omex ford duratec i4 he 2.0/2.3 tapered throttle body kitomextechnology.com/omex duratec tapered tb...

Brochure v2.00 03/01/14

Ford Duratec I4 HE 2.0/2.3 Tapered Throttle Body Kit

The ultimate throttle body kit for your engine. This comprehensive kit for the Ford Duratec engine provides an easy and reliable highpower upgrade to Omex Engine Management and Throttle Bodies. It offers a simplified way of putting together all of the required partsfrom one supplier at a fixed cost with one reliable source of technical backup. The kit comes pre-assembled allowing an experiencedDIY mechanic to fit it with ease.

The air temperature sensoris mounted in the engine bayto help with air densitycalculations. The standardcoolant temperature sensoris re-used.

Omex’s multi-championship winning 600 Series ECU controls the fuel injection, standard Ford distributorless ignition coil pack, andoptionally, many other functions around the vehicle. The ECU is connected to the hardware with a complete, heatshrunk, racespecification wiring harness, which is fully tagged and with the correct connections made for your Duratec engine, ensuring easy clip-onfitment, optimum performance and absolute reliability.

Inlet manifold, throttle bodies, fuel rail, injectors, air horns, and throttle position sensor are supplied built together, ready to fit the to thecylinder head.

OMEXPERFORMANCE ELECTRONICS

PC Windows based ECUmapping software anddatalogging analysis softwareis included allowing you fullaccess to the ECU.

These bungs block theoriginal injector pockets inthe head, allowing the newinjectors to be placed in thethrottle bodies, a position thatgives more air / fuel mixingtime at high engine speeds,and so more power

Example of installation, engine not included.

A fixed 3.5 bar fuel pressureregulator in a billet machinedaluminium housing. Fittingsare to suit -6 screw-on fuellines.

Inlet ManifoldThrottle BodiesFuel Rail (-6 screw-on connections)Air HornsInjectorsHead Injector Port BungsFuel Pressure RegulatorThrottle Position SensorAir Temperature Sensor600 Series ECURace Spec Ready Built Wiring HarnessInstructionsSoftware

Kit Contents

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

Brochure v2.00 03/01/14

227mm

17o

Will the kit fit?A minimum of 20mm should be allowed between the endof the air horn and the air filter material. Also allow spacefor the movement of the engine.

The throttle bodies mounting angle is inline with the portangle.

The wiring harness length allows the ECU to be mountedinside the passenger compartment in most applications,though with careful placement, the ECU can be mountedin the engine bay without problems.

All above dimensions and angles are approximate

Why Jenvey Taper Throttle Bodies?

The taper throttle bodies are the pinnacle of the Jenvey range. These special throttle body systems have a constant taper from theairhorn all the way to the head face, accelerating the air smoothly and progressively to give the best possible air flow. Also with carefulattention given to injector position and angle, port characteristics and butterfly and spindle position and shape these throttle bodysystems are a no-compromise solution for the best possible power output from your race engine.

All major components are backed by rig tests of over 1 million cycles and all throttle bodies are individually tested before release fromthe Jenvey factory.

Jenvey have proved these bodies to be the best in dyno results and in competition with race wins worldwide.

Wiring Harness Options

Upgrade – ‘Works’ SpecificationThe ‘works’ specification build is the same as currently used in FIA World Rally Car (WRC) and ACO Le Mans Prototypes (LMP) and isbuilt by engineers currently working in these top level motorsport series. As an upgrade from the ‘race’ specification, Raychem productsare used throughout. The same Raychem heatshrink as used in our ‘race’ harness now covers Raychem cable for further improved cutresistance, temperature resistance and reduced weight. Joints and connector backs are now covered using Raychem boots which arethen injected with a resin to provide full submersible waterproofing and absolute mechanical protection. Each ‘leg’ of the harness hasan extra section of heatshrink which can be shrunk down by the user when fitting to give extra protection at the points where the harnessis mounted to the engine. Harnesses are tested on a CIRRIS machine as the ‘race’ harnesses. These harnesses are individuallybuilt-to-order and so lengths can be specified by completing a simple form to give the best fit for your vehicle. The ‘works’ specificationis simply the best there is.

