Omex Duratec VVC 2 5 Engine v3 1omextechnology.co.uk/Omex Duratec VVC 2_5 Engine v3_1.pdf ·...

Ford 2.5L Duratec VVCPerformance Engine Packages

OMEXwww.omextechnology.co.uk

Ford Duratec 2.5L VVC Engine Packages

Our range of OmexPower engines has been developed to be engine package solutions that are truly ’turn key’. We have developed acoherent range of very high quality, fully tested engine packages with varying power outputs to suit your requirements and budget. Allour engine packages are built on brand new engines. The engines are all built at Omex, mounted on a special jig and hot run (052, 072are engine dyno tested). This means that the cams are run in, the throttle bodies (where applicable) are balanced, the idle speed is setand the emissions are checked for IVA and MOT compliance. The engines are supplied with the new Omex 710 Series ECU and a fullyassembled wiring loom as standard. To ensure absolute peace of mind the engine is tested with the actual loom and ECU that areshipped with your engine. As the ECUs are all pre-calibrated 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 2.5L VVC engines covers power outputs of 175 to 310 bhp. The engines are available as aninline (to suit front engine rear wheel drive) version. The engines use the superb RaceLine lowline fully baffled sump (do not confusethis with cheap inferior copies that are available). A dry sump is available as an option.

These superb engines features variable cam timing (VVC). The inlet camshaft timing is varied by up to 36 degrees under ECU controlto give a very wide power band, with excellent bottom end torque and a real rush at the top end of the rev range. The standardspecification of these engines is significantly enhanced from the non VVC Duratec engines, allowing a safe and totally reliable 7500RPM rev limit (6500 RPM for 022 and 032 specifications).

There are a wide range of mechanical options and upgrades available to suit your requirements, such as different clutches andflywheels, side water rails, a choice of linkages etc. The available options for each engine specification are detailed at the end of eachsection. In addition there are several electronic options available, such as full throttle gearshift, shift lights and more, again detailed atthe end of each engine. If you would like advice about which specification fits your vehicle best then please give us a call.

Selecting your engine

- Duratec Variable Valve Timing (VVC) engine package- 175 bhp (022 spec) / 210 bhp (032 spec)- Uprated cams (032 spec)- 6500 RPM rev limit- Multiple throttle bodies for instant throttle response- Inline installation

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- Duratec Variable Valve Timing (VVC) engine package- 270 bhp (052 spec)- Uprated cams- Steel / forged engine internals- 7500 RPM rev limit (7800 RPM for sprint events)- Multiple throttle bodies for instant throttle response- Inline installation 27

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- Duratec Variable Valve Timing (VVC) engine package- 310 bhp (072 spec)- Full competition spec cams with uprated valve guides- Steel / forged engine internals- CNC machined cylinder head with over sized valves- 7500 RPM rev limit (7800 RPM for sprint events)- Multiple throttle bodies for instant throttle response- Inline installation

2Omex Technology Systems Ltd, 3 Mackenzie Way, Manor Road, Cheltenham, GL51 9TX

Tel +44 (0)1242 260656 Fax +44 (0)1242 578069 [email protected] www.omextechnology.co.uk

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Duratec 2.5L VVC Engine - 175 bhp / 210 bhp

This superb all alloy, variable valve timing engine makes a fantastic road or track day engine for your vehicle. It offers great power outputin a lightweight package. This engine with its strong torque curve gives great performance and exceptional reliability and driveability.Available as an inline (front engine rear wheel drive) engine, it utilises individual throttle butterflies for each cylinder which givesunrestricted airflow to each cylinder and hence a high power output. In addition, the ability to produce more power and torque at thehigher end of the rev range means that the on road and track performance is enhanced. Also the sound of throttle bodies cannot bebeaten. The engine is fitted with the superb Raceline lowline wet sump (with a dry sump option) to allow maximum ground clearanceand no oil surge. A wide range of options and upgrades to suit your specific requirements are available.

New Duratec 2.5L VVC EngineOmex specification inlet and exhaust camshafts (D25VVC032 only)Ready mapped 710 Series ECUReady built wiring harnessLowline baffled sumpInlet manifold with multiple throttle bodiesLightweight alloy air hornsFuel railFuel pressure regulatorThrottle position sensorAir temperature sensorCoolant temperature sensorCrank position sensorInjectorsIgnition coil pack and leadsOil filterGaskets

Engine Specification175 BHP Engine (inline)210 BHP Engine (inline)

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OptionsAlternator outputs and positionsDry sump systemAir filtersThrottle linkagesFuel line fitting typeBrake servo pipingUprated big-end boltsSide water rail assemblyFlywheels and clutchesStarter motorsBell housingsUprated wiring harness specificationsElectronic controls

D25VVC022AD25VVC032A



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What comes with the engine?

