PERFORMANCE TUNING - Tunehouse · Subaru KK3670 Subaru WRX STI EJ25 (2 5L) Pr 2004-2006 20001699 Subaru WRX STI EJ25 (2 5L) Pr 2007 (with air injection ports) 20004544 Subaru WRX

PERFORMANCET UN I NGCOMPONENTS

High Performance Tuning Componentsfor Fast Road and Track Applications

2011

A History Of Excellence

Cosworth has a legendary reputation for high performance racing engines and vehicle electronics systems in Formula One, the IndyCar Series, NASCAR, WRC and many more.

In 40 years of F1 competition, Cosworth engines delivered 176 F1 wins, 13 Constructors’ Championships and 10 Drivers’ Championships. Cosworth’s results in American open-wheel racing, United States Auto Club (USAC), Championship Auto Racing Teams (CART) and the Indy Racing League (IRL), are equally impressive.

Cosworth has now diversified to be one of the premier suppliers of high quality tuning components to the performance aftermarket.

Our tuning portfolio of products and capabilities now extends throughout the vehicle, from the engine, to cooling, induction and fuel, thermal insulation, braking and filtration - with new, innovative products and extensions to ranges being added continually.

Every one of our products is engineered to Cosworth’s exacting standards and all are designed to maximise the performance of the vehicle without compromising reliability, consistency and crucially the driving experience.

Cosworth Aftermarket now design, manufacture and market an extensive range of tuning technologies for the enthusiast and motorsport professional alike including Japanese sport compact vehicles and luxury brand 4x4 vehicles.

Our involvement in motorsport and road car tuning, latterly with the Cosworth Impreza STi CS400 has allowed our customers to share our experiences through our performance tuning products.

New products and ranges are being added continuously. Please refer to www.cosworth.com Performance Tuning Components.

Big Valve Cylinder Heads 4High Performance Short Block Assemblies 6High Performance Long Block Assemblies 8Forged Pistons 10Performance Ring Sets 12Spare Piston Pins and Circlips 13Billet Crankshafts 14Stroker Engine Kits 15Forged Connecting Rods 16High Performance Cylinder Head Stud Kits 17High Performance Camshafts 18Ultra High Performance Engine Bearings 20Kevlar High Performance Timing Belts 22Intercooler Systems 23High Flow Intake Systems 26Induction 27High Flow Synthetic Air Filters 30Brake Pads 32Big Brake Upgrade Kits 35Fuel 36Oil Control 37High Performance Valve Train 40High Performance Head Gaskets 42Thermal Composite Gaskets 44Cosworth Rhino Skin - Thermal Heat Protection 45Miscellaneous 46Disclaimer 47

Contents

3

For over 40 years, Cosworth has been the leader in innovative multi-valve cylinder head design for both racing and high performance production cars. The Cosworth CNC Ported Big Valve Cylinder head range is the latest advancement. Modified from new OE cylinder head castings, substantial gas flow improvements and upgraded valve train components offer superior performance for your high performance engine.

Each original cylinder head design is carefully evaluated and tested to establish the improvements required to meet the target performance level. Hours of testing and flow bench validation are used to determine the best advanced port design yielding maximum usable power and response. However, there is more to cylinder head design than just maximum flow. It is critical that port velocity is maintained to ensure drivability and valve train components are matched to guarantee reliable performance. Once all of these factors have been tested and validated, the final port contour is digitized. Using the digitized program, we then reshape both intake and exhaust ports using a 5 axis CNC mill producing an accurate and consistent port shape every time. In addition to re-shaping and enlarging the intake and exhaust ports, most Big Valve Cylinder heads feature

CNC Ported Big Valve Cylinder HeadsPart No. Description

Subaru

KK3670 Subaru WRX STI EJ25 (2 5L) Pr 2004-2006

20001699 Subaru WRX STI EJ25 (2 5L) Pr 2007 (with air injection ports)

20004544 Subaru WRX STI EJ25 (2 5L) Pr 2008-2009 (with dual AVCS)

NiSSaN

KK3918 Nissan VQ35 (3 5L) Pr 2002-2006 (includes rev up version)

MitSubiShi

KK3672 Mitsubishi Evo V-VIII -2005 4G63 2 0 Litre

KK3852 Mitsubishi Evo IX 4G63 (2 0L) -2006 MIVEC

20005685 Mitsubishi Evo X 2008 - 4B11T (2 0L) MIVEC

OtherS

20000691 Ford Duratec, 2 0L/2 3L

CNC Ported Big Valve Cylinder Heads with CamshaftsPart No. Description

Subaru

SB8010 Subaru WRX STI EJ25 (2 5L) Pr 2004-2006 w KK3766 Camshafts (USA & MY06 Japan/Euro) Electronic Throttle

SB8012 Subaru WRX STI EJ25 (2 5L) Pr 2004-2006 w KK3920 Camshafts (Japan/Euro) Cable Throttle

20002024 Subaru WRX STI EJ25 (2 5L) Pr 2007 w KK3766 Camshafts (USA/Japan/Euro)

20002026 Subaru WRX STI EJ25 (2 5L) Pr 2007 w KK3920 Camshafts (Special Applications Only)

20010140 Subaru WRX STI EJ25 (2 5L) Pr 2008 w Dual AVCS Camshafts

Big Valve Cylinder Heads

Nissan VQ35DE

Subaru EJ25

a re-shaped combustion chamber to un-shroud the valves increasing air flow and performance. After machining, each cylinder head receives a multi-angle high performance valve job on our precision Newen® CNC valve seat cutter. Then

each cylinder head is ultrasonically cleaned, serialized and finally hand assembled with select high performance valve train components, ready to install on your engine.

4

Key Features: ■ All new OE Castings ■ Enlarged intake and exhaust ports ■ Large diameter stainless steel intake

valves ■ Large diameter inconel exhaust valves ■ Hi-rev, dual valve springs ■ Titanium retainers ■ Hardened steel spring platforms ■ Reshaped combustion chamber on

most applications ■ Flow bench proven design ■ Dynamometer tested ■ Machined Cosworth logo ■ Precision multi-angle valve job ■ Pre-assembled, ready to install ■ Machined port bore finish ■ Knife edge port divider

Mitsubishi 4B11

Precision Newen® CNC Valve Seat Machining

Cylinder head development

5

Cosworth high performance engine assemblies are the perfect basis for your high performance application. Each version has gone through countless hours of engineering and evaluation to determine the best combination of parts and build specification, ensuring maximum reliable performance. Each Cosworth high performance engine assembly starts with all new select components as the foundation of the performance build. Every block is thoroughly inspected before the cylinders are honed to perfection. We then balance the rotating assembly that includes either a new factory forged crankshaft or Cosworth billet crank along with Cosworth forged connecting rods, Cosworth tri-metal bearings and Cosworth forged pistons. The motorsport grade parts are then professionally assembled by expert engine builders in the Cosworth engine assembly facility. Each high performance engine assembly includes a complete specification sheet listing all critical dimensions along with a serialized plaque. For maximum performance, combine with a Cosworth CNC ported Big Valve Cylinder Head and camshaft set.

High Performance Short Block Assemblies

High Performance Short BlocksPart No. Description

Subaru

SB8005 Subaru STI EJ25 Short Block (2 5L)-Forged Pistons, Rods 8:2:1 cr

SB8007 Subaru STI EJ25 Short Block(2 5L)-Forged Pistons, Rods W 79mm Billet Crank 8:2:1 cr

20003486 Subaru STI EJ25 Short Block(2 5L)-Forged Pistons, Rods W 81mm Billet Crank 8:2:1 cr

20007702 Subaru STI EJ25 Short Block OE Crank 9 2:1 cr (High compression ratio)

20007697 Subaru STI EJ25 Short Block 81mm Crank 9 2:1 cr (High compression ratio)

20007703 Subaru STI EJ25 Short Block 79mm BLT Crank 9 2:1 cr (High compression ratio)

NiSSaN

20000067 Nissan VQ35 Short Block (3 5L) Lo comp 8 8:1

CI8019 Nissan VQ35 Short Block (3 5L) Hi comp 11:1

MitSubiShi

CI8015 Mitsubishi Evo VIII/IX 4G63 Short Block (2 0L)-Forged Pistons, Rods

CI8018 Mitsubishi Evo VII/IX 4G63 Short Block (2 2L)-Forged Pistons, Rods, Billet Crank

20014144 Mitsubishi Evo X 4B11T Short Block (2 2L)-Forged Pistons, Rods, Billet Crank

Subaru EJ25 High Performance Short Block 2.5/2.6L

The Cosworth EJ25 is an excellent starting point for high performance and track day applications.

■ New Subaru EJ25 STI EJ257 Block ■ New Subaru EJ25 STI Forged

Crankshaft or Cosworth Billet Crank (79 or 81mm)

■ Cosworth 79mm or 81mm Forged H-beam connecting rods

■ Cosworth Forged Pistons (99.5mm) and rings

■ Cosworth Tri-metal bearings ■ Balanced to within 0.5 gram ■ Complete blue-printed assembly ■ Ring gap set ■ Bearing clearance checked ■ Deck height checked ■ Connecting rod side clearance checked ■ Crankshaft end float checked

6

The Cosworth 4G63 2.2L stroker engine combines the perfect bore to stroke ratio, yielding potentially big gains in torque while still allowing the engine to rotate and produce power at higher RPMs.

■ New Mitsubishi 4G63 Evolution Block ■ New Cosworth Billet Crank (94mm) ■ Cosworth Forged H-beam connecting

rods ■ Cosworth Forged Pistons (86mm) and

rings ■ Cosworth Tri-metal bearings ■ Cosworth Heavy Duty main studs ■ Piston squirt jets ■ Balanced to within 0.5 gram ■ Complete blue-printed assembly ■ Ring gap set ■ Bearing clearance checked ■ Deck height checked ■ Connecting Rod side clearance checked ■ Crankshaft end float checked

Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.2L

The Cosworth VQ35DE high performance short block is the perfect foundation for your high performance application. Available in either high compression 11:1 or low compression 8.8:1 for turbo or supercharged applications.

