for the 6 speed Mazda MX5 Mk3 gearbox. This Sprung uprated clutch assembly suits the Mazda lightweight steel flywheel OMEP5104. We specified these for the Morgan Plus 4 Racecars that used our Duratec 265 bhp engine. They have a slightly higher pedal pressure than the standard clutch but are perfect for road or competition use. Suits the Mazda Mk3 5 speed gearbox. As OMEP5204 but for the Mazda MX5 Mk3 6 speed gearbox. Flywheel bolts are also required; standard flywheels bolts or ARP flywheel bolts can be supplied and fitted. Bellhousing A cast aluminium bell housing is available to suit the Ford Sierra Type 9 (short input shaft) gearbox (flywheel OMEP5100). A Raceline narrow aluminium bell housing to suit the Ford Sierra Type 9 is available for flywheel OMEP5106. Mazda gearboxes have integral bellhousings that directly fit the engine (flywheels OMEP5102 and OMEP5104). Options and Upgrades Starter Motors Starter Motor Standard starter motor (Ford and Mazda offsets available) High power starter motor (Ford and Mazda offsets available) Standard and high power starter motors can be supplied suitable for both the Ford offset and the Mazda offset flywheels. The high power starter is ideal for those using small race batteries or long battery leads that sap starting power as it operates more efficiently and so can start an engine with less electrical current. 16

17 Options and Upgrades Electronics Wiring Harness Options Standard Road Specification The standard specification harness in this kit is the road specification. This harness uses thin wall, lightweight automotive grade cable loomed together with PVC tubing and harness tape; a specification similar to that found on premium modern road cars. Each harness is individually computer tested to ensure the build is correct. 195 bhp Duratec VVC Engine Rubber connector boots PVC tubing covered cable Upgrade 1 Race Specification The race specification is the same dimensions as the road harness and uses the same high grade cable, but this time loomed together using Raychem DR25 heatshrink as found on nearly every professional motorsport harness for high flexibility, resistance to solvents and superior cut resistance. Within this Raychem outer, the cables are twisted together to provide resistance against radiated electrical noise from sources such as the high tension sparks, and starter motor giving clean sensor signals to the ECU. The terminals connecting to the ECU are then upgraded to gold plating to ensure the best connections to the ECU possible to maintain the clean signals from the sensors. All joints in the harness are made with crimps rather than solder to withstand the high vibrations often found with solidly mounted drivetrains in race vehicles. The joints and the component connectors are then covered in glue lined heatshrink which is inflexible and so any tension placed on the harness during service goes onto the strong connector housings and cables and so away from the cable joint. All of these improvements together give longer service life and improved reliability in the harsh environment of a motorsport engine bay. These harnesses are built by a team of engineers currently working in top worldwide works motorsport series (the same team responsible for our works spec bespoke harnesses) so not only are high quality materials used, they are built by the best too. Finally individually computer tested using a stateoftheart CIRRIS test machine at 500V to give extreme testing of the cable insulation. Heatshrink connector boots Twisted cables in heatshrink sleeving Heatshrink harness joints Gold plated terminals Upgrade 2 Bespoke Race Specification The perfect harness should also fit perfectly. The bespoke Race specification is built using the same materials and methods as the standard Race specification harness, but with lengths tailored to suit your engine bay. Heatshrink connector boots Twisted cables in heatshrink sleeving Heatshrink harness joints Gold plated terminals Bespoke lengths 17