Omex’s superb 710 Series ECU controls the fuel injection, standard Ford distributorless ignition coil pack, and optionally, many otherfunctions around the vehicle. The ECU is connected to the hardware with a complete, ready built wiring harness, which is fully taggedand with the correct connections made for the Duratec engine, ensuring easy clip-on fitment, optimum performance and absolutereliability. The ECU, wiring harness and sensors are kept with each engine build throughout assembly and testing work, ensuring thatthe engine package you receive has been tested as a whole package.

Electronics

Inlet System

Engine Internals

The 190 bhp D25VVC022 engine uses the standard inlet and exhaust cams while the 220 bhp D25VVC032 engine has upgraded Omexown specification inlet and exhaust cams. These are all fitted and timed up to our own specifications.

Proven, reliable, Omex throttle bodies are used on these specification engines. Individual throttle plates give the air an unrestrictedroute to the engine giving maximum power. There are three options of throttle body lengths and two manifold designs to suit allapplications.

Throttle bodies with long port angled inlet manifoldand 40mm air horns



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Bosch injectors are used giving excellentspray patterns to optimise power outputsand reduce emissions.

Injectors

Crank and throttle position sensors aresupplied and fitted to all engines.

Crank & Throttle Position Sensors

The engine utilises an aluminium billet fuelpressure regulator.

Fuel Pressure Regulator

All gaskets and an oil filter are includedand fitted.

Gaskets & Oil Filter

Air and coolant temperature sensors aresupplied and fitted.

Temperature SensorsIgnition System

DIS coil pack, ignition leads, and sparkplugs are all included.

Sump

The engines are fitted with a new low line increased ground clearance sump with internal baffling designed to keep the oil on the pickup.This sump has been tested in vehicles up to single seaters with slicks and wings generating very high cornering forces.

Inline wet sump in parts and assembled on the engine.


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All dimensions are approximate, if you need any other dimensions please ask.

Engine Dimensions - (Inline Version)

- 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

250mm

420mm

490mmEnd of

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Engines shown with optional alternator kit OMEP2110A(F)and standard inlet system arrangement.

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Options and Upgrades - Alternators

For chassis clearance there is the option of alternator mounting on either the inlet or the exhaust side of the engine. Racecars withminimal electrical requirements can use the smaller 50A alternator. Road cars and rally cars with higher electrical requirements willrequire the larger 130A alternator. All alternator kits are fitted to the engine and include; alternator, alternator pulley, billet brackets (ordirect mount), idler pullies and drive belt.

OMEP2110A(F) - 130A inlet side


Engine shown with standard length throttle bodies and low line sump


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Omex Technology Systems Ltd, 3 Mackenzie Way, Manor Road, Cheltenham, GL51 9TXTel +44 (0)1242 260656 Fax +44 (0)1242 578069 [email protected] www.omextechnology.co.uk

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OMEP2112A(F) - 130A exhaust side


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Exhaust side alternator kits

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Although not required for most applications, we offer the Raceline dry sump option for pure competition applications (inline only, notsuitable for transverse applications). It gives the advantage of an even lower sump line (approximately 25 mm lower than the lowlinewetsump) 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 insingle 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 proneto 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 thesump is kept empty of the oil mist that drags down power output. The sump also includes twin crank scraper plates and an additionaltrough 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 anda 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 2000and hundreds of Caterhams.


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Options and Upgrades - Dry Sump

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The engine as standard comes with a set of long throttle on the long port angled inlet manifold, push-on 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 inyour vehicle;

Air Horns

15mm Air Horn

40mm Air Horn (standard fitment)

60mm Air Horn

80mm Air Horn

Standard kit fitment

Options and Upgrades - Inlet System

Bosch injectors are used giving excellent spray patterns to maximise power outputs andminimise emissions. Ideally they are fitted in the throttle bodies (standard fitment), but can alsobe fitted in the head when space is restricted.

Injectors in the throttle bodies (standard fitment) Injectors in the cylinder head

Injector Position

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Air Filters

Central and LoweredAir Filter Back Plates

(Fits Ones Piece Air Filter Only)

Air Filter SocksDifferent Depth One PieceAir Filters

(Fits onto Back Plate)

The long throttle bodies will accept DCOE / DHLA pattern back plate air filters which can be supplied with a centralised back plate or a15mm 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.

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)

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Options and Upgrades - Mechanical

If your vehicle requires a brake servo vacuum, the manifold can be fitted with a vacuum take-off. This can be specified to exit to theeither side of the engine. A push-in adaptor to suit 8mm ID pipe is supplied.

