FORD DURATEC 1.8 / 2 - Webcon UK Ltd · 2016. 2. 4. · FORD DURATEC 1.8 / 2.0 Static Ignition...

ALPHA Ignition Management System Fitting Instructions K57039

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Fitting Instructions Kit K57039

FORD DURATEC

1.8 / 2.0 Static Ignition (Programmable)

For Weber 45 DCOE 152G Carburettor (5 Progression Hole Specification)



Alpha Group Webcon UK Ltd Dolphin Road Sunbury Middlesex England TW16 7HE Tel: +44 (0)1932 788805 Fax: +44 (0)1932 789809

Email: [email protected] Web: http://www.webcon.co.uk

NOTICE

In view of our policy of continuous improvement, the information in this guide is subject to change without

notice.

WEBCON UK LTD SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR

OMISSIONS CONTAINED HEREIN; NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES

RESULTING FROM THE FURNISHING, PERFORMANCE, OR USE OF THIS MATERIAL.

This guide contains information protected by copyright. No part of this guide may be photocopied or reproduced

in any form without prior written consent from

WEBCON UK LTD

Product names mentioned herein are for identification purposes only and may be trademarks and/or registered

trademarks of their respective companies.



Introduction This engine management system has been developed by engineers with experience of major successes in motor sport and in the production of prestigious sport cars including Aston Martin. Alpha Engine Management systems are also used in the following applications, where correct functionality and reliability is of extreme importance.

• Marine.

• Industrial.

• Military & General Aviation Engines.

General Kit Information These fitting instructions are written to enable a competent person with technical ability to install this performance kit to a vehicle. The instructions should be read through and fully understood before attempting to install the system to prevent mistakes being made. This point can not be emphasised enough as most problems are the result of incorrect installation of either the Ignition Management System or the Carburettor / Fuel System. All Alpha Performance full EMS kits are designed as stand alone systems. However in order to operate the Alpha wiring harness must be connected to the battery negative terminal and an ignition switched 12 volt supply most be provided.

It is of the utmost importance that all the information contained in this manual is strictly adhered to. In particular, the wiring harness connections must be carried out precisely as

described, and must not be modified in any way. Modification to any item or to the specification of this performance kit without the consent of Webcon UK Ltd will invalidate the guarantee.

The ECU is programmed with a 3D ignition map for the Ford Zetec 2.0 (Black Top) engine, to achieve the best possible power at all engine speeds and loads. To allow full utilisation of the 3D map for part load operation Throttle Position Sensor (TPS) is required – Kit No. 9990266000 N.B. Where the Ignition Management Kit is used without a Throttle Position Sensor (TPS) a 2D map only will function. The Programme data contained within the 2D map will give RPM / full throttle ignition timing only, therefore will compromise the optimum driveability and fuel economy.

ECU Diagnostics and Programming The PRO5 Ignition System is supplied with a USB interface and extension cable to allow access to the ECU ignition calibration for reprogramming and diagnostics purposes. The Alphacal calibration software can be downloaded from -http://www.webcon.co.uk/Download_Centre/index_new.html.

IGNITION MANAGEMENT SYSTEM



This Alpha PRO5 Ignition system has been designed for use with WEBER 45 DCOE 152G (5 progression spec.) carburettors. The ignition programme is suitable for standard and mild road specification engines.

• N.B. 1 Where this ignition system is used with carburettors not supplied direct from Webcon as part of the ALPHA PERFORMANCE Silver kit K59039 the carburettors require the progression stage of the carburettors modifying to 5 progression hole specification to achieve the correct functionality for good driveability in slow running and cruise operation.

• N.B. 2 Where ALPHA PERFORMANCE PRODUCTS are used on non standard specification engines it is recommended that the ignition programme is checked and modified whilst carrying out the carburettor calibration (jetting) by a rolling road specialist.

WEBER 45 DCOE 152G (5 progression spec.)