18 Options and Upgrades Electronics Electronic Controls With optional extra parts the Omex 600 ECU is capable of much more than simply running the engine; Shift lights a visual warning for the optimum rpm gearshift. Normally a high intensity 10mm red LED is used, but other sizes and colours are available. Full throttle gearshift gearshifts without lifting off the throttle. In the case of sequential gearboxes, even without using the clutch. Sequential gearboxes often have a switch inbuilt for input to the ECU, and those using a normal gearbox can use an Omex clutch switch, signalling an ignition retard that temporarily reduces engine power output. Launch control consistent fast starts. A button on the steering wheel that gives a temporary lower rev limit holding the engine steady on the startline. Radiator fan control reduce the number of joins and sensors in the cooling system, and have full programmability of the ON / OFF temperatures for the radiator fan. An additional relay is required for this control. Barometric air pressure correction If you are using the engine with large altitude changes (such as in the mountainous areas), then air pressure changes due to the altitude changes will affect the amount of fuel required. An upgrade to fit an air pressure sensor to automatically make these changes is available. Emissions control The engine simply needs a narrowband lambda sensor and an effective catalytic convertor and it will then pass UK MOT and IVA emissions tests with ease. Omex can provide a lambda sensor and boss to weld to the exhaust. A lambda sensor is not required to make the engine run, so if you have a vehicle that does not need to pass emissions tests, then a lambda sensor is optional. Throttle position sensor For use in extreme conditions such as offroad rallying, a contactless throttle position sensor can be used to give improved reliability due to improved protection against water and dust. 195 bhp Duratec VVC Engine Shift light (10mm LED) Full throttle gearshift (clutch switch) Launch control (button) Radiator fan control (Relay and base) Barometric pressure sensor and harness upgrade Lambda sensor Lambda sensor boss Throttle position sensor upgrade Why choose Omex Products? The difference between winning and losing is very small. In hillclimbing and sprinting it can regularly be 0.05 secs, in circuit racing a half cars length, in rallying one corner... So what makes Omex products win so many events and championships? Simple, attention to DETAIL. The very basics of how the ECU works makes a big difference. How it calculates when an ignition spark is going to be placed, when it s calculated, how engine acceleration is taken into account, and so ultimately how accurately that spark is placed, are things that you do not think about when looking at ECUs. Here at Omex we do because those details that are often taken for granted are the difference between one ECU system and another, the difference between winning and losing... The detailed approach to design of the basics by our team of top software and hardware design engineers, responsible for race wins throughout all forms of motorsport at the very highest levels, means you do not need to think about these details because we do. Features lists don t win races; it s how these features work that wins races. Other ECUs may have similar features lists, but how an Omex works makes all the difference. Naturally, Omex ECUs have all of the features you would expect from a top level ECU. Winning Championships is a combination of performance and reliability. Reliability is found in the details of the way the ECU is designed and built. All Omex ECUs are robot assembled in the UK on an ISO9001:2000 approved assembly line, ensuring a consistent, high quality build. They are all then thoroughly tested, twice, before leaving Omex. A well running system is a combination of ECU and many other components. It is important that all components in the system continue to work in order for the ECU to be able to perform, and so Omex source all other components such as sensors and injectors only from highly respected manufacturers. Of course, before you can even think about winning races and championships, you need to get to the race! Omex employ only degree qualified engineers to ensure that whenever you contact us you get only the very best advice, right from specification of the best parts for your application, through to advice during installation, and finally, getting your engine running to its maximum potential. And should something go wrong at any time during your ownership of your Omex ECU, the same team of technicians is available just a telephone call or mouse click away with free advice to help you through. All these details have helped countless others win races and championships. Maybe you will be next 18