Brake Servo

Brake servo adaptor

The fuel rail can be built with either push-on pipe or -6 screw fitting pipe fittings. The fuel pressure is regulated by a constant pressurebillet aluminium housed regulator (included). The regulator will also have either push-on (standard) or -6 screw fittings (optional) to suit.

Push-on pipe fittings -6 pipe fittings

Fuel Pipe Connections

As standard, the throttle bodies have a lever blade to which you can connect the inner throttle cable pulling from above or belowbetween throttles 2 and 3. A more complete cable solution is available by fitting one of the optional throttle linkage kits. These can bespecified for single or twin cables, fitting above or below the throttle bodies (above is the preference for ease of adjustment if space isavailable), and with the cable pulling from the left or the right. The linkages are supplied fitted, adjusted for best throttle action andcomplete with new throttle cables. Note that dependent on alternator and inlet system choice, it may not be possible to build all options

Throttle Linkages

Twin cable throttle linkage kit(top mounting)

Single cable throttle linkage kit(top mounting)


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Uprated Big-end 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 orextended trackday use, extra safety can be inbuilt through the upgrade to ARP big-end bolts.

Uprated ARP Big-end bolts

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 blockedoff 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 increaseclearance 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


Water Housing



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There are a bewildering range of flywheels and clutches available for the Duratec engine so at Omex we have sorted out the sensiblecombinations that cover nearly all applications. We offer flywheels and clutches that are suitable for road use right to full competitionversions. 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 pleasecall.

FLYWHEELSOMEP5100 Lightweight (4.7Kg) steel flywheel to suit Ford Type 9 or MT75 offsetOMEP5102 Medium weight cast flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed)OMEP5104 Lightweight (4.7Kg) steel flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed)OMEP5106 Lightweight steel flywheel to suit the Raceline narrow bellhousing only (Ford offset)

CLUTCHESAll our clutch kits include both pressure and driven plate and are designed to fit specific flywheels and gearboxes. We offer a range tocover both the Ford Type 9/MT75 gearboxes (1”x25 spline) and the Mazda MX5 Mk3 gearboxes that are fitted in so many niche vehiclesnow such as Morgan Plus 4.

OMEP5200

OMEP5200A

OMEP5202

OMEP5202AOMEP5204

OMEP5204A

Flywheel bolts are also required; standard flywheels bolts or ARP flywheel bolts can be supplied and fitted.

A cast aluminium bell housing is available to suit the Ford Sierra Type 9 (short inputshaft) gearbox (flywheel - OMEP5100).

A Raceline narrow aluminium bell housing to suit the Ford Sierra Type 9 is availablefor flywheel OMEP5106.

Mazda gearboxes have integral bellhousings that directly fit the engine (flywheels -OMEP5102 and OMEP5104).

Bellhousing

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 moreefficiently and so can start an engine with less electrical current.

Starter Motor

Standard starter motor(Ford and Mazda offsets available)

High power starter motor(Ford and Mazda offsets available)


Options and Upgrades - Starter Motors

AP Racing sprung organic clutch assembly to suit OMEP5100/5106 flywheel. This clutch assembly is ideal for roadand trackday use and has a great feel to it and is suitable for mild competition use. It has the Ford 1”x25 splinearrangement 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 asequential gearbox that is either driven on track or has a flat shift or paddle shift fitted. Suits the Ford 1”x25 splineinput shaft as used on many competition gearboxes.This is suitable for the OMEP5102 cast Mazda offset flywheel and is a completely standard Mazda clutchassembly. It fits the Mazda MX5 Mk3 gearbox (5 speed) and although is a road clutch it has proven totally reliablein 200bhp race cars. We specified this assembly for the 60 off Morgan Supersports, many of which have raced for3 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 thesefor the Morgan Plus 4 Racecars that used our Duratec 265 bhp engine. They have a slightly higher pedal pressurethan 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.

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Wiring Harness Options

Standard ‘Road’ SpecificationThe standard specification harness in this kit is the ‘road’ specification. This harness uses thin wall, lightweight automotive grade cableloomed together with PVC tubing and harness tape; a specification similar to that found on premium modern road cars. Each harnessis individually computer tested to ensure the build is correct.

Rubber connector boots PVC tubing covered cable

Bespoke lengthsTwisted cablesin heatshrink sleeving

Heatshrinkharness joints

Gold platedterminals

Heatshrinkconnector boots

Upgrade 2 – Bespoke ‘Race’ SpecificationThe perfect harness should also fit perfectly. The bespoke ‘Race’ specification is built using the same materials and methods as thestandard ‘Race’ specification harness, but with lengths tailored to suit your engine bay.