Calibration Item Size Pt. No. . Choke (Venturi) 40 7211640000 Auxiliary Venturi 4.5 6960245000 Main Jet (not specified) 73401XXX00 Air Corrector (not specified) 77401XXX00 Emulsion Tube (not specified) 61450XXX00 Idle Jet (not specified) 74821XXX00 Pump Jet (not specified) 76801XXX00 Needle Valve 200 7950320001 Float Height 12.0 mm +/- 0.5

Ignition Kit Contents Kit K57039 – Ford Duratec 1.8 / 2.0 Static Ignition

Ref. Number

Component Qty. Part Number

1 Electronic Control Unit (ECU) 1 PI501

2 Main Wiring Harness 1 9990317000

3 Feed Harness 1 9990180500

4 Cable Ties 10 9990033400

5 Shift Light 1 9990128200

6 Inlet Air Temperature Sensor 1 WAS008

7 Screw M3 x 8mm 2 9990280300

8* Throttle Shaft Forked Plate 1 WMS019

9* Throttle Shaft Nut Lock Tab 1 5552000400

10* Throttle Position Sensor Mounting Bracket 1 9990265400

11* M5 Screws 1 9990048800

12* Washer 5mm 2 9990002400

13* Throttle Position Sensor TPS 1 WTP037

14* Cover Plate 1 5848002601



15* M4 Screws 2 6472000101

16* Lock Washer 4mm 2 5552000400

17 USB Interface Comms Module 1 9990322900

18 Comms Module Extension Cable 1 9990385000

* Items supplied within Throttle Potentiometer Kit Pt. No. 9990266000



Installation Guide

Electronic Control Unit (ECU)

N.B. This ECU (1) has the fuelling components present in the ECU and can therefore be used to control a full Alpha PRO5 engine management system, with the addition of Alpha Throttle Bodies available as a complete Inlet Manifold and Throttle Body assembly Pt. No. ATB500 It is essential that the management system is supplied with a good source of electrical power at all times. A minimum working voltage should be no less than 10 volts, this is especially so during cold start cranking. This unit must always be located away from any direct heat source of the engine. The ECU casing has been designed to withstand water ingress. However where ever possible it is recommended that the unit is located inside the passenger compartment of the vehicle.

ALPHA IGNITION SYSTEM INSTALLATION INSTRUCTIONS N.B. The battery should be disconnected whilst this kit is being fitted.

Electronic Control Unit (ECU) Mounting 1. The ECU (1) should be mounted either above the passenger foot well or on the Transmission Tunnel

below the Facia. The ECU can be secured using the four mounting locations. N.B. Before the ECU (1) can be secured in position the Wiring Harness (2) must be routed through the bulkhead as detailed in the ‘Wiring Harness Installation and Connection’ detailed below

Wiring Harness Installation and Connection The Wiring Harness supplied in this ALPHA PERFORMANCE kit has been designed specifically for the MGB. N.B. Unauthorised modification to the Wiring Harness (2) will invalidate the warranty of this product. N.B. Great care must be taken when installing and connecting the Wiring Harness. The routing of the harness is very important and the notes below must be adhered to, failure to do so will invalidate the warranty of this management system. We therefore reserve the right to make charges for any technical support and assistance required to resolve problems arising from poor installation. The most common problems arise from incorrect ignition 12 volt connection*, and connections to the battery, particularly the ground connection which must go to the battery NOT the chassis. *12 volt ignition switched supply must also provide at least 9v when the engine is being cranked.

The wiring harness is supplied in two sections comprising of the Main Wiring Harness (2) and a Feed Harness (3). N.B. The Wiring Harness should be secured to the vehicle and not left unsupported. The cables must not run near any direct heat source. Ensure that no cables run closely to any ignition high tension leads, in particular, the engine speed sensor lead. If these wires do run too close, the high tension leads can induce a signal in the harness that the ECU can misinterpret causing uneven running, bad starting, and even failure to start. Where possible use the Cable Ties (4) to secure the Wiring Harness (2 & 3) to any suitable point on the vehicle. 1. The Main Wiring Harness (2) should be routed through the engine compartment bulkhead. Cut a 1.75

inch (44 mm) hole in a suitable position in the bulkhead as high up as is practical to avoid water leaks. Also, ensure the grommet is fitted correctly and securely, as the hole will very quickly cut into the harness if not adequately protected.