19 Price List: D20MZR021 (195 bhp) Kit Inline 195 bhp Duratec 2.0l engine Options and Upgrades Alternator kit 130A inlet side Alternator kit 50A inlet side Alternator kit 130A exhaust side Alternator kit 50A exhaust side Dry sump upgrade (inline engine only) Medium length throttle bodies on the long inlet manifold (202mm) Short length throttle bodies on the long inlet manifold (141mm) Long length throttle bodies on the short inlet manifold (193mm) Medium length throttle bodies on the short inlet manifold (166mm) Short length throttle bodies on the short inlet manifold (105mm) Part Number D20MZR021 OMEP2110A(F) OMEP2114A(F) OMEP2112A(F) OMEP2116A(F) OMEP3200(U)(F) THP45i(U) TSP45i(U) MFW01(U) THP45i(U) + MFW01(U) TSP45i(U) + MFW01(U) Retail Enquire Inc VAT Enquire bhp Duratec VVC Engine Injectors positioned in the cylinder head CFRxx(U) One piece air filter with centralised back plate One piece air filter with lowered back plate Air Filter Socks OMEM OMEM9203 OMEM OMEM9203A OMEM Throttle linkage single cable for long / medium kit over mount Throttle linkage twin cable for long / medium kit over mount CLS1 + LBO1 CLD1 + LBO Throttle linkage single cable for long / medium kit under mount Throttle linkage twin cable for long / medium kit under mount CLS1 + LBU1 CLD1 + LBU Throttle linkage single cable for short kit under mount Throttle linkage twin cable for short kit under mount CLS1 + LBU1 + LAO1 CLD1 + LBU1 + LAO Pushon to dash 6 fuel rail and pressure regulator upgrade FPR5356(U) + TBR32(U) Brake servo adaptors (fitted) OMEM9100(F) Uprated ARP bigend bolts fitted to inline specification engine Uprated ARP bigend bolts fitted to transverse specification engine OMEP4120(U)(F) OMEP4122(U)(F) Side water rail (complete assembly fitted) OMEP3010(U)(F) Flywheel lightweight steel 4.7Kg Ford offset Flywheel cast Mazda Mazda offset Flywheel lightweight steel 4.7Kg Mazda offset Flywheel lightweight steel suits Raceline compact bellhousing OMEP5100 OMEP5102 OMEP5104 OMEP Clutch assembly to suit OMEP5100 and OMEP5106 Clutch assembly to suit OMEP5100 and OMEP5106 Clutch assembly to suit OMEP5102 Clutch assembly to suit OMEP5102 Clutch assembly to suit OMEP5104 Clutch assembly to suit OMEP5104 OMEP5200 OMEP5200A OMEP5202 OMEP5202A OMEP5204 OMEP5204A Flywheel bolts standard (fitted) Flywheel bolts ARP (fitted) OMEP5000(F) OMEP5002(F) Bellhousing (alloy, to fit Ford type 9 gearbox) Narrow Raceline bellhousing (alloy, to fit Ford type 9 gearbox) OMEP3110 OMEP Starter motor standard Ford offset Starter motor standard Mazda offset Starter motor high power Ford offset Starter motor high power Mazda offset Starter motor to suit Raceline narrow bellhousing OMEP2010 OMEP2012 OMEP2014 OMEP2016 OMEP Race specification wiring harness upgrade Bespoke Race specification wiring harness upgrade OMEM1519(U) OMEM1539(U) Shift light (10mm LED red) inc mounting bezel and cables Shift light (5mm LED red) inc mounting bezel and cables Full throttle gearshift clutch switch inc cables Launch control button inc cables Throttle position sensor upgrade Radiator fan control relay and base (fitted) Barometric pressure sensor upgrade, including harness modification when using Road spec harness Barometric pressure sensor upgrade, including harness modification when using Road spec harness Lambda (oxygen) sensor Lambda sensor boss OMEM6003 OMEM6004 OMEM6010 OMEM6011 OMEM2006(U) OMEM5010(F) OMEM2100(U) + OMEM1419A(U) OMEM2100(U) + OMEM1519A(U) OMEM2301 OMEM Optional parts are standalone extra parts and can be added to your kit at any time. Upgrade parts, designated by a (U) in the part number, are upgrade parts in the kit and so are only available at the above prices at the time of kit purchase. They are available at any time, but at the full price of the part. E&OE. Price list (Retail). VAT@20.0% 19