Upgrade 1 – ‘Race’ SpecificationThe ‘race’ specification is the same dimensions as the ‘road’ harness and uses the same high grade cable, but this time loomed togetherusing Raychem DR-25 heatshrink as found on nearly every professional motorsport harness for high flexibility, resistance to solventsand superior cut resistance. Within this Raychem outer, the cables are twisted together to provide resistance against radiated electricalnoise from sources such as the high tension sparks, alternator and starter motor giving clean sensor signals to the ECU. The terminalsconnecting to the ECU are then upgraded to gold plating to ensure the best connections to the ECU possible to maintain the cleansignals from the sensors. All joints in the harness are made with crimps rather than solder to withstand the high vibrations often foundwith solidly mounted drivetrains in race vehicles. The joints and the component connectors are then covered in glue lined heatshrinkwhich is inflexible and so any tension placed on the harness during service goes onto the strong connector housings and cables and soaway from the cable joint. All of these improvements together give longer service life and improved reliability in the harsh environmentof a motorsport engine bay. These harnesses are built by a team of engineers currently working in top worldwide ‘works’ motorsportseries (the same team responsible for our ‘works’ spec bespoke harnesses) so not only are high quality materials used, they are builtby the best too. Finally individually computer tested using a state-of-the-art ‘CIRRIS’ test machine at 500V to give extreme testing of thecable insulation.

Twisted cablesin heatshrink sleeving





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Options and Upgrades - Electronics

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Shift light (10mm LED) Full throttle gearshift(clutch switch)

Launch control (button) Radiator fan control(Relay and base)

Barometric pressure sensorand harness upgrade

Lambda sensor Lambda sensor boss

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 andcolours 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 clutchswitch, 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 steadyon the startline.Radiator fan control - reduce the number of joins and sensors in the cooling system, and have full programmability of the ON / OFFtemperatures 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), thenair pressure changes due to the altitude changes will affect the amount of fuel required. An upgrade to fit an air pressure sensor toautomatically make these changes is available.Emissions control - The engine simply needs a narrowband lambda sensor and an effective catalytic convertor and it will then passUK MOT and IVA emissions tests with ease. Omex can provide a lambda sensor and boss to weld to the exhaust. A lambda sensor isnot required to make the engine run, so if you have a vehicle that does not need to pass emissions tests, then a lambda sensor isoptional.

Electronic Controls

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 ahalf 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’scalculated, how engine acceleration is taken into account, and so ultimately how accurately that spark is placed, are things that you donot think about when looking at ECUs. Here at Omex we do because those details that are often taken for granted are the differencebetween one ECU system and another, the difference between winning and losing... The detailed approach to design of the basics byour team of top software and hardware design engineers, responsible for race wins throughout all forms of motorsport at the veryhighest levels, means you do not need to think about these details because we do. Features lists don’t win races; it’s how these featureswork that wins races. Other ECUs may have similar features lists, but how an Omex works makes all the difference. Naturally, OmexECUs 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 designedand built. All Omex ECUs are robot assembled in the UK on an ISO9001:2000 approved assembly line, ensuring a consistent, highquality build. They are all then thoroughly tested, twice, before leaving Omex. A well running system is a combination of ECU and manyother components. It is important that all components in the system continue to work in order for the ECU to be able to perform, and soOmex 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 degreequalified engineers to ensure that whenever you contact us you get only the very best advice, right from specification of the best partsfor 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 justa 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…




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Optional parts are standalone extra parts and can be added to your kit at any time. Upgrade parts, designated by a ‘(U)’ in the partnumber, 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 anytime, but at the full price of the part. E&OE. Price list (Retail). [email protected]%

Options and UpgradesAlternator kit 130A inlet sideAlternator kit 50A inlet sideAlternator kit 130A exhaust sideAlternator kit 50A exhaust side

Dry sump upgrade (inline engine only)

Injectors positioned in the cylinder head

One piece air filter with centralised back plateOne piece air filter with lowered back plateAir Filter Socks

Throttle linkage single cable kitThrottle linkage twin cable kit

Push-on to dash 6 fuel rail and pressure regulator upgrade

Brake servo adaptors (fitted)

Side water rail (complete assembly - fitted)

Flywheel - lightweight steel 4.7Kg - Ford offsetFlywheel - cast Mazda - Mazda offsetFlywheel - lightweight steel 4.7Kg - Mazda offsetFlywheel - lightweight steel - suits Raceline compact bellhousing

Clutch assembly - to suit OMEP5100 and OMEP5106Clutch assembly - to suit OMEP5100 and OMEP5106Clutch assembly - to suit OMEP5102Clutch assembly - to suit OMEP5102Clutch assembly - to suit OMEP5104Clutch 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)