‘Race’ SpecificationThe ‘race’ specification is the standard specification for this kit. It uses lightweight automotive cable loomed together using RaychemDR-25 heatshrink as found on nearly every professional motorsport harness for high flexibility, resistance to solvents and superior cutresistance. Within this Raychem outer, the cables are twisted together to provide resistance against radiated electrical noise fromsources such as the high tension sparks, alternator and starter motor giving clean sensor signals to the ECU. The terminals connectingto the ECU are gold plated to ensure the best connections to the ECU possible to maintain the clean signals from the sensors. All jointsin the harness are made with crimps rather than solder to withstand the high vibrations often found with solidly mounted drivetrains inrace vehicles. The joints and the component connectors are then covered in glue lined heatshrink which is inflexible and so any tensionplaced on the harness during service goes onto the strong connector housings and cables and so away from the cable joint. All of thesebuild features together give long service life and good reliability in the harsh environment of a motorsport engine bay. These harnessesare finally individually computer tested using a state-of-the-art ‘CIRRIS’ test machine at 500V to give extreme testing of the cable insulation.

Heatshrinkconnector boots

Twisted cablesin Raychem sleeving

Heatshrinkharness joints

Gold platedterminals

Upgrade to Raychem fullysealed connector boots

Upgrade to twisted Raychemcable in Raychem Sleeving

Upgrade to Raychem fully sealed joints


Brochure v2.00 03/01/14

Will the engine need setting-up?As every modified engine is different the calibration supplied is simply to start the engine and check operation of the system. The enginewill need calibration on a rolling road or engine dyno. On request and with appropriate engine details given, Omex will write the best startupcalibration they can to suit your engine.

140mm

OMEX POWER

440mm

190m

m

Air filter and back plate adds 57mm to kit length Air filter socks

Air filtration – Large foam filters give the best results giving little restriction to airflow. They are supplied machined ready for fitment to thethrottle bodies with a specially shaped backplate to allow for the long air horns and location of the injectors. A flat back plate will not fit.‘Sock’ filters can be used where space is tight but they can affect airflow so should be avoided if possible. ‘Sock’ filters can be used wherespace is tight but they can affect airflow so should be avoided if possible.

Synchrometer - This tool measures the airflow through each airhorn to enable fine balancing of the throttle bodies. Fine balancing isrecommended for all engines, and is essential for those that need to pass emissions tests. If you are having the engine set-up by a tunerthen they will already have this tool.

Balancing tool

What else will I need?Throttle linkage – single and twin cable versions are available. They are supplied already built onto the throttle bodies assembly and maybe adjusted to give the best throttle action.

Single cable throttle linkage kit Twin cable throttle linkage kit

Will the engine pass emissions tests?The ECU is capable of running a lambda sensor which on astandard engine will allow easy passing of MOT and IVA emissionstests. However with very modified engines it cannot be guaranteedas the engine may not be capable of passing the tests regardless ofECU controls.

Lambda sensor Lambda sensor boss

How much power will my engine make?This kit is primarily designed for modified engines, not standard engines. Power figures are dependent on the build specification of yourengine.


Brochure v2.00 03/01/14

Further informationBrake servos – if your vehicle requires a brake servo vacuum, then the kit can be supplied with an adaptor pre-fitted to the manifold.Barometric air pressure correction – If you are using the engine with large altitude changes (such as in the Alps), then air pressurechanges due to the altitude changes will affect the amount of fuel required. An upgrade to fit an air pressure sensor to automatically makethese changes is available.Throttle position sensor – For use in extreme conditions such as off-road rallying, this contactless throttle position sensor can be usedto give improved reliability due to improved protection against water and dust.