■ New Nissan forged crankshaft (81.4mm) ■ Cosworth Forged H-beam connecting

rods ■ Cosworth Forged Pistons (95.5mm) and

rings ■ Cosworth Tri-metal bearings ■ Cosworth Heavy Duty main studs ■ Piston squirt jets

■ Balanced to within 0.5 gram ■ Complete blue-printed assembly ■ Ring gap set ■ Bearing clearance checked ■ Deck height checked ■ Connecting Rod side clearance checked ■ Crankshaft end float checked

Nissan VQ35DE (350Z-G35) High Performance Short Block 3.5L

The Cosworth 2.0L 4G63 is an excellent starting point for high performance and track day applications.

■ New Mitsubishi 4G63 Evolution Block ■ New Mitsubishi forged crankshaft

(88mm) ■ Cosworth Forged H-beam connecting

rods ■ Cosworth Forged Pistons (85mm) and

rings ■ Cosworth Tri-metal bearings ■ Cosworth Heavy Duty main studs ■ Piston squirt jets ■ Balanced to within 0.5 gram ■ Complete blue-printed assembly ■ Ring gap set ■ Bearing clearance checked ■ Deck height checked ■ Connecting Rod side clearance checked ■ Crankshaft end float checked

Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L

7

The Cosworth Subaru EJ25 CS600 series is designed for extreme track day use and the demanding performance enthusiast. Each assembly is precision built by one of Cosworth’s skilled craftsmen using the finest components from our parts catalogue to ensure maximum reliable power and performance. Starting with a new Subaru EJ257 semi closed deck block, we meticulously diamond hone each bore to guarantee perfect piston to cylinder wall clearance. The block is then assembled with our Forged Pistons, motorsport grade Forged H-Beam connecting rods along with our high performance rod and main bearings and a new STI forged crankshaft. For maximum performance, an optional steel billet crank is available (CS600X). Once the cylinder block assembly is completed, we install a pair of our CNC machine port-bored Big Valve Cylinder heads with our proven “S2” camshafts complete with valve lash set to our specifications. The cylinder heads are secured with our high performance 11mm steel studs and sealed with a Cosworth high performance stopper layer steel head gasket. Finally, we install one of our blue-printed, high pressure oil pumps for maximum lubrication. This proven engine combination has been used by top teams to win race and rally events in both North America, Asia and Europe.

High Performance Long Block Assemblies

High Performance Long Block AssembliesPart No. Description

Subaru - NOrth aMericaN SPec 2004-2006 eJ25 “cS600 & cS600X”

20000161 Subaru EJ25 (2 5L) 2004-2006 w/ Big Valve Cylinder heads and KK3766 Cams-STD Crank 8 2:1cr

20000162 Subaru EJ25 (2 5L) 2004-2006 w/ Big Valve Cylinder heads and KK3766 Cams-Billet Crank 8 2:1cr

20003488 Subaru EJ25 (2 6L) 2004-06 w/ Big Valve Cylinder heads and KK3766 Cams-81mm Crank 8 2:1cr

20007711 Subaru EJ25 (2 6L) 2004-06 w/ Big Valve Cylinder heads and KK3766 Cams-81mm Crank 9 2:1cr

Subaru - NOrth aMericaN SPec 2007 eJ25 “cS600 & cS600X”

20002504 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-STD Crankshaft 8 2:1cr

20002503 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-Billet Crankshaft 8 2:1cr

20007706 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-STD Crank 9 2:1cr

20007705 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-Billet Crank 9 2:1cr

20007710 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-STD Crankshaft 9 2:1cr

20007709 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-Billet Crankshaft 9 2:1cr

20003489 Subaru EJ25 (2 6L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-81mm Crank 8 2:1cr

20007712 Subaru EJ25 (2 6L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-81mm Crank 9 2:1cr

Subaru - eurOPeaN/aSia SPec eJ25 iMPreza 2004-2006 eJ25 “cS600 & cS600X” - iNcluDeS eNgiNe aSSeMbly with cyliNDer heaDS, caMShaftS, Oil PuMP aND caM cOverS

SB8008 Subaru EJ25 (2 5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-STD Crank 8 2:1cr

20007707 Subaru EJ25 (2 5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-STD Crank 9 2:1cr

20003490 Subaru EJ25 (2 6L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Cams 81mm Billet Crank 8 2:1cr

20007708 Subaru EJ25 (2 5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-Billet Crank 9 2:1cr

20000160 Subaru EJ25 (2 5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-Billet Crank 8 2:1cr

Includes engine assembly with cylinder heads, camshafts, oil pump and cam covers

8

Subaru Engine Testing

Features ■ New Subaru EJ25 STI Engine case ■ New Subaru EJ25 STI Forged

Crankshaft ■ Optional Cosworth Billet Crankshaft

(79/81mm stroke available) ■ Cosworth forged H-beam Connecting

rods ■ Cosworth Forged Pistons and rings ■ Cosworth motorsport Tri-metal bearings ■ Balanced to within 0.5 gram ■ Complete blue-printed assembly ■ Enlarged intake and exhaust ports ■ Large diameter stainless steel intake

valves ■ Large diameter inconel exhaust valves ■ Hi-rev, dual valve springs ■ Titanium retainers ■ Hardened steel spring platforms ■ Multi angle valve job ■ CNC machined port finish ■ Knife edge port divider ■ Cosworth S2 High lift camshafts ■ Valve lash set ■ Cosworth high pressure oil pump ■ Cam covers ■ Cosworth serial number

High Performance Long Block AssembliesPart No. Description

Subaru - iMPreza 2007 Sti eJ25 “cS600 & cS600X”

20002504 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-STD Crank 8 2:1cr

20002503 Subaru EJ25 (2 5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-Billet Crank 8 2:1cr

20003489 Subaru EJ25 (2 6L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams 81mm Billet Crank 8 2:1cr

20007713 Subaru EJ25 (2 6L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams 81mm Billet Crank 9 2:1cr

Subaru iMPreza 2008+ Sti eJ25 “cS600 & cS600X”

20010271 Subaru EJ25 (2 5L) 2008-09 Big Valve heads & 20007395 Camshafts- 79mm STD Crankshaft 8:2:1 cr

20010272 Subaru EJ25 (2 5L) 2008-09 Big Valve heads & 20007395 Camshafts-79mm Billet Crankshaft 8:2:1 cr

20010273 Subaru EJ25 (2 5L) 2008-09 Big Valve heads & 20007395 Camshaft -79mm STD Crankshaft 9 2:1 cr

20010274 Subaru EJ25 (2 5L) 2008-09 Big Valve heads & 20007395 Camshafts - 79mm Billet Crankshaft 9 2:1 cr

20010275 Subaru EJ25 (2 6L) 2008-09 Big Valve heads & 20007395 Camshafts- 81mm Billet Crankshaft 8:2:1cr

20010276 Subaru EJ25 (2 6L) 2008-09 Big Valve heads & 20007395 Camshafts- 81mm Billet Crankshaft 9:2:1cr

9

Subaru EJ25Mitsubishi 4G63Subaru EJ25, 9 2:1

Forged Piston Sets (Includes pistons, rings, pins and clips)

Part No. DescriptionSubaru

10001430 Subaru WRX STI EJ25 (2 5L) 99 5mm 8 2:1cr


10001432 Subaru WRX STI EJ25 (2 5L) 100 mm 8 2:1cr

10001445 Subaru WRX EJ20 (2 0L) 92 mm 8 0:1cr

10001446 Subaru WRX EJ20 (2 0L) 92 5mm 8 0:1cr

10001447 Subaru WRX EJ20 (2 0L) 93mm 8 0:1cr

10001433 Subaru WRX STI EJ25 (2 6L) 99 5mm 8 2:1cr (For use with 81mm crankshaft)


10001435 Subaru WRX STI EJ25 (2 6L) 100 mm 8 2:1cr (For use with 81mm crankshaft)

10001442 Subaru WRX EJ20 (2 2L) 92 mm 8 0:1cr (For use with 79mm crankshaft)

10001443 Subaru WRX EJ20 (2 2L) 92 25mm 8 0:1cr (For use with 79mm crankshaft)

10001444 Subaru WRX EJ20 (2 2L) 92 5mm 8 0:1cr (For use with 79mm crankshaft)


With 50 years of world class engine design and manufacturing experience, Cosworth’s intimate knowledge of the interaction between the piston and other engine components gives the us the distinct advantage in piston design resulting in the finest piston available.

The piston is one of the most important components within the engine. It can be subjected to directional change up to 285 times every second and must withstand acceleration forces of 8,500 Gs. Cosworth high performance forged pistons are designed and engineered to withstand this type of punishment and still perform. All Cosworth pistons are manufactured using the same methods as our Formula One pistons and include features such as anti-scuff skirt coating, ultra-strong pins, polished top and patented anti-detonation bands. Additionally, each application uses a unique forging to minimize weight and ensure the strongest possible piston.