20 Duratec 2.0L VVC (MZR) Engine 215 bhp Brochure v /01/15 As an upgrade from our 195 bhp Duratec VVC (MZR) engine, this 215 bhp specification is a significant step up in terms of performance. Although only a 20 bhp increase, the on road and especially on track performance is significantly enhanced due to the increase in torque and mid to high RPM power output. Available as an inline (front engine rear wheel drive) engine, it utilises individual throttle butterflies for each cylinder which gives unrestricted airflow to each cylinder and hence a high power output. In addition, the ability to produce more power and torque at the higher end of the rev range means that the on road and track performance is enhanced. Also the sound of throttle bodies cannot be beaten. The engine is fitted with the superb Raceline lowline wet sump (with a dry sump option) to allow maximum ground clearance and no oil surge. A wide range of options and upgrades to suit your specific requirements are available. Inline Specification Engine 215 BHP Engine (inline) Options Alternator outputs and positions Dry sump system Alternative Inlet system lengths and angles Air filters Throttle linkages Fuel line fitting type Brake servo piping Uprated bigend bolts Side water rail assembly Flywheels and clutches Starter motors Bell housings Uprated wiring harness specifications Electronic controls Engine shown is D20MZR031 with kit OMEP2110A(F) D20MZR031 Engine Specification New Duratec 2.0L VVC (MZR) Engine Omex specification inlet and exhaust camshafts Ready mapped 630 Series ECU Ready built wiring harness Lowline baffled sump Inlet manifold with multiple throttle bodies Lightweight alloy air horns Fuel rail Fuel pressure regulator Throttle position sensor Air temperature sensor Coolant temperature sensor position sensor Injectors Ignition coil pack and leads Oil filter Gaskets 215 bhp Duratec VVC Engine Engine Power Graphs How much power will my engine make? The power and torque graph shows the results obtained from an engine in a RAW Striker, using an Omex specific exhaust manifold, and silencer system. These results are from testing on Omex s Superflow rolling road D20MZR BHP / Torque Power Torque RPM Duratec 2.0 VVC (MZR) 215 bhp Engine Power Graph

21 What comes with the engine? Engine Internals Upgraded from standard, this 215 bhp specification adds Omex s own inlet and exhaust cams. These are all fitted and timed up to our own specifications. Electronics 215 bhp Duratec VVC Engine Omex s new 630 Series ECU controls the fuel injection, standard Ford distributorless ignition coil pack, and optionally, many other functions around the vehicle. The ECU is connected to the hardware with a complete, ready built wiring harness, which is fully tagged and with the correct connections made for the Duratec engine, ensuring easy clipon fitment, optimum performance and absolute reliability. The ECU, wiring harness and sensors are kept with each engine build throughout assembly and testing work, ensuring that the engine package you receive has been tested as a whole package. Inlet System Standard fitment long throttle bodies with long port angled inlet manifold and 40mm air horns Proven, reliable, Jenvey throttle bodies are used on these specification engines. Individual throttle plates give the air an unrestricted route to the engine giving maximum power. There are three options of throttle body lengths and two manifold designs to suit all applications. 21

22 What comes with the engine? Sump Inline wet sump in parts and assembled on the engine. The engines are fitted with a new low line increased ground clearance sump with internal baffling designed to keep the oil on the pickup. This sump has been tested in vehicles up to single seaters with slicks and wings generating very high cornering forces. Ignition System DIS coil pack, ignition leads, and spark plugs are all included. & Throttle Position Sensors Temperature Sensors Injectors Air and coolant temperature sensors are supplied and fitted. 215 bhp Duratec VVC Engine and throttle position sensors are supplied and fitted to all engines. Bosch injectors are used giving excellent spray patterns to optimise power outputs and reduce emissions. Gaskets & Oil Filter Fuel Pressure Regulator All gaskets and an oil filter are included and fitted. The engine utilises an aluminium billet fuel pressure regulator. 22