Barometric pressure sensorand harness upgrade

Brake servo adaptor Throttle position sensorupgrade

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 halfcars 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 do notthink about when looking at ECUs. Here at Omex we do because those details that are often taken for granted are the difference betweenone ECU system and another, the difference between winning and losing... The detailed approach to design of the basics by our team oftop software and hardware design engineers, responsible for race wins throughout all forms of motorsport at the very highest levels, meansyou 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 thefeatures you would expect from a top level ECU.Winning Championships is a combination of performance and reliability. Reliability is foundin the details of the way the ECU is designed and built. All Omex ECUs are robot assembled in the UK on an ISO9001:2000 approvedassembly line, ensuring a consistent, high quality build. They are all then thoroughly tested, twice, before leaving Omex. A well runningsystem is a combination of ECU and many other components. It is important that all components in the system continue to work in orderfor the ECU to be able to perform, and so Omex source all other components such as sensors and injectors only from highly respectedmanufacturers.

Of course, before you can even think about winning races and championships, you need to get to the race! Omex employ only the verybest engineers to ensure that whenever you contact us you get only the very best advice, right from specification of the best parts for yourapplication, 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 atelephone 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…

Extra ECU functionsWith 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 coloursare available on request.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 onthe startline.Radiator fan control - reduce the number of sensors, joins in the cooling system, and have full programmability of the ON / OFFtemperatures for the radiator fan. An additional relay is required for this control.

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

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


Brochure v2.00 03/01/14

The kit is not designed for use with coil-per-plug ignition coils. Omex can supply a DIS coil pack or kits using the Omex 710 ECU can besupplied to run coil-per-plug. See below for prices.

HT leads are not supplied when ordering a DIS coil pack (OMEM3501) as there are various coil mounting locations

To enable us to write your startup calibration we need the following information when ordering a kit;Is the engine size 2.0l or 2.3l?What internal modification does the engine have? (cams, compression ratio, etc)If you are not purchasing an Omex lambda sensor will you be using your own narrowband lambda sensor on the engine?

Ordering InformationThe Duratec engine has been fitted with several different ignition coil types; two different DIS coil packs, and coil-per-plug. When ordering,please state whether the DIS coil is connector type A or connector type B as shown in the images below.

Type BType A

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 upgradingparts 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. [email protected]%

All information provided is, to the best of Omex’s knowledge, correct at time of print. Due to differences in individual engines, differences in specification fromoriginal manufacturer that we may be unaware of, and differences in individual installations such as different exhaust designs, any claims of power oremissions cannot be guaranteed.

Kit

Tapered Throttle Body and ECU Kit to suit Ford Duratec 2.0 / 2.3

Options and Upgrades

Retail

£2225.00

£280.00

£55.00£10.40

£104.00£157.00

£159.00£44.00

£7.80£7.80£6.50£10.00£25.00£95.00

£50.00£POA

£43.00£30.00£50.00

inc VAT

£2670.00

£336.00

£66.00£12.48

£124.80£188.40

£190.80£52.80

£9.36£9.36£7.80£12.00£30.00£114.00

£60.00£POA

£51.60£36.00£60.00

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‘Works’ specification wiring harness upgrade

Lambda (oxygen) sensorLambda sensor boss

Throttle linkage single cable (inc mount)Throttle linkage twin cable (inc mount)

Air filter and machined back plateAir filter socks (set of 4)

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 modification

Throttle position sensor upgradeCoil-per-plug ECU and harness upgrade

Synchrometer for balancing of the throttle bodiesBrake servo adaptorsCoil pack - DIS Wasted Spark (HT leads not supplied)

OMTBKIT000301T

Part Number

OMEM1619(U)

OMEM2301OMEM2351

CLS1 + LBF2CLD1 + LBF2

ABB2/50 + ABB2/M + OMEM9052OMEM9051

OMEM6003OMEM6004OMEM6010OMEM6011OMEM5010(F)OMEM2100 + OMEM1519A

OMEM2006(U)

OMEM9900OMEM9100OMEM3505

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omex ford duratec i4 he 2.0/2.3 tapered throttle body kitomextechnology.com/omex duratec tapered tb...

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