Forged Pistons

Anti-detonation bands

Optimised forging

Xylan skirt coating

Polished crown

Features & Benefits: ■ Skirt profile & oval technology - reduces engine noise, increases life & performance ■ F1 quality forgings - proprietary CosAl 010 for high stress applications ■ Oil and combustion gas control features - reduced blow-by and oil consumption ■ Offset pin bores - for reduced engine noise

Continued ->

10

Features Include: ■ Unique forgings for each application ■ ‘Xylan’ anti scuff skirt coating ■ Polished tops (reduces carbon build up

and relieves stress) ■ Manufactured from proprietary alloy

(CosAl 010) ■ Ultra strong pin ■ Patented anti-detonation bands ■ Supplied with full ring pack

Nissan VQ35 High Compression

Cosworth Tech: Green PistonsXylan is a fluoropolymer coating designed for use on various engine components and fasteners Cosworth pistons use xylan coating to provide lubrication and control friction, wear resistance, heat resistance, nonstick and release properties and, at the same time, can also protect from corrosion This is the same coating we use on many of our ultra-high performance race engines

Forged Piston Sets (Includes pistons, rings, pins and clips)

Part No. Description


10001438 Subaru WRX STI EJ25 (2 5L) 100 mm 9 2:1cr



10001441 Subaru WRX STI EJ25 (2 6L) 100 mm 9 2:1cr (For use with 81mm crankshaft)

NiSSaN

10001466 Nissan VQ35 (3 5L) High CR 95 5mm 11 0:1cr (Left and right hand bank)

10001467 Nissan VQ35 (3 5L) High CR 96 mm 11 0:1cr (Left and right hand bank)

10001468 Nissan VQ35 (3 5L) Low CR 95 5mm 8 8:1cr (Turbo application)

10001469 Nissan VQ35 (3 5L) Low CR 96 mm 8 8:1cr (Turbo application)

10001470 Nissan SR20DET 86mm 8 5:1cr

10001471 Nissan SR20DET 86 5mm 8 5:1cr

TBA Nissan RB26DETT 86 5mm 8 5:1cr-Stroker

TBA Nissan RB26DETT 87 mm 8 5:1cr-Stroker

TBA Nissan RB26DETT 87 5mm 8 5:1cr-Stroker

20023158 Nissan VR38DETT 95 5mm 9 0:1cr

MitSubiShi

10001448 Mitsubishi Evo IV-IX 4G63 (2 0L) 85mm 8 8:1cr

10001449 Mitsubishi Evo IV-IX 4G63 (2 0L) 85 5mm 8 8:1cr

10001450 Mitsubishi Evo IV-IX 4G63 (2 0L) 86mm 8 8:1cr

10001451 Mitsubishi Evo IV-IX 4G63 (2 2L) 85mm 8 8:1cr use with 94mm crank (PA2701+100)

10001452 Mitsubishi Evo IV-IX 4G63 (2 2L) 85 5mm 8 8:1cr use with 94mm crank (PA2701+100)

10001453 Mitsubishi Evo IV-IX 4G63 (2 2L) 86mm 8 8:1cr use with 94mm crank (PA2701+100)

10001454 Mitsubishi 4B11T (2 0L) 86mm 9 2:1cr

10001455 Mitsubishi 4B11T (2 0L) 86 5mm 9 2:1cr

10001456 Mitsubishi 4B11T (2 0L) 87mm 9 2:1cr

10001457 Mitsubishi 4B11T (2 2L) 86mm 9 2:1cr Stroker for use with 94mm crankshaft

10001458 Mitsubishi 4B11T (2 2L) 86 5mm 9 2:1cr Stroker for use with 94mm crankshaft

10001459 Mitsubishi 4B11T (2 2L) 87mm 9 2:1cr Stroker for use with 94mm crankshaft

10001460 Mitsubishi 4B11T (2 2L) 86mm 10:1cr Stroker for use with 94mm crankshaft

10001461 Mitsubishi 4B11T (2 2L) 86 5mm 10:1cr Stroker for use with 94mm crankshaft

10001462 Mitsubishi 4B11T (2 2L) 87mm 10:1cr Stroker for use with 94mm crankshaft

hONDa

10001463 Honda K20A 86mm 12:1cr

10001464 Honda K20A 86 25mm 12:1cr

10001465 Honda K20A 86 5mm 12:1cr

20006695 Honda K20A 86mm 9:1cr (for forced induction applications)

20006696 Honda K20A 86 5mm 9:1cr (for forced induction applications)

20006697 Honda K20A 87mm 9:1cr (for forced induction applications)

tOyOta

TBA Toyota 2JZ-GTE 87mm 8 5:1cr

11

Cosworth Tech: Ring SetsCosworth Performance Ring Sets are comprised of a chrome top ring, an iron second ring, and three-piece oil ring Some Cosworth Performance Ring Sets offer upper rings that are gas nitride treated for quicker break-in, lower wear, and improved sealing Manufacturing tolerances exceed OEM standards Axial tolerance is +/- 0 0002” and radial tolerance is +/- 0 0005”

Performance Ring Sets for Cosworth PistonsPart No. Description

Subaru

20001515 Subaru WRX STI EJ25 (2 5L) 99 5mm

20001516 Subaru WRX STI EJ25 (2 5L) 99 75mm

20001517 Subaru WRX STI EJ25 (2 5L) 100 mm

20005160 Subaru WRX EJ20 (2 0L) 92 mm

20005161 Subaru WRX EJ20 (2 0L) 92 5mm

20003605 Subaru WRX EJ20 (2 0L) 92 mm (Use with Stroker pistons 20002489/ 20003685)

20003607 Subaru WRX EJ20 (2 0L) 92 5mm (Use with Stroker pistons 20002491/ 20003687)

NiSSaN

20001512 Nissan VQ35 (3 5L) 95 5mm

20001514 Nissan VQ35 (3 5L) 96 mm

MitSubiShi

PR7317 Mitsubishi Evo 4G63 (2 0L) 85mm

20002246 Mitsubishi Evo 4G63/4B11 86mm

20005705 Mitsubishi Evo 4B11 86 5mm

20005706 Mitsubishi Evo 4B11 87mm

tOOl

20008832 Tool -85 00Mm Ring Compressor













Performance Ring Sets

Developed using the latest technologies, and highest quality materials, Cosworth Performance Ring Sets are designed to meet the demands of modern high performance engines for higher power output, improved sealing, lower friction, and longer life.

Piston Ring Compressor

Cosworth Cylindrical Ring Compressors are precision machined to exact tolerance to ensure easy piston installation on most engines. They feature a smooth, tapered bore along with a knurled top ring to securely hold it in place while installing the piston. Each tool is machined form high grade aluminium and features a hard anodised finish.

12

Spare Piston Pins and Circlips

Spare Piston Pins and CirclipsPart No. Description

PA2674 23mm Pin, Subaru EJ20 / EJ25 Piston

PA1846 22mm Pin, Mitsubishi 4G63 Piston

PA1251 22mm Pin, Nissan VQ Piston

PP5433 Circlip, 23mm Subaru EJ20 / EJ25 Piston 2 req per piston

PP2371 Circlip, 22mm Nissan / Mitsubishi Piston 2 req per piston

SB8004 Circlip install tool, Subaru

Cosworth Pistons feature heavy duty, ultra strong piston pins designed for the higher stress and elevated load levels found in high performance engines. Spare parts are available for routine engine rebuilds.

For ease of circlip installation on Subaru engines, we offer an exclusive installation tool engineered to simplify the task. This high quality tool is machined from steel to ensure years of trouble free use.

13

ISF® - ISF is a registered trademark of REM Chemical Inc All Rights Reserved

Cosworth Tech: Isotropic Super Finish (ISF®)The ISF® process is a chemically accelerated vibratory mass finishing process Any time two metal parts come into contact with each other, the resulting friction causes heat build up These high temperatures cause wear and over time reduce efficiency and eventually create the need for replacement By creating a smooth and shiny finish, the ISF®

process improves the life and efficiency of moving metal parts Increased life translates into lower operating costs as well as better performance In extreme environments, such as automobile or motorcycle racing, every component must work in harmony at 100% capacity Races are won and lost by fractions of a second, so it all comes down to getting

the most power output possible With the ISF® process, the energy normally lost to friction is now available in the form of increased power output Once friction is reduced, the engine will run cooler allowing for longer durability of parts and fewer failures

Increased engine performance often means increased engine speed and load. Original factory crankshafts may not be able to withstand the added stress, resulting in catastrophic engine failure. Additionally, many OE crankshafts rod journals are lubricated from only one main oil feed. Cosworth billet crankshafts feature full-flow oiling whereby each rod journal is lubricated from two main sources. This provides superior lubrication during sustained high rpm use preventing rod bearing failure. Cosworth Subaru crankshafts are manufactured entirely from high grade steel in a light-weight, high strength design with a unique Isotropic Super Finish (ISF®).

Features Include: ■ Superior lubrication ■ Profiled counterweights ■ High strength ■ Light weight

Billet CrankshaftsPart No. Description

MitSubiShi

20004138 Mitsubishi EVO 4G63 (2 2L conversion) 94mm stroke - Fully counter-weighted Billet Steel, F1 Rod Bearing type (must use with Cosworth connecting rod 20020201)

20006577 Mitsubishi EVO 4B11T (2 2L conversion) 94mm stroke - Fully counter-weighted Billet Steel

20002315 Subaru WRX STI EJ25 (2 5L) 79mm stroke - Light weight version Billet Steel

20002316 Subaru WRX STI EJ25 (2 5L) 81mm stroke - Light weight version Billet Steel

Billet Crankshafts

■ Allows a freer movement of parts with less surface resistance

■ Extends life of parts and reduces risk of part failure during operation

■ Reduces maintenance expenses and fuel costs

■ Improves oil shedding ■ Increases power output resulting in

increased speed

14

Mitsubishi 4G63 (Evolution VII-IX) 2.2L ■ Cosworth Forged Pistons (86mm) ■ Cosworth Fully Counterweighted Billet

Crankshaft (94mm) ■ Forged Cosworth Connecting Rods ■ Cosworth Rod and Main Bearings ■ Cosworth Piston Rings

Mitsubishi 4B11T (Evolution X) 2.2L ■ Cosworth Forged Pistons (86mm) ■ Cosworth Fully Counterweighted Billet


Subaru EJ25 2.6L ■ Cosworth Forged Pistons (99.5mm) ■ Cosworth Fully Counterweighted Billet


Stroker KitsPart No. Description

MitSubiShi

KK3831 Mitsubishi Evo 4G63 (2 2L) - 94mm Crank

20007783 Mitsubishi Evo 4B11T (2 2L) - 94mm Crank

Subaru

20002500 Subaru EJ25 (2 6L) w 81mm Billet Crankshaft

20002501 Subaru EJ20 (2 2L) w 79mm Forged Crankshaft (92mm Pistons)

20004359 Subaru EJ20 (2 2L) w 79mm Forged Crankshaft (92 5mm Pistons)

20002502 Subaru EJ20 (2 2L) w 79mm Billet Crankshaft (92mm Pistons)

Stroker Engine Kits

Cosworth stroker kits are the perfect way to add displacement, torque and power to your engine. Each kit includes select matched components from our parts list ensuring reliable performance.