23 Engine Dimensions (Inline Version) All dimensions are approximate, if you need any other dimensions please ask. Ignition coil pack can be removed and mounted remotely Optional side water rail reduces the size of the water housing (see options list) Oil filter can be changed for a shorter filter Engines shown with optional kit OMEP2110A(F) and standard inlet system arrangement. Front of pulleys 630mm Back of Water housing 510mm cam cover Bottom of sump 150mm 440mm 250mm 175mm 260mm 160mm Rear of block 120mm Rear of coil 330mm 570mm 590mm oil cap & cam cover Bottom of sump Side throttle bodies Bottom of throttle bodies End of Throttle bodies 215 bhp Duratec VVC Engine Side 420mm 490mm End of Throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 23

24 Options and Upgrades Alternators Inlet side kits For chassis clearance there is the option of mounting on either the inlet or the exhaust side of the engine. Racecars with minimal electrical requirements can use the smaller 50A. Road cars and rally cars with higher electrical requirements will require the larger 130A. All kits are fitted to the engine and include;, pulley, billet brackets (or direct mount), idler pullies and drive belt. OMEP2110A(F) 130A inlet side cam cover 180mm 110mm 270mm 160mm 80mm Bottom of Engine shown with standard length throttle bodies and low line sump 215 bhp Duratec VVC Engine Side of engine Side of OMEP2114A(F) 50A inlet side cam cover 355mm 85mm 70mm Bottom of 200mm 80mm Engine shown with standard length throttle bodies and low line sump Side of Side of engine 24

25 Options and Upgrades Alternators Exhaust side kits OMEP2112A(F) 130A exhaust side cam cover 190mm Bottom of 260mm 60mm 115mm Side of Side of engine 130mm OMEP2116A(F) 50A exhaust side Engine shown with standard length throttle bodies and low line sump 215 bhp Duratec VVC Engine Bottom of 190mm cam cover 260mm 60mm Engine shown with standard length throttle bodies and low line sump Side of 85mm Side of engine 130mm 25

26 Options and Upgrades Dry Sump Although not required for most applications, we offer the Raceline dry sump option for pure competition applications (inline only, not suitable for transverse applications). It gives the advantage of an even lower sump line (approximately 25 mm lower than the lowline wetsump) so the engine can be mounted even lower in the chassis. Also available as a no cost option are mounting lugs on the front of the dry sump for engine mounting directly to the chassis tub in single seaters or via stiff silentblocks in seven type vehicles. Inline dry sump in parts and assembled. Internal oil pump drive Our dry sump oil pump is built into the engine in the place of the standard oil pump, without any external drive belts that are so prone to damage and subsequent failure causing destruction of the engine. As well as being much more reliable it is lighter in weight than other dry sump systems. With a scavenge to pressure ratio of 2:1 the sump is kept empty of the oil mist that drags down power output. The sump also includes twin crank scraper plates and an additional trough baffle. 215 bhp Duratec VVC Engine Installation in your vehicle is really simple, with a single pipe from the sump to the oil cooler, a pipe from the cooler to the oil tank and a feed pipe to the sump. As part of your engine build if you choose this option, plates to seal the engine block are included and fitted. This sump is incredibly well proven, being used on the Palmersport Formula 4 single seaters, the Radical SR3 SL, MCR Sports 2000 and hundreds of Caterhams. 26

27 Options and Upgrades Inlet System Standard kit fitment The engine as standard comes with a set of long throttle on the long port angled inlet manifold, pushon 8mm fuel pipe connections, the injectors fitted in the throttle bodies and with 40mm long air horns. These parts can be changed to allow for the space available in your vehicle; 2 different inlet manifolds 3 different lengths of throttle bodies 4 lengths of air horns Injector placement in either the throttle bodies or the cylinder head Air filters of different lengths Filter back plates centred or lowered 15mm Throttle Bodies Long Throttle Bodies (Standard fitment) 118mm Medium Throttle Bodies 91mm Short Throttle Bodies 30mm 215 bhp Duratec VVC Engine Inlet Manifold Long Port Angled Inlet Manifold (Standard fitment) 17 degree angle Short Inlet Manifold 0 degree angle with 15mm offset Air Horns 90mm Air Horn 60mm Air Horn 40mm Air Horn (standard fitment) 19mm Air Horn 27