2. Route the Wiring Harness for connection to the items as detailed below. Carefully avoid sharp edges and moving parts then allowing for engine movement, secure with the Cable Ties (4).



Feed Harness Plug the Feed Harness (3) into connector QQQQ, this supplies the Main Wiring Harness (2) with Power, Ground, and also takes the Tacho and Gear Shift Lamp.

1 2

34

Pin 1 It is recommended that the ignition 12v power supply is taken from the ignition switch, preferably from the ignition barrel.

N.B. Ensure a 12 volt supply is maintained when the ignition switch is in the engine cranking position.

Pin 2 The Tacho signal to the rev counter (yellow) needs to be connected to the rev counter signal input. Pin 3 The Power ground must be connected directly to the Battery negative earth terminal, not to the

chassis. Pin 4 The Gearshift lamp ground connects to the Shift Light (5) provided, or alternatively a suitable LED. N.B. The ECU provides the earth for the light, (Blue/White wire) the shift light requires a 12v ignition

switched supply.

Main Harness Connections - Refer to Appendix A & B for layout of harness A - Connect to ECU (1) 35 pin socket E - Connect to Engine speed sensor JJJ - Connect to Air Temperature Sensor (6) S - Connect to the Throttle Position Sensor TPS, where applicable (Pt. No.9990266000) GGGG - Connect to Coil Connector. QQQQ - Sureseal connector for the Feed Harness (3) NNNN - Locate in a place that will enable easy access to the connector for calibration and diagnostics

purposes.

Inlet Air Temperature Sensor The Inlet Air Temperature Sensor (6) should be securely mounted ideally into the air filter using the two M3 Screws (7) or suitably close to the air intakes to allow accurate measurement of inlet air temperature. N.B. The Sensor is already fitted to the Air Filter base plate if a K59039 series Performance kit is being installed.

Pin Number Wire Colour Connection

1 White Power +12v ignition switched

2 Yellow Tacho signal to rev counter

3 Black Power Ground

4 Blue/White Gear Shift Lamp



Appendix A : Wiring Harness Layout

Figure 1 : Layout of Wiring Harness



Appendix B : Harness Connections / Wiring Colour Coding Connector

I.D. Item Connector

Type Connector

Colour Pin No.

Wire Colour Connects To Item

Pin No.

A ECU AMP Minitimer

Black See Appendix C

E RPM Sensor AMP Minitimer

Black 1 2

Clear (red ident) Black

A A

2 1

Q Coolant Temp. Sensor (optional)

AMP Minitimer

Black 1 2

Blue Blue/Yellow

A A

11 29

S Throttle Position Sensor

AMP Minitimer

Black 1 2 3

Purple/Blue Blue

Red/Green

A A A

17 11 30

JJJ Air Temperature Sensor

Packard Black A B

Brown/Green Blue

A A via OOOO

31 11

QQQQ Feed Harness Sureseal

Black 1 2 3 4

White Yellow Black

Blue/White

12v Ign (sw) Tacho

Battery Earth Shift Light

20 7

19 16

GGGG

Ignition Coil FORD 1W7T

14A464 LA

Black 1 2 3

Orange/Brown White

Purple/Green

A QQQQ

A

26 1

25

NNNN ECU Communications

Grey 1 4 5

Can Vary A 1 8

27

The above specification is subject to change; therefore please consult Webcon UK should difficulties be experienced.



Appendix C : Pin Outs from ECU

Pin Description Connector Pin No.

