OMEX. Ford 2.0L Duratec Performance Engine Packages

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1 OMEX Ford 2.0L Duratec Performance Engine Packages

2 Ford Duratec 2.0L Engine Packages 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 multi championship winning Omex 600 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 engines covers power outputs of 180 to 260+ bhp. The engines are available in both inline (to suit front engine rear wheel drive) and transverse (to suit mid engine transverse applications) versions. The inline engines use the superb RaceLine lowline fully baffled sump (do not confuse this with cheap inferior copies that are available) whilst the transverse engines use the original Ford aluminium sump. There are a wide range of mechanical options and upgrades available to suit your requirements, 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 D20NA021A with kit OMEP2110A(F) 180 bhp Multiple throttle bodies for instant throttle response Transverse and inline installations Economical engine package 180 bhp Duratec Engine Engine shown is D20NA031A with kit OMEP2110A(F) 200 bhp Uprated cams for increased power Multiple throttle bodies for instant throttle response Transverse and inline installations 200 bhp Duratec Engine Engine shown is D20NA051A with kit OMEP2110A(F) 260+ bhp Full race engine suitable for road applications CNC ported cylinder head Uprated forged pistons and steel rods Tapered throttle body inlet system Transverse and inline installations 260+ bhp Duratec Engine 2

3 Duratec 2.0L Engine 180 bhp This superb all alloy engine makes a fantastic road car or track day engine for your vehicle. It offers great power output in a lightweight package. Although our entry level Duratec package, this engine with its strong torque curve and great power output gives great performance and exceptional reliability and driveability. Available in both inline (front engine rear wheel drive) and transverse (mid engined or front wheel drive), 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 inline version is fitted with the superb Raceline lowline wet sump (with a dry sump option) to allow maximum ground clearance and no oil surge, whilst the transverse specification uses the Ford standard alloy sump assembly. Both versions are available with a wide range of options and upgrades to suit your specific requirements. Inline Specification Transverse Specification 180 bhp Duratec Engine Engine shown is D20NA021A with kit OMEP2110A(F) Engine shown is D20NA021C with kit OMEP2110A(F) Engine 180 BHP Engine (inline) 180 BHP Engine (transverse) Options D20NA021A D20NA021C 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 Engine Ready mapped 600 Series ECU Ready built wiring harness Lowline baffled sump (inline only) 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 D20NA21 BHP / Torque Power Torque RPM Duratec bhp Engine Power Graph

4 What comes with the engine? Electronics 180 bhp Duratec Engine Omex s multichampionship winning 600 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 Throttle bodies with long port angled inlet manifold and 40mm air horns Proven, reliable, Omex 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 Transverse sump assembled on the engine. Inline wet sump in parts and assembled on the engine. Transverse specification engines are supplied with the standard sump as this is designed for transverse mounting. Inline engines have cornering forces in a different direction on the engine and so the inline specification 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 180 bhp Duratec 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 180 bhp Duratec Engine 510mm cam cover sump 150mm 440mm 330mm 160mm Side Rear of block 120mm Rear of coil End of Throttle bodies 250mm 175mm 260mm throttle bodies throttle bodies 570mm 590mm oil cap & cam cover sump Side 420mm 490mm End of Throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 6

7 Engine Dimensions (Transverse Version) All dimensions are approximate, if you need any other dimensions please ask. Ignition coil pack can be removed and mounted remotely Exhaust manifold can be replaced with customers own exhaust manifold Optional side water rail reduces the size of the water housing (see options list) Oil filter can be changed for a shorter filter 180 bhp Duratec Engine Engines shown with optional kit OMEP2110A(F) and standard inlet system arrangement. Front of pulleys 630mm Back of Water housing 510mm cam cover 330mm 160mm Side Rear of block 120mm Rear of coil End of Throttle bodies sump 220mm 440mm Side 250mm 420mm 490mm 175mm 260mm End of Throttle bodies throttle bodies throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 640mm 660mm oil cap & cam cover sump 7

8 Options and Upgrades Alternators Inlet side kits 180 bhp Duratec Engine 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 270mm cam cover 160mm 80mm 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 200mm 80mm Engine shown with standard length throttle bodies and low line sump Side of Side of engine 8

9 Options and Upgrades Alternators Exhaust side kits OMEP2112A(F) 130A exhaust side cam cover 260mm 180 bhp Duratec Engine 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 260mm 60mm Engine shown with standard length throttle bodies and low line sump Side of 85mm Side of engine 130mm 9

10 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. 180 bhp Duratec 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. 10

11 Options and Upgrades Inlet System Standard kit fitment 180 bhp Duratec Engine 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; Air Horns 80mm Air Horn 60mm Air Horn 40mm Air Horn (standard fitment) 15mm Air Horn 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 11