Starter motor standard - Ford offsetStarter motor standard - Mazda offsetStarter motor high power - Ford offsetStarter motor high power - Mazda offsetStarter motor to suit Raceline narrow bellhousing

‘Race’ specification wiring harness upgradeBespoke ‘Race’ specification wiring harness upgrade

Shift light (10mm LED - red) - inc mounting bezel and cablesShift light (5mm LED - red) - inc mounting bezel and cablesFull throttle gearshift clutch switch - inc cablesLaunch control button - inc cablesRadiator fan control relay and base (fitted)Barometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessBarometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessLambda (oxygen) sensorLambda sensor boss

Kit

Inline 175 bhp Duratec 2.5l engineInline 210 bhp Duratec 2.5l engine

Part Number

OMEP2110A(F)OMEP2114A(F)OMEP2112A(F)OMEP2116A(F)

OMEP3200(U)(F)

CFRxx(U)

AFFB + AFBA/97AFFB + AFBA/97/LOWOMEM9051

CL1-SingleCL1-Twin

FPR535-6(U) + FRA/97-6(U)

OMEM9100(F)

OMEP3010(U)(F)

OMEP5100OMEP5102OMEP5104OMEP5106

OMEP5200OMEP5200AOMEP5202OMEP5202AOMEP5204OMEP5204A

OMEP5000(F)OMEP5002(F)

OMEP3110OMEP3112

OMEP2010OMEP2012OMEP2014OMEP2016OMEP2018

OMEM1519(U)OMEM1539(U)

OMEM6003OMEM6004OMEM6010OMEM6011OMEM5010(F)OMEM2100(U) + OMEM1419A(U)

OMEM2100(U) + OMEM1519A(U)

OMEM2301OMEM2351

Retail

£360.00£475.00£380.00£540.00

Enquire

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£110.00£230.00

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£55.00£10.40

Inc VAT

£432.00£570.00£456.00£648.00

Enquire

£24.00

£134.40£134.40£52.80

£123.60£189.60

£9.60

£36.00

£360.00



EnquireEnquire

EnquireEnquire


£132.00£276.00

£9.36£9.36£7.80£12.00£30.00£114.00

£120.00

£66.00£12.48

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D25VVC022AD25VVC032A

£7695.00£8595.00

£9234.00£10314.00

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Brochure v3.10 05/12/19

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Duratec 2.5L VVC Engine - 270 bhp

New Duratec 2.5L VVC EngineOmex specification inlet and exhaust camshaftsFull race spec valve springs and retainersForged high compression pistonsSteel connecting rodsCNC ported cylinder headInlet manifold CNC matched to cylinder headARP big end boltsCompetition big end bearingsReady mapped 710 Series ECUReady built wiring harnessLowline baffled sumpInlet manifold with multiple throttle bodiesLightweight alloy air hornsFuel railFuel pressure regulatorThrottle position sensorAir temperature sensorCoolant temperature sensorCrank position sensorInjectorsIgnition coil pack and leadsOil filterGaskets

Engine Specification270 BHP Engine (inline)Engine

-

OptionsAlternator outputs and positionsDry sump systemAir filtersThrottle linkagesFuel line fitting typeBrake servo pipingSide water rail assemblyFlywheels and clutchesStarter motorsBell housingsUprated wiring harness specificationsElectronic controls

D25VVC052A


The engine features new forged alloy pistons, high quality steel connecting rods, bespoke Omex camshafts and race valve springs withlightweight spring retainers. This gives a safe and reliable 7500 RPM rev limit (7800 RPM in sprint events). It has a CNC ported cylinderhead, which is also CNC matched to a ‘direct shot’ inlet manifold.These specifications of engines can meet the IVA and MOT emissions requirements.

As with any engine of this specification, the design of the exhaust system is critical and Omex can supply details of lengths anddiameters required.



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Engine Internals


CNC ported cylinder head

ARP Big-end boltsForged high compression pistons, steel connecting rodsAnd competition big end bearings

Omex specification inlet and exhaust camshafts,full race valve springs and retainers


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Electronics


Sump


Inlet System




270

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21


Injectors




Temperature Sensors

Ignition System

DIS coil pack, ignition leads, and spark plugs are all included.






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Brochure v3.10 05/12/19



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Air Horns

15mm Air Horn


60mm Air Horn

80mm Air Horn





Injector Position


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Air Filters








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Brake Servo

Brake servo adaptor





Throttle Linkages




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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 blockedoff 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 increaseclearance 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


Water Housing



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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 sensiblecombinations that cover nearly all applications. We offer flywheels and clutches that are suitable for road use right to full competitionversions. 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 pleasecall.