Wire Colour

1 Engine Speed Sensor Ground E 2 Black

1 Communications NNNN 1 Can vary

2 - - - -

3 - - - -

4 Engine Speed Sensor Input E 1 Clear (red I.D.)

5 - - - -

6 - - - -

7 Tachometer Signal QQQQ 2 Yellow

8 Communication NNNN 4 can vary

9 - - - -

10 - - - -

11 (TPS) Sensor Ground S 1 Blue

11 Water Temp Sensor Ground Q 1 Blue

11 Air Temp Sensor Ground JJJ B Blue

12 Gear Shift Light QQQQ 4 Blue/White

13 Switch Input (Not Used) - - -

14 - - - -

15 - - - -

16 - - - -

17 Throttle Position Input S 1 Purple/Blue

18 - - - -

19 Battery Negative QQQQ 3 Black

20 Voltage Supply (Battery +12V) QQQQ 1 White

21 - - - -

22 - - - -

23 - - - -

24 Ignition Signal Ground QQQQ 3 Black

25 Ignition Signal Output 1 GGGG 3 Purple/Green

26 Ignition Signal Output 2 GGGG 1 Orange/Brown

27 Communications NNNN 5 can vary

28 - - - -

29 Coolant Temp Sensor Input Q 2 Blue/Yellow

30 Reference Voltage (5v) S 3 Red/Green

31 Air Temperature Sensor Input JJJ A Brown/Green

32 - - - -

33 - - - -

34 - - - -

35 - - - -

Important: The above information is may be subject to change –



When carrying out continuity tests should it be found that the wiring harness connection differ from the information detailed above, please contact Webcon UK for confirmation of any specification

changes. Appendix D : Wiring Harness Connectors

Connector Appearance

AMP Minitimer 35 pin

AMP Minitimer 3

pin

AMP Minitimer 2

pin

Sureseal



Additional Throttle Position Sensor (TPS) Fitting – Pt. No. 9990266000 The ECU is programmed with a 3D ignition map for the Ford Zetec 2.0 (Black Top), to achieve the

best possible power at all engine speeds and loads. To allow full utilisation of the 3D map for part load operation Throttle Position sensor is required. N.B. Where the Ignition Management Kit is used without a Throttle Position sensor a 2D map only will function. The Programme data contained within the 2D map will give RPM / full throttle ignition timing only.

Fig.1

Fig. 2

Fig. 3

Fig. 4

1. Remove the throttle shaft nut from the right hand side the carburettor, leave the bearing cover plate in position

2. Fit the Throttle Shaft Forked Plate (8) as shown in Fig.2. Secure in position using the original throttle shaft nut using the new Lock Tab (9) provided.

3. Fit the Throttle Position Sensor Mounting Bracket (10) in position and secure in position using the two M5 Screws (11) and Washers (12) provided, as shown in Fig. 3

4. Fit the Throttle Position Sensor TPS (13) with the Cover Plate (14) and secure in position using the two M4 Mounting Screws (15) and Lock Washers (16) provided as shown in Fig.4.

N.B. Ensure that the TPS lever sits within the fork of Forked Plate (8) and that the sensor is seated fully into the mounting bracket (10).

Adjustment of Throttle Position Sensor (TPS)

5. Fit the Wiring Harness TPS connector (S) to the TPS (13) 6. Peel back the rubber cover on the TPS connector (S) to enable a

voltmeter to be connected to the pins whilst still connected to the TPS.

7. Loosen the two M4 Mounting Screws (15) holding the TPS (13) to the bracket and rotate the TPS fully anticlockwise, then retighten the screws Fig. 4.

8. Start the engine and allow it to reach its normal operating temperature. Ensure the carburettor(s) are adjusted correctly in respect of air flow / balance and idle mixture strength, to obtain the desired idle speed.

9. Connect the voltmeter to the following pins of the TPS connector (S): Negative to pin 2 (blue wire) and positive to pin 3 (red/green wire). The reading should be 5 Volts (±0.1 Volt).

10. Slacken the two M4 Mounting Screws (15) holding the TPS (13) to the bracket so that it can be moved easily, but is not so loose that it will slip out of position – Fig. 4.

11. Connect the voltmeter positive to pin 1 (purple/blue wire) and the negative to pin 2 (blue wire), and with the engine at idle turn the TPS clockwise until the voltage reaches 0.75V (±0.05V).

12. Tighten the screws (15) and recheck the voltage – Fig. 4. 13. Stop the engine and turn the ignition on. Hold the throttle fully open,

the voltage should be at least 3.8V. 14. When the calibration is complete, disconnect the voltmeter and refit

the rubber cover on the plug.

ALPHA Ignition Management System Fitting Instructions FL0377


FORD DURATEC 1.8 / 2 - Webcon UK Ltd · 2016. 2. 4. · FORD DURATEC 1.8 / 2.0 Static Ignition...

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