15

The connecting rod is the vital link between the piston and power. When engine output is increased, the demands placed on the connecting rod increase as well. To ensure engine reliability in all conditions, original connecting rods should be replaced with heavy duty specification parts. Cosworth Forged Connecting Rods are manufactured from high strength 4340 (EN24) steel and machined to exacting tolerances.

Features: ■ Rods include genuine Cosworth H11

tool steel rod bolts (260,000psi). ■ Proprietary forging made in the USA. ■ Detailed machined work to maintain

optimum weight and strength. ■ Solid beam design for high power

applications ■ “Radial Truss” small end for superior

strength and reduced reciprocating mass

■ Manufactured from 4340 (EN24) steel

Forged Connecting Rods

Part No. Description ctr. to ctr. (mm)

P.e. bore (mm)

b.e. bore (mm)

total Nominal

weight (g)Subaru

20002587 Subaru WRX STI EJ20 (2 0L) set of four 130 48 23 03 55 01 530

MitSubiShi

20002632 Mitsubishi Evo 4G63 (2 0L) set of four 150 01 22 03 48 00 568

20015908 Mitsubishi Evo 4G63 (2 2L) set of four for use with Cosworth crankshaft 20004138 150 01 22 03 52 89 565

20002596 Mitsubishi 4B11T (2 0L) set of four 143 74 23 03 55 01 565

20007184 Mitsubishi 4B11T (2 2L) 94mm Stroker Rod set of four 142 72 21 03 55 01 556

NiSSaN

20002585 Nissan VQ35 (3 5L) set of six 144 17 22 03 55 01 547

20007115 Nissan VQ35 (3 8L) Stroker Rod set of six 141 71 22 03 55 01 538

20002588 Nissan RB26 (2 6L) set of six 121 51 21 02 51 02 507

20002589 Nissan SR20 (2 0L) set of four 136 30 22 03 51 02 564

20011563 Nissan VR38 (3 8L) set of six 164 99 23 03 59 00 629

hONDa

20002590 Honda K20 (2 0L) set of four H-Beam 139 03 22 03 51 02 430

Forged Connecting Rods

16

High Performance Cylinder Head Stud Kits

Ultra High Performance Head Stud Kits (260,000psi tensile strength)


20002440 Subaru WRX STI EJ25/EJ20 (2 5L) 11mm

20002442 Mitsubishi Evo 4G63 (2 0L) 11mm

20006025 Mitsubishi Evo X 4B11T Head Stud Kit

20002444 Nissan SR20DET (2 0L) 11mm

Essential for high performance engine builds, heavy duty head studs reduce cylinder head movement in high boost or high compression engines optimising cylinder head to block sealing. Cosworth Ultra High Performance Head Studs are manufactured from H11 tool steel with 260,000psi tensile strength and come complete with nuts and washers. Manufactured with hex broach end for ease of installation.

Additionally, genuine Cosworth head studs utilize a base seating feature to evenly distribute maximum load on the stud and not the threads. This feature is typically found only in high level race engines.

Features: ■ Essential for high power applications ■ Superior strength compared to other

brands ■ High clamping force helps to seal block

to cylinder head joint ■ Hex broach ends ease installation ■ Roll die formed threads ■ 260,000psi+ tensile strength ■ Special heat treat process includes

heating in vacuum sealed furnace and quenched in a nitrogen chamber for precision control

High Performance Cylinder Head Stud Kits (180,000psi tensile strength)


PR7243 Subaru WRX STI EJ25/EJ20 (2 5L) 11mm

PR7420 Nissan VQ35 (3 5L)

PR7767 Nissan SR20DET (2 0L)

PR7843 Mitsubishi Evo 4G63 (2 0L)

PR7422 BMW MINI Cooper/Cooper S (1 6L)

17

Cosworth has been engineering camshafts for nearly 50 years. That coupled with years of innovative multi valve cylinder head design ensures our camshaft designs are the most efficient in providing maximum usable power across the widest power band.

Each cam is ground from a new blank and finished using the same procedures we use in our extreme level race engines. Cosworth camshafts are the perfect compliment to our CNC Ported Big Valve Cylinder Heads. Our cams are profiled to increase boost response thereby increasing engine torque and power and are fully compatible with our CNC Ported Big Valve Cylinder Heads.

Performance CamshaftsPart No. Description Specification

Subaru

KK3766 Subaru WRX STI EJ25 (2 5L) Set of four (AVCS Type) S2 Grind (Electronic throttle) - North American spec

Int "278" deg 10 7mm lift / Exh "274" deg 10 mm lift

KK3765Subaru WRX EJ20 (2 0L) Set of four 9/99 - 8/05 non AVCS JDM EJ205 ~ 9/01 - 8/05 non AVCS USDM WRX EJ205 engines - Euro/Asian spec

"272" deg 10mm lift

KK3920 Subaru WRX STI EJ25/EJ20 Set of four (AVCS Type) S2 Grind (Cable throttle) - Japan / European spec


20007395 Subaru WRX STI EJ257B Set of four (Dual AVCS) S2D Grind - North American , Asian and European spec


20005187 Subaru WRX EJ20 (2 0L) Set of four Compatible with GC8 Version IV (09/1997) - Euro/Asian spec "270" deg 10 4mm lift

KK3814 Subaru WRX STI EJ25 (2 5L) Set of four (AVCS Type) North American spec - North American spec

Int ”260” deg 9 6mm lift / Exh “260” deg 9 6mm lift

MitSubiShi

KK3805 Mitsubishi Evo 4G63 (2 0L) Pr (1 intake and 1 exhaust cam) M1 Grind "264" deg 10 2 mm lift

KK3806 Mitsubishi Evo 4G63 (2 0L) Pr (1 intake and 1 exhaust cam) M2 Grind "272" deg 11 mm lift

20002513 Mitsubishi Evo 4G63 (2 0L) Pr (1 intake and 1 exhaust cam) M3 Grind Intake"280" deg 11 6mm / Exhaust "272" deg 11mm lift

KK3921 Mitsubishi Evo IX 4G63 (2 0L) Pr (1 intake and 1 exhaust cam) M2 Grind

MIVEC Intake/Exhaust "272" deg 11 mm lift

20002517 Mitsubishi Evo IX 4G63 (2 0L) Pr (1 intake and 1 exhaust cam) M3 Grind

MIVEC Intake "280" deg 11 6mm lift / Exhaust "272" deg 11 mm lift

20004124 Mitsubishi Evo X 4B11 (2 0L) Pr (1 intake and 1 exhaust cam) MX1 Grind

MIVEC Intake "266" deg 10 8mm / Exhaust "266" deg 10 4mm lift

MitSubiShi “Swb” race caMShaftS

20002698 Mitsubishi Evo 4G63 (2 0L) "280" Intake cam 280 deg / 11 6 mm

20016008 Mitsubishi Evo 4G63 (2 0L) "290" Intake cam 290 deg / 11 6 mm

20004722 Mitsubishi Evo IX 4G63 MIVEC (2 0L) "280" Intake cam 280 deg / 11 6 mm

20016009 Mitsubishi Evo IX 4G63 MIVEC (2 0L) "290" Intake cam 290 deg / 11 6 mm

20016006 Mitsubishi Evo 4-9 4G63 (2 0L) "280" Exhaust cam 280 deg / 11 6 mm

20016007 Mitsubishi Evo 4-9 4G63 (2 0L) "290" Exhaust cam 290 deg / 11 6 mm

NiSSaN

20002507 Nissan VQ35 "287hp" Set (2 intake and 2 Exhaust cams) "ZK1" Grind Intake "268" deg 10 4mm lift / Exhaust "268" deg 9 5mm lift

20002508 Nissan VQ35 “287hp” Set (2 intake and 2 Exhaust cams) “ZK2” Grind Intake “270” deg 10 65mm lift / Exhaust “270” deg 10 65mm lift

20002510 Nissan VQ35 “Rev up” Set (2 intake and 2 Exhaust cams) “ZK1” Grind Intake “268” deg 10 4mm lift / Exhaust “268” deg 9 5mm lift

20002511 Nissan VQ35 “Rev up” Set (2 intake and 2 Exhaust cams) “ZK2” Grind Intake “270” deg 10 65mm lift / Exhaust “270” deg 10 65mm lift

High Performance Camshafts

Cosworth Tech - Subaru CamsOur Subaru AVCS cams are available for both North American and Japanese/European applications. While cam profiles are the same, cam angle triggers are significantly different AVCS camshafts for North American applications use a series of three slots to activate the cam angle sensor Japanese/European applications rely on four raised triggers to activate the sensor If in doubt, check your original cams before ordering

North American Japanese/European

18

Features Include: ■ Ground from new blanks ■ Engineered and tested profiles ■ Broad power band ■ Compatible with Cosworth CNC ported

Big Valve Cylinder Heads

Subaru AVCS

Mitsubishi 4B11T

Nissan VQ35

Mitsubishi EVO 4G63 Mivec

Subaru WRX STi EJ257B

19

Engine bearings are one of the most vital components within an engine and are often overlooked when considering high performance upgrades Performance engineered, multi-layer bearings generate less heat than normal bearings by reducing friction Cosworth race bearing sets feature unique combinations of design, metallurgy and engineering to deliver performance in extreme conditions Cosworth race bearings sets are available in three sizes to accommodate most applications