FLYWHEELSOMEP5100 Lightweight (4.7Kg) steel flywheel to suit Ford Type 9 or MT75 offsetOMEP5102 Medium weight cast flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed)OMEP5104 Lightweight (4.7Kg) steel flywheel to suit Mazda MX5 Mk3 gearbox (5 and 6 speed)OMEP5106 Lightweight steel flywheel to suit the Raceline narrow bellhousing only (Ford offset)

CLUTCHESAll our clutch kits include both pressure and driven plate and are designed to fit specific flywheels and gearboxes. We offer a range tocover both the Ford Type 9/MT75 gearboxes (1”x25 spline) and the Mazda MX5 Mk3 gearboxes that are fitted in so many niche vehiclesnow such as Morgan Plus 4.

OMEP5200

OMEP5200A

OMEP5202

OMEP5202AOMEP5204

OMEP5204A

Flywheel bolts are also required; standard flywheels bolts or ARP flywheel bolts can be supplied and fitted.

A cast aluminium bell housing is available to suit the Ford Sierra Type 9 (short inputshaft) gearbox (flywheel - OMEP5100).

A Raceline narrow aluminium bell housing to suit the Ford Sierra Type 9 is availablefor flywheel OMEP5106.

Mazda gearboxes have integral bellhousings that directly fit the engine (flywheels -OMEP5102 and OMEP5104).

Bellhousing

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 moreefficiently and so can start an engine with less electrical current.

Starter Motor

Standard starter motor(Ford and Mazda offsets available)

High power starter motor(Ford and Mazda offsets available)


Options and Upgrades - Starter Motors

AP Racing sprung organic clutch assembly to suit OMEP5100/5106 flywheel. This clutch assembly is ideal for roadand trackday use and has a great feel to it and is suitable for mild competition use. It has the Ford 1”x25 splinearrangement 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 asequential gearbox that is either driven on track or has a flat shift or paddle shift fitted. Suits the Ford 1”x25 splineinput shaft as used on many competition gearboxes.This is suitable for the OMEP5102 cast Mazda offset flywheel and is a completely standard Mazda clutchassembly. It fits the Mazda MX5 Mk3 gearbox (5 speed) and although is a road clutch it has proven totally reliablein 200bhp race cars. We specified this assembly for the 60 off Morgan Supersports, many of which have raced for3 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 thesefor the Morgan Plus 4 Racecars that used our Duratec 265 bhp engine. They have a slightly higher pedal pressurethan 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.

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Wiring Harness Options

Standard ‘Road’ SpecificationThe standard specification harness in this kit is the ‘road’ specification. This harness uses thin wall, lightweight automotive grade cableloomed together with PVC tubing and harness tape; a specification similar to that found on premium modern road cars. Each harnessis individually computer tested to ensure the build is correct.

Rubber connector boots PVC tubing covered cable

Bespoke lengthsTwisted cablesin heatshrink sleeving




Upgrade 2 – Bespoke ‘Race’ SpecificationThe perfect harness should also fit perfectly. The bespoke ‘Race’ specification is built using the same materials and methods as thestandard ‘Race’ specification harness, but with lengths tailored to suit your engine bay.

Upgrade 1 – ‘Race’ SpecificationThe ‘race’ specification is the same dimensions as the ‘road’ harness and uses the same high grade cable, but this time loomed togetherusing Raychem DR-25 heatshrink as found on nearly every professional motorsport harness for high flexibility, resistance to solventsand superior cut resistance. Within this Raychem outer, the cables are twisted together to provide resistance against radiated electricalnoise from sources such as the high tension sparks, alternator and starter motor giving clean sensor signals to the ECU. The terminalsconnecting to the ECU are then upgraded to gold plating to ensure the best connections to the ECU possible to maintain the cleansignals from the sensors. All joints in the harness are made with crimps rather than solder to withstand the high vibrations often foundwith solidly mounted drivetrains in race vehicles. The joints and the component connectors are then covered in glue lined heatshrinkwhich is inflexible and so any tension placed on the harness during service goes onto the strong connector housings and cables and soaway from the cable joint. All of these improvements together give longer service life and improved reliability in the harsh environmentof a motorsport engine bay. These harnesses are built by a team of engineers currently working in top worldwide ‘works’ motorsportseries (the same team responsible for our ‘works’ spec bespoke harnesses) so not only are high quality materials used, they are builtby the best too. Finally individually computer tested using a state-of-the-art ‘CIRRIS’ test machine at 500V to give extreme testing of thecable insulation.