12 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. 180 bhp Duratec Engine 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) 12

13 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 180 bhp Duratec Engine Single cable throttle linkage kit (top mounting) Twin cable throttle linkage kit (top mounting) 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. Brake servo adaptor 13

14 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. 180 bhp Duratec 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 14

15 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) 180 bhp Duratec 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. 15

16 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. 180 bhp Duratec 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 16

17 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. 180 bhp Duratec 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 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 17

18 Price List: D20NA021A / D20NA021C (180 bhp) Kit Inline 180 bhp Duratec 2.0l engine Transverse 180 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) Injectors positioned in the cylinder head Part Number D20NA021A D20NA021C OMEP2110A(F) OMEP2114A(F) OMEP2112A(F) OMEP2116A(F) OMEP3200(U)(F) CFRxx(U) Retail Enquire Inc VAT Enquire bhp Duratec Engine One piece air filter with centralised back plate One piece air filter with lowered back plate Air Filter Socks AFFB + AFBA/97 AFFB + AFBA/97/LOW OMEM Throttle linkage single cable Throttle linkage twin cable CL1Single CL1Twin Pushon to dash 6 fuel rail and pressure regulator upgrade FPR5356(U) + FRA/976(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 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 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% 18

19 Duratec 2.0L Engine 200 bhp As a first stage upgrade from our 180 bhp Duratec engine, this 200 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 in both inline (front engine rear wheel drive) and transverse (mid engined or front wheel drive), 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 inline version is fitted with the superb Raceline lowline wet sump (with a dry sump option) to allow maximum ground clearance and no oil surge, whilst the transverse specification uses the Ford standard alloy sump assembly. Both versions are available with a wide range of options and upgrades to suit your specific requirements. Inline Specification Transverse Specification Engine shown is D20NA031A with kit OMEP2110A(F) Engine 200 BHP Engine (inline) 200 BHP Engine (transverse) Options D20NA031A D20NA031C 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 D20NA031C with kit OMEP2110A(F) Engine Specification New Duratec 2.0L Engine Omex specification inlet and exhaust camshafts Uprated valve springs to suit new cam Ready mapped 600 Series ECU Ready built wiring harness Lowline baffled sump (inline only) 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 200 bhp Duratec 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 Toniq CB200, using an Toniq specific exhaust manifold, catalytic convertor, and silencer system. These results are from testing on Omex s Superflow rolling road D20NA BHP / Torque Power Torque RPM Duratec bhp Engine Power Graph

20 What comes with the engine? Engine Internals Upgraded from standard, this 200 bhp specification adds Omex s own inlet and exhaust cams along with uprated valve springs. These are all fitted and timed up to our own specifications. Electronics 200 bhp Duratec Engine Omex s multichampionship winning 600 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 Throttle bodies with long port angled inlet manifold and 40mm air horns Proven, reliable, Omex 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. 20

21 What comes with the engine? Sump Transverse sump assembled on the engine. Inline wet sump in parts and assembled on the engine. Transverse specification engines are supplied with the standard sump as this is designed for transverse mounting. Inline engines have cornering forces in a different direction on the engine and so the inline specification 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 Temperature Sensors DIS coil pack, ignition leads, and spark plugs are all included. Air and coolant temperature sensors are supplied and fitted. 200 bhp Duratec Engine & 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. 21

22 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 200 bhp Duratec Engine cam cover sump 150mm 440mm 250mm 175mm 160mm Rear of block 120mm Rear of coil 330mm 260mm 570mm 590mm oil cap & cam cover Side End of Throttle bodies throttle bodies throttle bodies sump Side 420mm 490mm End of Throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 22

23 Engine Dimensions (Transverse Version) All dimensions are approximate, if you need any other dimensions please ask. Ignition coil pack can be removed and mounted remotely Exhaust manifold can be replaced with customers own exhaust manifold 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 200 bhp Duratec Engine 160mm Rear of block 120mm Rear of coil 330mm cam cover sump Side End of Throttle bodies 220mm 440mm Side 250mm 420mm 490mm 175mm 260mm End of Throttle bodies throttle bodies throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 640mm 660mm oil cap & cam cover sump 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 Engine shown with standard length throttle bodies and low line sump 200 bhp Duratec Engine Side of engine Side of OMEP2114A(F) 50A inlet side cam cover 355mm 85mm 70mm 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 260mm 60mm Engine shown with standard length throttle bodies and low line sump 115mm Side of Side of engine 130mm OMEP2116A(F) 50A exhaust side 200 bhp Duratec Engine 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. 200 bhp Duratec 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; Air Horns 80mm Air Horn 15mm Air Horn 60mm Air Horn 40mm Air Horn (standard fitment) 200 bhp Duratec Engine 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 27