Ultra High Performance Engine Bearings

High Performance Engine BearingsPart No. Description Specification

Subaru eJ25 / eJ20

20002720 Subaru WRX/STI EJ25/ EJ20 Main Bearing Set - Tri Metal Size 0

20002721 Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal Size 0

PR7940 Subaru WRX/STI EJ25/ EJ20 Main Bearing Set - Tri Metal Size 1

PR7889 Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal Size 1

SB0006 Subaru WRX/ STI EJ25/EJ20 Main Bearing Set - Tri Metal Size 2

SB0007 Subaru WRX/STI EJ25/EJ20 Rod Bearing Set - Tri Metal Size 2

MitSubiShi evO 4g63 “evO” 1992-2006

20002723 Mitsubishi Evo 4G63 (2 0L) Main Bearing Set - Tri Metal Size 0

20002722 Mitsubishi Evo 4G63 (2 0L) Rod Bearing Set - Tri Metal Size 0

PR7894 Mitsubishi Evo 4G63 (2 0L) Main Bearing Set - Tri Metal Size 1

PR7893 Mitsubishi Evo 4G63 (2 0L) Rod Bearing Set - Tri Metal Size 1

PR7427 Mitsubishi Evo 4G63 (2 0L) Main Bearing Set - Tri Metal Size 2

PR7428 Mitsubishi Evo 4G63 (2 0L) Rod Bearing Set - Tri Metal Size 2

PR7429 Mitsubishi Evo 4G63 (2 0L) Thrust Bearing set

MitSubiShi 4b11t evO X

20007172 Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal Size 0

20007175 Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal Size 0





20007178 Mitsubishi Evo X 4B11T Thrust Bearing Set

NiSSaN vg35De

20002725 Nissan VQ35 (3 5L) Main Bearing Set - Tri Metal Size 0

20002724 Nissan VQ35 (3 5L) Rod Bearing Set - Tri Metal Size 0

PR7911 Nissan VQ35 (3 5L) Main Bearing Set - Tri Metal Size 1

PR7910 Nissan VQ35 (3 5L) Rod Bearing Set - Tri Metal Size 1

PR7853 Nissan VQ35 (3 5L) Main Bearing Set - Tri Metal Size 2

PR7854 Nissan VQ35 (3 5L) Rod Bearing Set - Tri Metal Size 2

PR7859 Nissan VQ35 (3 5L) Thrust Bearing Set

engineered with the following features: ■ High strength overlay plate with

reduced thickness for better oil control and less friction

■ Hardened steel backing on all connecting rod bearings

■ Increased crush for better retention ■ 3/4 grooving on main bearings

providing optimum oil supply ■ Tight consistent wall tolerances ■ Oversize chamfers where applicable ■ Flash plating eliminated for improved

heat transfer ■ Tested to over 1000 horsepower!

20

Our bearings are available in 3 sizes: 0 , 1, 2. We do not offer undersized bearings for ground crankshafts.

■ Size 1 is what we used to call “STD” ■ Size 2 is what we used to call “RACE” ■ Size 0 provides .025mm or .001” less oil

clearance than our size 1 bearing ■ Size 2 provides .025mm or .001” more

oil clearance than our size 1 bearing

Bearing half shells can be mixed and match to provide the incremental changes in oil clearance However it is imperative that bearing clearances are measured before selecting the appropriate bearing size.

High Performance Engine BearingsPart No. Description Specification

NiSSaN Sr20Det (eXcePt rNN14 PulSar gti-r)

20002727 Nissan SR20 (2 0L) Main Bearing Set - Tri Metal Size 0

20002726 Nissan SR20 (2 0L) Rod Bearing Set - Tri Metal Size 0

PR7896 Nissan SR20 (2 0L) Main Bearing Set - Tri Metal Size 1

PR7895 Nissan SR20 (2 0L) Rod Bearing Set - Tri Metal Size 1

PR7851 Nissan SR20 (2 0L) Main Bearing Set - Tri Metal Size 2

PR7852 Nissan SR20 (2 0L) Rod Bearing Set - Tri Metal Size 2

PR7937 Nissan SR20 (2 0L) Thrust Bearing Set

NiSSaN rb25/26

20002729 Nissan RB25/26 Main Bearing Set - Tri Metal Size 0

20002728 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 0

PR7892 Nissan RB25/26 Main Bearing Set - Tri Metal Size 1

PR7891 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 1

PR7655 Nissan RB25/26 Main Bearing Set - Tri Metal Size 2

PR7656 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 2

hONDa K20/K23/K24 (eXcePt a3)

20002731 Honda K20 (2 0L) Main Bearing Set - Tri Metal Size 0

20002730 Honda K20 (2 0L) Rod Bearing Set - Tri Metal Size 0

PR7914 Honda K20 (2 0L) Main Bearing Set - Tri Metal Size 1

PR7912 Honda K20 (2 0L) Rod Bearing Set - Tri Metal Size 1

PR7915 Honda K20 (2 0L) Main Bearing Set - Tri Metal Size 2

PR7913 Honda K20 (2 0L) Rod Bearing Set - Tri Metal Size 2

PR7916 Honda K20 (2 0L) Thrust Bearing Set

21

Cosworth Kevlar High Performance Timing belts are 300% stronger than original equipment timing belts and are the perfect compliment when installing Cosworth camshafts or cylinder heads.

■ High saturation HNBR elastomeric composites ensure durability and heat resistance

■ Durable nylon fibre provides extra wear resistance and increased tooth strength

■ Kevlar backing improves strength

Cosworth Kevlar High Performance Timing BeltsPart No. Description

20004950 Timing Belt – Mitsubishi 4G63 Heavy Duty, All

20004952 Balance Belt - Mitsubishi 4G63 Heavy Duty, All

20004953 Timing Belt – Subaru EJ20/25 Heavy Duty, All

20019487 Timing Belt - Nissan Skyline RB25/26

Kevlar High Performance Timing Belts

22

Large diameter aluminium tubing

Large efficient intercooler core

Intercooler Systems

Subaru front-mount Intercooler System 2008+ STI - 20005378

Front mounted intercoolers offer improved performance potential for Subaru applications. The Cosworth front mount intercooler for the 2008+ Subaru STI replaces the restrictive, heat-soak prone original top mounted core. The engineered system features an efficient large aluminium core with mandrel bent aluminium tubing for maximum performance up to and exceeding 600hp. The intercooler core is rubber mounted on a secure bracket system to help eliminate cracking and breakage.

Installation is simplified as no cutting of vehicle is required

Features ■ Large efficient core available in anodised

black finish for subtle appearance ■ Large diameter mandrel bent aluminium

tubing with grey powder coated finish ■ 4-ply heavy duty silicone coupling hoses ■ Isolated mounting system ■ Liner hose clamps

CAD Assembly

Intercooler UpgradePart No. Description

20014525 Mitsubishi EVO X Front Mount Intercooler (Uses factory piping)

20019677 Mitsubishi EVO X Intercooler Hard Pipe Kit

20005378 Subaru STI 2008+ Front Mount Intercooler System

23

Robust mounting system

Features ■ Smooth transition cast aluminium end

tanks for optimum airflow. Purposeful airflow management without the compromises of fabricated sheet metal end tanks.

■ Large, efficient intercooler core ensure low restriction and high-efficiency heat transfer.

■ Easy installation - under 30 minutes with simple hand tools, no modification to car needed

■ Heavy duty steel brackets with rubber isolated mounting

■ 4-ply heavy duty silicone couplers with liner hose clamps

■ Made in USA ■ Core size: 20” x 12.3” x 3.5” ■ 55% increased flow over the factory OE

intercooler ■ Optional large-diameter hard intercooler

pipe kit - Part number 20019677

Mitsubishi EVO X Front Mount Intercooler Upgrade - PN 20014525

The Cosworth front mount intercooler for 2008 and newer Mitsubishi Evolution X features cast end tanks and an efficient large core to ensure maximum charge air cooling capability. Steel brackets with rubber vibration isolators for optimal resistance to the fatigue failure common with hard mounted aluminium brackets. Installation does not require any vehicle modifications.

24

EVO X Intercooler Pipe Upgrade Kit - PN 20019677

The Cosworth Intercooler Pipe Upgrade for the Mitsubishi EVO X features large diameter single piece mandrel bent aluminium tubes with 4-ply silicone couplers and stainless steel liner type hose clamps and is designed to decrease turbo lag and increase power in your Mitsubishi Evolution X.

The mounting location of the bypass valve has been optimised for reduced turbocharger lag and is compatible with both the original component and many aftermarket versions.

Engineered to work with the factory intercooler or Cosworth intercooler kit (Cosworth part # 20014525) but may be compatible with other brands.

Features ■ Bright Silver, durable powder coated

finish ■ Relocated bypass valve for reduced

turbocharger lag ■ 2.5” / 63.5mm diameter tubing (hot side) ■ 2.75” / 69.85mm diameter tubing (cold

side) ■ 4-ply silicone couplers ■ Robust mounting system

25

High Flow Intake SystemsPart No. Description

20019421 2001-2007 Subaru Impreza WRX, 2004-2007 Subaru Impreza WRX STI

20019422 2008-2010 Subaru Impreza WRX

20019423 2008-2010 Subaru Impreza WRX STI

20019424 2008-2010 Mitsubishi Lancer EVO X

High Flow Intake Systems

Cosworth’s High Flow Intake Systems feature increased diameter, large smooth radius bent aluminium inlet tubes for superior air flow management coupled with a high flow air filter for maximum air flow and performance.

Each kit includes an integrated heat shield designed to isolate the air intake from engine heat - delivering cold air into the engine for superior power conversion. The filter element is large, conical in shape and engineered to dramatically reduce intake restriction resulting in additional power and torque.

Up to 15% More Performance ■ Lightweight aluminium mandrel shaped

inlet tube for maximum airflow ■ Conical Cosworth blue cotton gauze

cleanable air filter with Cosworth embossed dry carbon composite end cap

■ Integrated heat shield for cold air isolation

■ Hardware kit included for easy, perfect fit ■ Made in USA

26

Induction

VQ35 Twin Plenum Intake Manifold - PN 20000063

The Cosworth Twin Plenum Inlet Manifold for the Nissan VQ35DE has been designed to enhance mid-range and high RPM power. It features increased plenum volume for improved high RPM power while torque enhancing velocity stacks improve mid-range power. With performance derived from countless hours of development including computational fluid dynamics, the Cosworth Twin Plenum Inlet Manifold is perfect for both normally aspirated and forced induction applications. Cast from lightweight aluminium alloy with carbon fibre end caps and includes all required mounting hardware. Will fit with original strut tower brace. Can be used with the factory fuel rail system or the Cosworth High Volume Fuel Rail kit.