Twisted cablesin heatshrink sleeving





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Shift light (10mm LED) Full throttle gearshift(clutch switch)

Launch control (button) Radiator fan control(Relay and base)

Barometric pressure sensorand harness upgrade

Lambda sensor Lambda sensor boss Throttle position sensorupgrade

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 andcolours 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 clutchswitch, 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 steadyon the startline.Radiator fan control - reduce the number of joins and sensors in the cooling system, and have full programmability of the ON / OFFtemperatures 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), thenair pressure changes due to the altitude changes will affect the amount of fuel required. An upgrade to fit an air pressure sensor toautomatically make these changes is available.Emissions control - The engine simply needs a narrowband lambda sensor and an effective catalytic convertor and it will then passUK MOT and IVA emissions tests with ease. Omex can provide a lambda sensor and boss to weld to the exhaust. A lambda sensor isnot required to make the engine run, so if you have a vehicle that does not need to pass emissions tests, then a lambda sensor isoptional.Throttle position sensor – For use in extreme conditions such as off-road rallying, a contactless throttle position sensor can be usedto give improved reliability due to improved protection against water and dust.

Electronic Controls

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 ahalf 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’scalculated, how engine acceleration is taken into account, and so ultimately how accurately that spark is placed, are things that you donot think about when looking at ECUs. Here at Omex we do because those details that are often taken for granted are the differencebetween one ECU system and another, the difference between winning and losing... The detailed approach to design of the basics byour team of top software and hardware design engineers, responsible for race wins throughout all forms of motorsport at the veryhighest levels, means you do not need to think about these details because we do. Features lists don’t win races; it’s how these featureswork that wins races. Other ECUs may have similar features lists, but how an Omex works makes all the difference. Naturally, OmexECUs 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 designedand built. All Omex ECUs are robot assembled in the UK on an ISO9001:2000 approved assembly line, ensuring a consistent, highquality build. They are all then thoroughly tested, twice, before leaving Omex. A well running system is a combination of ECU and manyother components. It is important that all components in the system continue to work in order for the ECU to be able to perform, and soOmex 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 degreequalified engineers to ensure that whenever you contact us you get only the very best advice, right from specification of the best partsfor 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 justa 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…




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Optional parts are standalone extra parts and can be added to your kit at any time. Upgrade parts, designated by a ‘(U)’ in the partnumber, 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 anytime, but at the full price of the part. E&OE. Price list (Retail). [email protected]%

Options and Upgrades

Alternator kit 130A inlet sideAlternator kit 50A inlet sideAlternator kit 130A exhaust sideAlternator kit 50A exhaust side

Dry sump upgrade (inline engine only)

Injectors positioned in the cylinder head

One piece air filter with centralised back plateOne piece air filter with lowered back plateAir Filter Socks

Throttle linkage single cable kitThrottle linkage twin cable kit

Push-on to dash 6 fuel rail and pressure regulator upgrade

Brake servo adaptors (fitted)

Uprated ARP big-end bolts - fitted to inline specification engineUprated ARP big-end bolts - fitted to transverse specification engine

Side water rail (complete assembly - fitted)

Flywheel - lightweight steel 4.7Kg - Ford offsetFlywheel - cast Mazda - Mazda offsetFlywheel - lightweight steel 4.7Kg - Mazda offsetFlywheel - lightweight steel - suits Raceline compact bellhousing

Clutch assembly - to suit OMEP5100 and OMEP5106Clutch assembly - to suit OMEP5100 and OMEP5106Clutch assembly - to suit OMEP5102Clutch assembly - to suit OMEP5102Clutch assembly - to suit OMEP5104Clutch 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)

Starter motor standard - Ford offsetStarter motor standard - Mazda offsetStarter motor high power - Ford offsetStarter motor high power - Mazda offsetStarter motor to suit Raceline narrow bellhousing

‘Race’ specification wiring harness upgradeBespoke ‘Race’ specification wiring harness upgrade

Shift light (10mm LED - red) - inc mounting bezel and cablesShift light (5mm LED - red) - inc mounting bezel and cablesFull throttle gearshift clutch switch - inc cablesLaunch control button - inc cablesRadiator fan control relay and base (fitted)Barometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessBarometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessLambda (oxygen) sensorLambda sensor boss

Kit

Inline 270 bhp Duratec 2.5l engine

Part Number

OMEP2110A(F)OMEP2114A(F)OMEP2112A(F)OMEP2116A(F)

OMEP3200(U)(F)

CFRxx(U)

AFFB + AFBA/97AFFB + AFBA/97/LOWOMEM9051

CL1-SingleCL1-Twin

FPR535-6(U) + FRA/97-6(U)

OMEM9100(F)

OMEP4120(U)(F)OMEP4122(U)(F)

OMEP3010(U)(F)