28 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) 200 bhp Duratec Engine 28

29 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) Twin cable throttle linkage kit (top mounting) 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. 200 bhp Duratec Engine 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. Brake servo adaptor 29

30 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. 200 bhp Duratec Engine Standard Water Housing Side Water Rail Housing 30

31 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. 200 bhp Duratec Engine 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. 31

32 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. 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. 200 bhp Duratec Engine 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 32

33 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. Shift light (10mm LED) Barometric pressure sensor and harness upgrade Full throttle gearshift (clutch switch) Lambda sensor Launch control (button) Lambda sensor boss Radiator fan control (Relay and base) 200 bhp Duratec Engine 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 33

34 Price List: D20NA031A / D20NA031C (200 bhp) Kit Part Number Retail Inc VAT Inline 200 bhp Duratec 2.0l engine Transverse 200 bhp Duratec 2.0l engine D20NA031A D20NA031C Options and Upgrades Alternator kit 130A inlet side Alternator kit 50A inlet side Alternator kit 130A exhaust side Alternator kit 50A exhaust side OMEP2110A(F) OMEP2114A(F) OMEP2112A(F) OMEP2116A(F) Dry sump upgrade (inline engine only) OMEP3200(U)(F) Enquire Enquire 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 AFFB + AFBA/97 AFFB + AFBA/97/LOW OMEM Throttle linkage single cable kit Throttle linkage twin cable kit CL1Single CL1Twin Pushon to dash 6 fuel rail and pressure regulator upgrade FPR5356(U) + FRA/976(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 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 Flywheel bolts standard (fitted) Flywheel bolts ARP (fitted) Bellhousing (alloy, to fit Ford type 9 gearbox) Narrow Raceline bellhousing (alloy, to fit Ford type 9 gearbox) OMEP5100 OMEP5102 OMEP5104 OMEP5106 OMEP5200 OMEP5200A OMEP5202 OMEP5202A OMEP5204 OMEP5204A OMEP5000(F) OMEP5002(F) OMEP3110 OMEP bhp Duratec Engine 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 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 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% 34

35 Duratec 2.0L Engine 260+ bhp The current pinnacle of the Omex 2L Duratec range, this superb lightweight all alloy engine is hand built to the highest standard using the best components available. The specification is very different to our other Duratec engines, with new forged alloy pistons, high quality steel connecting rods, bespoke Omex camshafts and race valve springs with lightweight spring retainers. This gives a safe and reliable 8700 RPM rev limit. It has a CNC ported cylinder head, which is also CNC matched to a direct shot inlet manifold. The throttle bodies are ultimate specification individual bodies with aluminium air horns. Although this engine specification is capable of winning outright in 2L competition, due to the careful design it is also very suitable for road use in a niche vehicle. If you are looking for the very best 2L Duratec engine available you have found it! As with any engine of this specification, the design of the exhaust system is critical and Omex can supply details of lengths and diameters required. Inline Specification Transverse Specification Engine shown is D20NA051A with kit OMEP2110A(F) Engine shown is D20NA051C with kit OMEP2110A(F) Engine 260+ BHP Engine (inline) 260+ BHP Engine (transverse) Options Alternator outputs and positions Dry sump system Air filter with shaped back plate Throttle linkages Fuel line fitting type Brake servo piping Side water rail assembly Flywheels and clutches Starter motors Bell housings Uprated wiring harness specifications Electronic controls D20NA051A D20NA051C Engine Specification New Duratec 2.0L Engine Omex specification inlet and exhaust camshafts Full race valve springs and retainers Forged high compression pistons Steel connecting rods CNC ported cylinder head Inlet manifold CNC matched to cylinder head ARP big end bolts Competition big end bearings Ready mapped 600 Series ECU Ready built wiring harness Lowline baffled sump (inline only) dry sump optional 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 260+ bhp Duratec Engine 35

36 Engine Power Graphs How much power will my engine make? Power Torque D20NA51 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. BHP / Torque RPM Duratec bhp Engine Power Graph What comes with the engine? Engine Internals CNC ported cylinder head Omex specification inlet and exhaust camshafts, full race valve springs and retainers Forged high compression pistons, steel connecting rods And competition big end bearings ARP Bigend bolts 260+ bhp Duratec Engine 36

37 What comes with the engine? Electronics Omex s multichampionship winning 600 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 Throttle bodies with long port angled inlet manifold and 40mm air horns Proven, reliable, Omex 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 Transverse sump assembled on the engine. Inline wet sump in parts and assembled on the engine. Transverse specification engines are supplied with the standard sump as this is designed for transverse mounting. Inline engines have cornering forces in a different direction on the engine and so the inline specification 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 bhp Duratec Engine 37