Mitsubishi 4B11T Intake Manifold

The Cosworth Intake Manifold for the 4B11T engine is designed for high performance and maximum horsepower and torque. The design has been

engineered top Cosworth’s high standards of excellence and has been tested for maximum performance as well as durability. This intake manifold features a significantly

larger plenum volume and larger tapered runners with airhorn inlets for improved airflow. The Cosworth manifold is designed with stock throttle body location.

High-polished finish optional

InductionPart No. Description

NiSSaN

20000063 Nissan VQ35DE (3 5L) Twin Plenum Intake Manifold with Carbon plenum covers

20005779 Nissan VQ35DE (3 5L) Twin Plenum Intake Manifold with Carbon plenum covers "Bright Polish Finish"

Subaru

20006438 Subaru High Volume Inlet Manifold

20015678 TGV Delete Kit - Subaru EJ25 Top Feed Injectors

MitSubiShi

TBA 4B11T Intake Manifold

27

Subaru High Volume Air Intake Manifold - PN 20006438

The Cosworth Subaru High Volume Inlet Manifold is cast from aluminium featuring large tapered runners with radiused inlets for improved air flow. Plenum volume has been substantially increased and tuned for power. Engineered for easy installation and is the key to making big power.

■ Substantially increased plenum volume ■ Large, tapered runners with radiused

inlets ■ Tuned plenum volume and runner

length/taper ■ Over 10% increase in flow ■ Integral vacuum manifold for connection

of brake booster, boost gauge, MAP sensor, boost controller, etc.

■ Will work with standard or forward mount throttle body configurations

■ Stock throttle body location for compatibility with most aftermarket FMIC kits

28

TGV Delete Kit - PN 20015678

The Cosworth Tumble Generating Valve (TGV) Delete Kit is designed to maximize airflow to your engine by eliminating the obstructions inherent to the OEM TGV intake ports. The TGV deletes are made of a fibre reinforced polymer to insulate the cylinder head from the intake tract, providing your engine with a cooler, denser charge of air. To further increase performance, the Cosworth TGV deletes are port matched to our CNC cylinder heads and intake manifold. This product is a direct fit for the 07+ Subaru STi due to the top feed injector design and due to a revision to the upper bolt pattern of the TGV, specifically moving the centre two M6 holes. With our manifold and top feed injectors, the TGV delete kit will work without issue on most WRX/STi applications

■ 07+ Subaru STi specific, top feed injector specific

■ Produced from fibre reinforced polymer to lower intake air temperatures

■ Deletes factory Tumble Generating Valve for increased airflow

■ Free flowing design, port matched to Cosworth CNC Cylinder head & intake manifold

■ Includes high temp o-rings, shoulder bolts, and shims.

■ New OEM Subaru injector o-rings included

29

High Flow Synthetic Air Filters

Honda FitMitsubishi Evo 8/9

Nissan 350Z / Subaru Impreza

Subaru Legacy 2008+ STI

Lexus IS250/350

Toyota Tundra

Honda S2000

Mazda 3

Cosworth High Flow Synthetic Air Filters are constructed from a proprietary synthetic, non-woven single layer, pleated polyester filter media that requires no oiling. For an OE-like fit, the filter housing is injection moulded from high impact polystyrene or polypropylene. Each Cosworth air filter has been engineered to fit the vehicles original air box providing a true cold air supply to the engine. Cosworth Performance Air Filters also provide increased air flow when compared to original equipment air filters.

■ Improved performance ■ Superior filtration ■ Exceptional dust holding capacity ■ Reduced restriction (10%+ compared to

OE filters) ■ Over 98% efficiency (ISO5011:200 Fine

Dust Test)

30

Performance Air FiltersPart No. Description year

acura (hONDa)