28 Options and Upgrades Inlet System Inlet System Selection The ideal inlet is as long as possible, feeds the air to the head at port angle to minimize turbulence, injects the fuel upstream of the head to allow fuel mixing time, and uses a large single air filter for minimum restriction. Long Throttle Bodies with Long Inlet Manifold (standard kit fitment) 229mm 17 o Medium Throttle Bodies with Long Inlet Manifold 202mm 17 o 215 bhp Duratec VVC Engine Short Throttle Bodies with Long Inlet Manifold 141mm 17 o 28

29 Options and Upgrades Inlet System Long Throttle Bodies with Short Inlet Manifold 193mm Port centre to throttle body centre 15mm offset 0 o Medium Throttle Bodies with Short Inlet Manifold Port centre to throttle body centre 15mm offset 166mm 0 o 215 bhp Duratec VVC Engine Short Throttle Bodies with Short Inlet Manifold 105mm Port centre to throttle body centre 15mm offset 0 o 29

30 Options and Upgrades Inlet System Injector Position Bosch injectors are used giving excellent spray patterns to maximise power outputs and minimise emissions. Ideally they are fitted in the throttle bodies (standard fitment), but can also be fitted in the head when space is restricted. Injectors in the throttle bodies (standard fitment) Injectors in the cylinder head Air Filters The long throttle bodies will accept DCOE / DHLA pattern back plate air filters which can be supplied with a centralised back plate or a 15mm lowered back plate. Sock filters can be used where space is tight but they can affect airflow so should be avoided if possible. The short throttle bodies cannot accept the back plate style airfilter, so the sock style filters must be used with these throttle bodies. Different Depth One Piece Air Filters (Fits onto Back Plate) Central and Lowered Air Filter Back Plates (Fits Ones Piece Air Filter Only) Air Filter Socks 215 bhp Duratec VVC Engine One Piece Air Filter with Central Back Plate (Long throttle body use only) One Piece Air Filter with 15mm Lowered Back Plate (Long throttle body use only) Air Filter Socks 30

31 Options and Upgrades Mechanical Throttle Linkages As standard, the throttle bodies have a lever blade to which you can connect the inner throttle cable pulling from above or below between throttles 2 and 3. A more complete cable solution is available by fitting one of the optional throttle linkage kits. These can be specified for single or twin cables, fitting above or below the throttle bodies (above is the preference for ease of adjustment if space is available), and with the cable pulling from the left or the right. The linkages are supplied fitted, adjusted for best throttle action and complete with new throttle cables. Note that dependent on and inlet system choice, it may not be possible to build all options Single cable throttle linkage kit (top mounting, left pull) Twin cable throttle linkage kit (top mounting, right pull) Fuel Pipe Connections The fuel rail can be built with either pushon pipe or 6 screw fitting pipe fittings. The fuel pressure is regulated by a constant pressure billet aluminium housed regulator (included). The regulator will also have either pushon (standard) or 6 screw fittings (optional) to suit. Pushon pipe fittings 6 pipe fittings 215 bhp Duratec VVC Engine Brake Servo If your vehicle requires a brake servo vacuum, the manifold can be fitted with a vacuum takeoff. This can be specified to exit to the either side of the engine. A pushin adaptor to suit 8mm ID pipe is supplied. 31

32 Options and Upgrades Mechanical Uprated Bigend Bolts For engines that are expected to spend a lot of time at high engine speeds, such as those which are intended for competition use or extended trackday use, extra safety can be inbuilt through the upgrade to ARP bigend bolts. Uprated ARP Bigend bolts Water Housing The standard fitment water housing is mounted on the back of the cylinder head and also acts as a mounting for the ignition coil pack. This points the main 32mm water outlet towards the inlet side of the engine. It also has takeoffs for a heater if required. We offer an alternative aluminium water rail that runs over the top of the exhaust and brings the water outlet to the front of the engine. It also has mountings for the supplied ignition coil pack. It can be supplied with heater takeoffs as well or they can be supplied blocked off to suit your application. If space at the rear of the engine near the bulkhead is an issue we can machine the coil mountings off the side water rail to increase clearance and in that instance we can either relocate the coil with longer HT leads or we would recommend our coil on plug option that includes 4 plug top coils and an expander box for the ECU. 215 bhp Duratec VVC Engine Standard Water Housing Side Water Rail Housing 32