38 What comes with the engine? Ignition System 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 All gaskets and an oil filter are included and fitted. Fuel Pressure Regulator The engine utilises an aluminium billet fuel pressure regulator bhp Duratec Engine 38

39 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 330mm 160mm Side Rear of block 120mm Rear of coil End of Throttle bodies sump 150mm 440mm Side 250mm 420mm 490mm 175mm 260mm End of Throttle bodies throttle bodies throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 570mm 590mm oil cap & cam cover sump 260+ bhp Duratec Engine 39

40 Engine Dimensions (Transverse Version) All dimensions are approximate, if you need any other dimensions please ask. Ignition coil pack can be removed and mounted remotely Exhaust manifold can be replaced with customers own exhaust manifold 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 330mm 160mm Side Rear of block 120mm Rear of coil End of Throttle bodies cam cover sump 220mm 440mm Side 250mm 420mm 490mm 175mm 260mm throttle bodies throttle bodies Front of pulleys 510mm Rear of block 120mm Rear of coil 640mm 660mm oil cap & cam cover sump 260+ bhp Duratec Engine 40

41 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. OMEP2110B(F) 130A inlet side 270mm cam cover 160mm 80mm 180mm 110mm Engine shown with standard length throttle bodies and low line sump Side of engine Side of OMEP2114B(F) 50A inlet side cam cover 355mm 200mm 80mm Side of Side of engine 85mm 70mm Engine shown with standard length throttle bodies and low line sump 260+ bhp Duratec Engine 41

42 Options and Upgrades Alternators Exhaust side kits OMEP2112B(F) 130A exhaust side cam cover 190mm 260mm 60mm Engine shown with standard length throttle bodies and low line sump 115mm 130mm Side of Side of engine OMEP2116B(F) 50A exhaust side 190mm cam cover 85mm 260mm 60mm Side of Side of engine 130mm Engine shown with standard length throttle bodies and low line sump 260+ bhp Duratec Engine 42

43 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. 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 bhp Duratec Engine 43

44 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; Air Horns 80mm Air Horn 15mm Air Horn 60mm Air Horn 40mm Air Horn (standard fitment) 200 bhp Duratec Engine 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 44

45 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) 200 bhp Duratec Engine 45

46 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) Twin cable throttle linkage kit (top mounting) 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. 200 bhp Duratec Engine 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. Brake servo adaptor 46

47 Options and Upgrades Mechanical 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 260+ bhp Duratec Engine 47

48 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 OMEP5104 OMEP5106 Lightweight (4.7Kg) steel flywheel to suit Ford Type 9 or MT75 offset 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 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.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 bhp Duratec Engine 48

49 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. 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 260+ bhp Duratec Engine 49

50 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. 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 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 bhp Duratec Engine All these details have helped countless others win races and championships. Maybe you will be next 50

51 Price List: D20NA051A / D20NA051C (260+ bhp) Kit Part Number Retail Inc VAT Inline 260+ bhp Duratec 2.0l engine Transverse 260+ bhp Duratec 2.0l engine D20NA051A D20NA051C 11, Enquire 13, Enquire Options and Upgrades Alternator kit 130A inlet side Alternator kit 50A inlet side Alternator kit 130A exhaust side Alternator kit 50A exhaust side OMEP2110B(F) OMEP2114B(F) OMEP2112B(F) OMEP2116B(F) Dry sump upgrade (inline engine only) OMEP3200(U)(F) Enquire Enquire One piece air filter with dished back plate glass fibre One piece air filter with dished back plate carbon fibre Air filter socks AFFB + AFBA/97 AFFB + AFBA/97/LOW OMEM Throttle linkage single cable kit Throttle linkage twin cable kit CL1Single CL1Twin Pushon to dash 6 fuel rail and pressure regulator upgrade FPR5356(U) + FRA/976(U) Brake servo adaptors (fitted) OMEM9100(F) Side water rail (complete assembly fitted) OMEP3010(U)(F) Flywheel lightweight steel 4.7Kg Ford offset Flywheel lightweight steel 4.7Kg Mazda offset Flywheel lightweight steel suits Raceline compact bellhousing OMEP5100 OMEP5104 OMEP Clutch assembly to suit OMEP5100 and OMEP5106 Clutch assembly to suit OMEP5100 and OMEP5106 Clutch assembly to suit OMEP5104 Clutch assembly to suit OMEP5104 OMEP5200 OMEP5200A 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 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 OMEM5010(F) OMEM2100(U) + OMEM1419A(U) OMEM2100(U) + OMEM1519A(U) OMEM2301 OMEM Engine shown is D20NA051 with kit OMEP2110A(F) 260+ bhp Duratec Engine 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% 51