20005380 Acura Rsx 2002-2007

20005380 Acura Rsx Type S 2002-2006

citrOeN

20006783 C-Crosser 2008-2009

fOrD

20002270 Maverick (2 4L) 1993-1998

hONDa

20002271 S2000 (2 0/2 2L) 1999-2009

20005380 Integra Type R (2 0L) JDM 2001-2006

20005380 Civic Type R (2 0L) 2000-2006

20005380 Civic Type R (2 0L) JDM 2001-2005

20005380 Civic (2 0L) 2001-2006

20005380 Fr-V 2005-2008

20005380 Cr-V 2002-2006

20002272 Jazz (1 4L) 2007-2008

20002273 Fit (1 5L) 2007-2009

20002273 Fit JDM (1 3/1 5L) 2001-2006

20005380 Stream (2 0L) 2001-2005

20005380 Stepwagon (2 0L) 2001-2005

20002273 Mobilio JDM (1 5L) 2001-2007

20002273 Mobilio Spike JDM (1 5L) 2002-2007

hOlDeN

2002270 Calais (3 8L) 2002

2002270 Commodore (3 8/5 0L) 1988-1996

iNifiNiti

20005381 G37 (3 7L) (Twin Air Box) 2008-2010

20005381 G35 (3 5L) 2007-2008

20002270 G35 (3 5L) 2003-2007

20002270 G20 (2 0L) 1991-2002

20005381 Ex35 (3 5L) 2008-2009

20002270 Fx35 (3 5L) 2003-2008

20002270 I35 (3 5L) 2002-2004

20002270 I30 (3 0L) 1996-2001

20002270 J30 (3 0L) 1993-1997

20002270 Q45 (4 5L) 2001

20002270 Qx4(3 3/3 5L) 1997-2003

20002270 M30 (3 0L) 1990-1992

iSuzu

20002270 Gemini (1 5/1 7L) 1985

leXuS

20002281 IS250 2005-2009

20002281 IS350 2006-2009

20002281 IS220 2005-2009

20002281 GS350 2005-2009

20002281 GS430 2006

lOtuS

20002282 Elise 1 8L (Toyota Engine) 2004-2007

MazDa

20002273 RX-8 2003-2009

20002275 MX-5 (1 8/2 0L) 2005-2008

20002274 Mazda 3 (2 0/2 3L) 2003-2008

20002274 Mazda 3 Mazdaspeed 2007-2008


MitSubiShi

20006783 Lancer Evo X 2008-2010

20002277 Lancer Evo IX - IX 1996-2007

20006783 Lancer (1 5/1 8/2 0L) 2008-2010

20002277 Lancer (1 3/1 6/2 0L) 1999-2008

20006783 Outlander (2 0/2 4L) Diesel 2007-2009

20002277 Outlander (2 0/2 4L) 2003-2007

20002277 Colt (1 3/1 6L) 1996-2005

20002277 Mirage (1 5/1 8L) 1997-2004

NiSSaN

20002270 350Z 2003-2006

20005381 350Z (Twin Air Box) 2007-2010

20002270 R34 Skyline Gtr (2 6L) 1999-2002

20002270 R33 Skyline Gtr (2 6L) 1995-1998

20002270 R32 Skyline Gtr (2 6L) 1989-1994

20002270 Skyline Coupe V35 (2 5/3 0/3 5L) 2001-2006

20002270 R34 Skyline (2 0/2 5L) 1998-2001

20002270 R33 Skyline (2 0/2 5L) 1993-1998

20002270 R32 Skyline (2 0/2 5L) 1989-1993

20002270 R31 Skyline (2 0L) 1985-1989

20002270 R30 Skyline (2 0/2 8L) 1981-1990

20002270 Stagea (2 0/2 5/3 0/3 5L) 1996-2006

20002270 300Zx (3 0L) 1987-1990

20002270 200Sx (1 8/2 0L) 1988-1999

20002270 Silvia JDM (1 8 /2 0L) S12/13/14/15 1980-2002

20002270 Primera (1 6/1 8/2 0L) 1990-2007

20002270 Xtrail (2 0/2 2/2 5L) 2001-2006

20002270 Maxima (2 0/2 4/2 8/3 0/3 5L) 1982-2009

20002270 Altima (2 4/2 5/3 5L) 1993-2008

20002270 Almera (1 5/1 8/2 0/2 2L) Incl Tino 1995-2007

20002270 Quest (3 5L) 2004-2008

20002270 Sentra (1 6/1 8/2 0/2 5L) 1991-2006

20002270 Terrano (2 4L) 1992-2005

20002270 Navarra (3 0L) 2004-2005

20002270 Xterra (3 3L) 2000-2004

20002270 Pathfinder (2.7/3.0/3.3/3.5L) 1990-2004

20002270 Frontier (3 3L) 1999-2004

20002270 Patrol (4 2L) 1988-1997

20002270 Serena (1 6/2 0/2 3L) 1992-2001

20002270 Prairie (2 0/2 4L) 1989-1996

20002270 Pickup (3 0L) 1990-1996

20002270 QX (2 0/3 0L) 1995

20002270 Sunny (1 5/1 6/1 7/1 8/2 0L) 1985-1993

20002270 NX (1 6/1 8/2 0L) 1987-1993

20002270 Stanza (2 4L) 1990-1992

20002270 Axxess (2 4L) 1990-1991

20002270 Bluebird (1 9/2 0L) 1982-1990

20002270 Laurel (2 0/2 4/2 8/3 0L) 1980-1989

20002270 Cedric (2 8L) 1983

20002270 810 (2 4/2 8L) 1981


OPel / vauXhall

20002270 Corsa (1 5L Diesel) 1988-1993

20002270 Vectra (1 7L) Turbo Diesel 1992-1995

20002270 Astra (1 7L) with Isuzu Diesel Engine 1991-1992

20002270 Cavalier with Isuzu Diesel Engine 1992-1995

20002270 Nova (1 5L) Incl Diesel & Novavan 1989-1992

20002270 Kadett (1 5L) 1989

PeugeOt

20006783 4007 2007-2009

PONtiac

20002282 Vibe 2003-2009

SciON

20002282 Tc (2 4L) 2007-2009

Subaru

20002278 Impreza WRX STi 2008-2010

20002278 Impreza WRX 2008-2010

20002278 Impreza 2 5L 2008-2009

20002278 Impreza 2 0L 2008-2009

20002270 Impreza WRX STi 1997-2007

20002270 Impreza WRX 1993-2007

20002270 Impreza 1993-2007

20002278 Legacy (2 5L/3 0L/GT) 2005-2009

20002278 Legacy B4 (2 0/2 5/3 0L) JDM 2003-2008

20002270 Legacy B4 (2 0/2 5/3 0L) JDM 1998-2005

20002270 Legacy (1 8/2 0/2 5L/3 0L) 1989-2003

20002278 Forester (2 0L/2 5L) 2008-2009

20002278 Outback (2 0/2 5/3 0L) 2005-2009

20002278 Tribeca (3 0/3 6L) 2006-2008

20002279 Tribeca (3 0/3 6L) 2006-2009

20002270 Alcione Svx (3 3L) JDM 1991-1996

20002278 Exiga (2 0L) JDM 2006-2008

tOyOta

20002281 Rav4 (2 2L) Diesel 2006-2010

20002282 Corolla T Sport 2002

20002282 Corolla (1 4/1 6/1 8L) 2002-2009

20002282 Matrix Xrs/Xr (1 8L) 2003-2009

20002282 Avensis (1 6/1 8/2 0/2 4L) 2003-2007

20002282 Altis (1 6/1 8/2 0L) 2001

20002270 Lexcen (3 8L) 1989-1997

20002282 Premio JDM 2001-2007

20002282 Noah JDM 2001-2008

20002282 Opa JDM 2000-2008

20002282 Isis JDM 2004-2008

20002282 Allion JDM 2001-2007

20002282 Ipsum JDM 2001-2008

20002282 Wish JDM 2003-2008

20002282 Voxy JDM 2001-2007

20002282 Volt JDM 2008-2009

20002282 Caldina (Non-Turbo) JDM 2002-2008

31

Brake Pads

■ Track day driving ■ Extremely high friction level 0.7µ friction

coefficient ■ Strong brake effect through 800°C ■ “Vee” line expansion groove technology -

superb debris clearance ■ Fitted with premium quality shim

hardware - silent braking technology ■ Durability Factor 9.5 with minimal disc

abrasion ■ Super fast “bed-in” typically under 2 laps ■ Heat stable, predictable & heat cycle

exceptionally well ■ This track formulation CAN be safely

used on highways except in Europe where ECE R90 approvals are required. This pad has too much brake effect to be compliant with these regulations.

■ Medium-hard sports pad suitable for heavy duty/fast road

■ ECE R90 approval ■ Superior bite - 0.5µ friction coefficient -

virtually from first pedal ■ Strong brake effect up to 650°C ■ Chamfered edge – avoid lifting ■ Fitted with premium quality shim

hardware - silent braking technology ■ Durability factor 6.5 with rotor minimal

disc abrasion ■ Produces consistent, predictable braking

performance

The racing performance pedigree that is so much part of Cosworth’s heritage, is clearly demonstrated in this exciting addition of brake pads to our Aftermarket Performance Parts range.

With two grades of friction material, the StreetMaster and TrackMaster ranges deliver exceptional levels of stopping power specifically tailored for fast road and track applications respectively.

Manufactured in the United Kingdom, Cosworth brake pads feature a 1.5mm granulated interlayer which not only serves to act as a shock absorber, helping to reduce stress on the rotor surface but triples bonding strength so diminishing edge lifting.

To reduce the “bedding-in” or “seating-in” time - this is the time it takes for the pad and disc to adapt to each other - all Cosworth brake pads are heat seared. This process heats the friction material to in excess of 600°C “toasting” the surface greatly enhancing the performance the first time that the driver applies the brakes. Scorching pads also significantly reduces initial fading. Fading increases the necessary force and pressure required to maintain the deceleration of the vehicle.

Cosworth’s brake pads range offer exceptional performance with no compromise.

Why choose Cosworth Brake Pads? ■ Heat seared for reduced “bedding-in”

time ■ Superior bite from cold ■ Exceptional stopping performance - 0.7µ

braking coefficient ■ Silent running technology ■ “Vee” groove for fast debris clearance ■ Fade resistant ■ Premium grade friction material ■ Consistent & predictable braking

patterns

32

Vehicle Application List

Model year StreetMasterfront Pads

trackMasterfront Pads

StreetMasterrear Pads

trackMasterrear Pads

fOrD

Fiesta 2 0 ST 2004-2008 CFS3011 CFS3005

Escort/Orion 2 0 Cosworth 92-95 CFS3024 CFS3021

Focus 2 5 Turbo ST 2005-2009 CFS3010 CFS3013

Focus 2 5 Turbo RS 2009- CFS3020 CFS3017

Sierra/Sapphire 2 0 Cosworth 85-90 CFS3022 CFS3021

Sierra/Sapphire 2 0 Cosworth 4x4 90-93 CFS3024 CFS3021

hONDa

S2000 2 0 99- CFS3006 CFT3006 CFS3002 CFT3002

Civic 2 0 Type-R (EP3) 2001-2007 CFS3006 CFT3006 CFS3002 CFT3002

Civic 2 0 Type-R (FN2) 2007- CFS3006 CFT3006 CFS3016 CFT3016

Integra (Not UK) 2 0 Type R (DC5) 2001- CFS3012 CFT3012 CFS3002 CFT3002

Integra (Not UK) 2 0 Type S (DC5) 2004- CFS3006 CFT3006 CFS3002 CFT3002

MazDa

MX5 1 8 2006- CFS3014 CFS3015

MX5 2 0 2006- CFS3014 CFS3015

MitSubiShi

Lancer Evo 5 2 0 Turbo GSR 97-99 CFS3004 CFT3004 CFS3009 CFT3009

Lancer Evo 6 2 0 Turbo 98-2001 CFS3004 CFT3004 CFS3009 CFT3009




Lancer Evo 10 2 0 Turbo 2008- CFS3004 CFT3004 CFS3019 CFT3019

NiSSaN

GT-R (R35) 3 8 Twin Turbo 2008- CFS3018 CFT3018 CFS3001 CFT3001

Skyline R32 GTR 89-95 CFS3003 CFT3003 CFS3023 CFT3023

Skyline R33 GTS 2 5 Turbo 93-98 CFS3003 CFT3003 CFS3023 CFT3023

Skyline R34 GTT 97-2002 CFS3003 CFT3003 CFS3023 CFT3023

Skyline 3 5 (V35 V36) (Brembo) 2001-2006 CFS3012 CFT3012 CFS3008 CFT3008

350Z 3 5 (Brembo) 2003- CFS3012 CFT3012 CFS3008 CFT3008

Subaru

Impreza 2 0 Turbo (Not UK) 98-2002 CFS3003 CFT3003 CFS3023 CFT3023

Impreza 2 0 Turbo (UK) 98-2002 CFS3003 CFT3003 CFS3007

Impreza 2 0 Turbo P1 2000-2002 CFS3003 CFT3003 CFS3007

Impreza 2 0 Turbo WRX 2001-2005 CFS3003 CFT3003 CFS3023 CFT3023

Impreza 2 2 Turbo (22B) 98-2000 CFS3003 CFT3003 CFS3023 CFT3023

Impreza 2 5 Turbo WRX 2006-2007 CFS3003 CFT3003 CFS3023 CFT3023

Impreza 2 0 Turbo WRX STi 2002-2005 CFS3004 CFT3004 CFS3008 CFT3008

Impreza 2 5 Turbo WRX STi 2006-2007 CFS3004 CFT3004 CFS3008 CFT3008

Impreza 2 5 Turbo WRX STi 2007- CFS3004 CFT3004 CFS3008 CFT3008

tOyOta

Toyota Supra 3 0ltr Twin Turbo 17" wheel 93 - 2002 CFS3025 CFT3025 CFS3026 CFT3026

See next page for brake pad applications to fit AP Racing callipers

33

Cosworth Brake Pads to Fit AP Racing Calipers

Model year Position caliper type aPr caliper ref cosworth SKuStreetMaster

cosworth SKutrackMaster

fOrD

Civic Type R 2002 -2006 Front 4 Piston CP5200 CFSA001 CFTA001

Civic Type R 2002 -2006 Front 6 Piston CP5570 CFSA002 CFTA002

Civic Type R 2007 on Front 4 Piston CP6637 CFSA005 CFTA005

S2000 1999 on Front 4 Piston CP6637 CFSA005 CFTA005

Evo 7 - 8 & 9 2001 on Front 6 Piston CP7040 CFSA003 CFTA003




350Z 2005 on Front 6 Piston CP7040 CFSA003 CFTA003

GTR32 1992 on Front 4 Piston CP5200 CFSA001 CFTA001



WRX,STI 2001 - 2007 Front 4 Piston CP5200 CFSA004 CFTA004



WRX,STI 2008- Front 6 Piston CP7048 CFSA006 CFTA006

Escort Cosworth 1991 on Front 6 Piston CP5570 CFSA002 CFTA002

Escort Cosworth 1991 on Front 4 Piston CP5200 CFSA001 CFTA001

Sierra Cosworth 1987 on Front 4 Piston CP5200 CFSA001 CFTA001

Sierra Sapphire Cosworth 4x4 1990 on Front 4 Piston CP5200 CFSA001 CFTA001

Fiesta ST 2005 Front 4 Piston CP6637 CFSA005 CFTA005

Focus RS 2002 on Front 6 Piston CP7040 CFSA003 CFTA003

Focus ST170 2001 on Front 4 Piston CP5200 CFSA001 CFTA001

The Cosworth brake pad range is constantly expanding and a full list of applications can be found at www.cosworth.com, Performance Tuning Components section

34

Big Brake Upgrade Kits

Cosworth has combined over 50 years of motorsport heritage and technology with the unrivalled experience of AP Racing to develop a range of joint branded high performance Big Brake Upgrade kits.

The Cosworth AP Racing brake kit delivers ultimate stopping power consistently and quickly from cold whilst offering corner weight reduction over the OEM brakes of 1.58Kg.