OMEP5100OMEP5102OMEP5104OMEP5106

OMEP5200OMEP5200AOMEP5202OMEP5202AOMEP5204OMEP5204A

OMEP5000(F)OMEP5002(F)

OMEP3110OMEP3112

OMEP2010OMEP2012OMEP2014OMEP2016OMEP2018

OMEM1519(U)OMEM1539(U)

OMEM6003OMEM6004OMEM6010OMEM6011OMEM5010(F)OMEM2100(U) + OMEM1419A(U)

OMEM2100(U) + OMEM1519A(U)

OMEM2301OMEM2351

Retail

£360.00£475.00£380.00£540.00

Enquire

£20.00

£112.00£112.00£44.00

£103.00£158.00

£8.00

£30.00

£150.00£180.00

£300.00



EnquireEnquire

EnquireEnquire


£110.00£230.00

£7.80£7.80£6.50£10.00£25.00£95.00

£100.00

£55.00£10.40

Inc VAT

£432.00£570.00£456.00£648.00

Enquire

£24.00

£134.40£134.40£52.80

£123.60£189.60

£9.60

£36.00

£180.00£216.00

£360.00



EnquireEnquire

EnquireEnquire


£132.00£276.00

£9.36£9.36£7.80£12.00£30.00£114.00

£120.00

£66.00£12.48

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Price List: D25VVC052A



Brochure v3.10 05/12/19

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Duratec 2.5L VVC Engine - 310 bhp



Brochure v3.10 05/12/19

New Duratec 2.5L VVC EngineFull competition race cams with uprated valve guidesFull race spec valve springs and retainersForged high compression pistonsSteel connecting rodsCNC ported cylinder headInlet manifold CNC matched to cylinder headOver sized inlet and exhaust valvesARP big end boltsCompetition big end bearingsReady mapped 710 Series ECUReady built wiring harnessLowline baffled sumpInlet manifold with multiple throttle bodiesLightweight alloy air hornsFuel railFuel pressure regulatorThrottle position sensorAir temperature sensorCoolant temperature sensorCrank position sensorInjectorsIgnition coil pack and leadsOil filterGaskets

Engine Specification310 BHP Engine (inline)Engine

-

OptionsAlternator outputs and positionsDry sump systemAir filtersThrottle linkagesFuel line fitting typeBrake servo pipingSide water rail assemblyFlywheels and clutchesStarter motorsBell housingsUprated wiring harness specificationsElectronic controls

D25VVC072A


The engine features new forged alloy pistons, high quality steel connecting rods, bespoke Omex competition spec camshafts and racevalve springs with lightweight spring retainers. This gives a safe and reliable 7500 RPM rev limit (7800 RPM in sprint events). It has aCNC ported cylinder head, which is also CNC matched to a ‘direct shot’ inlet manifold. This engine features over sized inlet and exhaustvalves as well as competition spec camshafts, new valve guides and further uprated valve springs.

This specification of engine is not recommend for IVA and MOT emissions requirements.

As with any engine of this specification, the design of the exhaust system is critical and Omex can supply details of lengths anddiameters required.

35

310

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Engine Internals


CNC ported cylinder head

ARP Big-end boltsForged high compression pistons, steel connecting rodsAnd competition big end bearings

Omex specification competition inlet and exhaust camshafts,full race dual valve springs and retainers


Brochure v3.10 05/12/19


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Electronics


Sump


Inlet System





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Injectors




Temperature Sensors

Ignition System

DIS coil pack, ignition leads, and spark plugs are all included.






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250mm

420mm

490mmEnd of

Throttle bodies

175m

m

Cra

nkce

ntre

line

Bot

tom

of

sum

p 150m

m48

5mm

Top

ofca

m c

over

Side

275m

m

510mm

585m

m

606m

m

Front ofpulleys

Rear ofblock

Rear ofcoil

120mm

Bot

tom

of

sum

pTo

p of

oil

cap

& c

am c

over

120mm

510mm

630mm

Rear ofblock

Rear ofcoil

Front ofpulleys


Cra

nkce

ntre

line

160m

m33

0mm

Sid

eE

nd o

fTh

rottl

e bo

dies

Top

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ebo

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tom

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thro

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160m

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110mm

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200mm

370m

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85m

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80mm

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Air Horns

15mm Air Horn


60mm Air Horn

80mm Air Horn





Injector Position

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Air Filters








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Brake Servo

Brake servo adaptor





Throttle Linkages




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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

Omex Duratec VVC 2 5 Engine v3 1omextechnology.co.uk/Omex Duratec VVC 2_5 Engine v3_1.pdf ·...

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Transcript of Omex Duratec VVC 2 5 Engine v3 1omextechnology.co.uk/Omex Duratec VVC 2_5 Engine v3_1.pdf ·...