33 Options and Upgrades Mechanical Flywheel and Clutch There are a bewildering range of flywheels and clutches available for the Duratec engine so at Omex we have sorted out the sensible combinations that cover nearly all applications. We offer flywheels and clutches that are suitable for road use right to full competition versions. As there are such a large range of choices please call to speak to one of our powertrain engineers if you have any queries. All of these clutches and flywheels are suitable for front engine/rear wheel drive, if you are specifying a transverse application please call. FLYWHEELS OMEP5100 OMEP5102 OMEP5104 OMEP5106 Lightweight (4.7Kg) steel flywheel to suit Ford Type 9 or MT75 offset Medium weight cast flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed) Lightweight (4.7Kg) steel flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed) Lightweight steel flywheel to suit the Raceline narrow bellhousing only (Ford offset) CLUTCHES All our clutch kits include both pressure and driven plate and are designed to fit specific flywheels and gearboxes. We offer a range to cover both the Ford Type 9/MT75 gearboxes (1 x25 spline) and the Mazda MX5 Mk3 gearboxes that are fitted in so many niche vehicles now such as Morgan Plus 4. OMEP5200 OMEP5200A OMEP5202 OMEP5202A OMEP5204 OMEP5204A Flywheel bolts are also required; standard flywheels bolts or ARP flywheel bolts can be supplied and fitted. Bellhousing AP Racing sprung organic clutch assembly to suit OMEP5100/5106 flywheel. This clutch assembly is ideal for road and trackday use and has a great feel to it and is suitable for mild competition use. It has the Ford 1 x25 spline arrangement so is ideal for the Ford type 9 and MT75 gearboxes. As the OMEP5200 but with a solid driven plate which is more suitable for full competition use or essential with a sequential gearbox that is either driven on track or has a flat shift or paddle shift fitted. Suits the Ford 1 x25 spline input shaft as used on many competition gearboxes. This is suitable for the OMEP5102 cast Mazda offset flywheel and is a completely standard Mazda clutch assembly. It fits the Mazda MX5 Mk3 gearbox (5 speed) and although is a road clutch it has proven totally reliable in 200bhp race cars. We specified this assembly for the 60 off Morgan Supersports, many of which have raced for 3 years now without a clutch change. As OMEP5202 but for the 6 speed Mazda MX5 Mk3 gearbox. This Sprung uprated clutch assembly suits the Mazda lightweight steel flywheel OMEP5104. We specified these for the Morgan Plus 4 Racecars that used our Duratec 265 bhp engine. They have a slightly higher pedal pressure than the standard clutch but are perfect for road or competition use. Suits the Mazda Mk3 5 speed gearbox. As OMEP5204 but for the Mazda MX5 Mk3 6 speed gearbox. A cast aluminium bell housing is available to suit the Ford Sierra Type 9 (short input shaft) gearbox (flywheel OMEP5100). 215 bhp Duratec VVC Engine A Raceline narrow aluminium bell housing to suit the Ford Sierra Type 9 is available for flywheel OMEP5106. Mazda gearboxes have integral bellhousings that directly fit the engine (flywheels OMEP5102 and OMEP5104). Options and Upgrades Starter Motors Starter Motor Standard starter motor (Ford and Mazda offsets available) High power starter motor (Ford and Mazda offsets available) Standard and high power starter motors can be supplied suitable for both the Ford offset and the Mazda offset flywheels. The high power starter is ideal for those using small race batteries or long battery leads that sap starting power as it operates more efficiently and so can start an engine with less electrical current. 33