The Cosworth BBK calipers are 6 piston, with differential bores to eliminate “pad taper”. The trailing pistons have a larger bore than the leading ones to compensate for mechanical end load & to even out the wear on the pads. All our performance brake calipers use conventional seals in conjunction with a dirt seal and are finished with an eye-catching high gloss black PTFE based paint coating which is impervious to normal brake fluids & high brake temperatures.

The 2-piece discs features Cosworth technology embedded within the pair of 48 vaned discs together with lightweight high grade aluminium mounting bells designed to deliver enhanced airflow than the original brakes. The discs have been developed to produce optimum braking bite, as well as thermal stability and durability.

The upgrade kits also contain a set of high performance brake pads, mounting brackets individually designed for each application, brake hoses, a complete set of fixings and two bottles of AP Racing Formula DOT 5.1 brake and clutch fluid.

Cosworth Big Brake Upgrade Kits are a stylish and effective way of up-rating your cars braking performance.

Detailed Specification:

■ 2 x Ø355 x 32mm 2 piece brake discs ■ 2 x 6 piston brake calipers ■ High performance brake pad friction

material* ■ Braided brake hoses ■ 2 x Dot 5.1 high temperature brake fluid ■ 2 x Mounting brackets ■ 2 x Aluminium mounting bells ■ Steel braided hoses ■ Fixings

Big Brake Upgrade KitsPart No. Description

20017603 Subaru 2008 on (to fit 17 and 18 inch wheels)

CBK3002 EVO X (to fit 17 and 18 inch wheels)

CBK3003 350z (to fit 17 and 18 inch wheels)

*Braking material is not R90 approved for road use

35

Nissan VQ35 High Volume Fuel Rail

System - KK3905

The original factory VQ35DE fuel rail arrangement is limited in performance. The Cosworth VQ35 High Volume Fuel System features high volume anodised fuel rails, with o-ringed fittings and is fully configurable for various applications. Each system includes sleeved high pressure fuel lines along with a CNC machined distribution block that includes an additional port for various sensors. The Cosworth High Volume Fuel Rail System can be used with original or various aftermarket injectors.

Mitsubishi EVO X High Volume Fuel Rail System - 20005241

The Cosworth High Volume Fuel Kit features a machined from solid, hard anodised aluminium fuel rail with o-ringed fittings and a pre-shaped inlet pipe. The Cosworth High Volume Fuel Rail Kit can be used with original or various aftermarket injectors and PRV’s.

■ Direct fit replacement- includes all necessary components for a complete bolt-on installation

■ Designed with expansion in mind, facilitating installation of custom fuel systems including AN fuel lines and remote mounted fuel pressure regulators

■ Full-flow ½” bore will support upwards of 600hp worth of fuelling

■ Hard anodised finish is methanol compatible.

(upgraded fittings and seals required)

VQ35 Fuel Rail System

Mitsubishi Evo Fuel Rail System

Fuel

FuelPart No. Description

NiSSaN

KK3905 Nissan VQ35DE (3 5L) High Volume Fuel rail system

MitSubiShi

20005241 Mitsubishi EVO X High Volume Fuel rail kit

36

Fuel Oil Control

Subaru Dry Sump - 20004463

The Cosworth Dry Sump Setup Kit for the Subaru EJ series engine is a must for race and performance applications. Dry sump oiling systems offer an unparalleled level of safety and reliability compared to factory wet sump systems. Complete crankcase oil scavenging reduces excessive and residual oil that can cause blow-by and power loss. A dry sump also offers more consistent oil pressure to the engine,

improved scavenging, and increased ring seal due to greater pan vacuum. The Cosworth Dry Sump System for the Subaru EJ20/EJ25 replaces the original oil sump with a machined from solid, low profile alloy pan with twin scavenge ports, internal baffling and o-ring sealing. A two stage scavenge pump driven by a HTD belt, mounted to a heavy duty bracket evacuates the oil from the engine.

Includes: ■ Machined from Solid Sump ■ 2-Stage Scavenge Pump ■ Pump Mounting Bracket/Manifold ■ 34T Pump Drive Pulley ■ Crankshaft Drive Adapter Assembly ■ HTD Drive Belt ■ Crankcase Breather Filter and Fitting ■ Fittings and Hardware

Required to complete the installation: ■ Oil Tank ■ Hoses/Hose Ends ■ 2004-2007 Subaru STI Alternator

Bracket ■ Cosworth High Volume/Pressure Oil

Pump 20001185

Internal baffling

Twin Scavenge Ports

Heavy duty mounting bracket / pump manifold

Low profile design

37

Oil ControlPart No. application

Subaru

20001238 Subaru (EJ20/EJ25) High Volume Oil Pan

20002499 Subaru (EJ20/EJ25) Oil Control Baffle

KK3928 Subaru (EJ20/EJ25) Blueprinted Oil Pump with high pressure mod & install kit

20001185 Subaru (EJ20/EJ25) High Volume/Pressure Blueprinted Oil Pump & install kit

20009093 Subaru 2008+ STI (EJ25) Blueprinted Oil Pump with high pressure mod & install kit

20004463 Dry Sump Kit, Subaru EJ (Includes pan, 2 stage scav pump, brackets and pump drive-fluid lines / tank are not included)

NiSSaN

20009175 Nissan (VQ35) High Pressure Oil Pump Kit

20008841 Nissan (VQ35) Oil Control Baffle

20008632 Nissan (VQ35) Oil Control Baffle 03-04 Install kit

MitSubiShi

20001382 Mitsubishi Evo VII-IX 4G63 (2 0L) Crankshaft Oil Scraper

MazDa

20007845 Mazda Miata NC Oil Cooler Kit

Mitsubishi 4G63 Crankscraper

The Cosworth 4G63 Crankscraper is engineered to reduce parasitic drag on the crankshaft caused by oil accumulation that surrounds the crankshaft during rotation. This oil buildup causes additional drag and can reduce power output. Additionally, overall oil control is improved by keeping oil in the sump. Especially useful in high rpm and race applications. Mounts to main bearing girdle. Designed from 2.6 mm (12gauge) steel plate and includes required mounting hardware.

Subaru Oil Pan Baffle

Oil control can be a problem with high performance and high revving Subaru engines. High crankcase pressure along with the horizontal engine platform restricts rapid oil return from the cylinder heads to the oil pan. Pressure builds in the heads and crankcase causing massive blow by and power loss. The Cosworth Subaru Oil Pan Baffle has been engineered with diverters to control oil returning from the cylinder heads to the pan directing it away from the crankshaft. Additionally, one-way valves prevent oil from re-entering the upper crankcase chamber thereby limiting blow by and preventing oil starvation during hard driving. Manufactured from stainless steel and installs easily between the block and oil pan on both EJ20/EJ25 series engines. Use with our High Volume Oil Pan for maximum oil control.

Nissan Oil Control Baffle

The Cosworth Oil Control Baffle for the Nissan VQ35 has been engineered to stop oil from surging away from the oil pick up during hard driving conditions. The unique Cosworth one-way control valves allow oil to flow towards the pickup but restrict oil from migrating to the back of the sump during aggressive manoeuvres to help maintain constant oil pressure. Manufactured from stainless steel. Model Year 2003-2004 require fit kit PN 20008632 for proper installation.

High performance engines reject a substantial amount of heat through the oil system. Maintaining oil pressure and control along with an increase in actual volume will help dissipate heat and stabilise oil temperatures. Cosworth oil control components are engineered to combat several problem areas experienced in high performance engines.

Nissan Baffle Install Kit

Nissan Oil Control BaffleSubaru Oil Control Baffle

38

Subaru EJ20/25 High Volume Oil Pan - 20001238

Sustained high RPM or prolonged high speed driving will result in elevated oil temperatures. Additional oil volume along with improved oil control will reduce damaging oil temperatures. The Cosworth EJ20/EJ25 High Volume Oil Pan is fabricated from both custom and original components resulting in an additional 2qts oil capacity when compared to standard oil pan. Each kit includes powder coated oil pan, mounting hardware, oil pickup and spacer. Will not work with some equal length exhaust manifolds.

Subaru EJ20/25 Oil pump - High Pressure - KK3928

High performance engines require additional oil pressure because of the increased demand placed upon various components within the engine. The Cosworth High Pressure Subaru EJ20/EJ25 series oil pump is modified to

increase oil pressure helping to ensure superior lubrication. Each pump is carefully inspected and de-burred for unobstructed oil flow. Perfect for high performance daily use. Each kit includes all required mounting hardware and seals.

Pump Gear: 10mm vs 12mm

Subaru EJ20/25 Oil pump - High Volume, High Pressure - 20001185

Increasing oil volume will help to prevent bearing damage and engine failure. Additionally, sustained high RPM use may cause oil starvation at the rod and main

bearings. The Cosworth High Volume Subaru EJ20/EJ25 series oil pump utilizes a completely new inner and outer 12mm rotor to increase volume by 20%.

Suggested applications include drag, track day and race use. Each kit includes all required mounting hardware and seals.

Oil pump - 20009093

High performance engines require additional oil pressure because of the increased demand placed upon various components within the engine.

The Cosworth High Pressure Oil Pump for the Subaru 2008 and newer STI is modified to increase oil pressure helping to ensure superior lubrication.

Each pump is carefully inspected and de-burred for unobstructed oil flow.

Perfect for high performance daily and track use. Each kit includes all required mounting hardware and seals for quick and easy installation.

Features:

■ 11mm oil pump gears ■ Essential for sustained high rpm

applications ■ Installation kit included ■ Maintain superior lubrication

39

Valve Train Specification (L1=Install Height, F1=Force @ L1, L2=Max Lift, F2=Force @ Max Lift)

Part No. application free height l1 mm f1 N f1 lbs l2 mm f2 N f2 lbs Max lift coil bind

20000164 Mitsubishi EVO 7-9 47 00 38 1 381 85 26 1 900 202 12 0 24 3

KK3813 Mitsubishi EVO 7-9 50 00 38 1 512 115 26 9 1268 285 12 0 25 7

20000169 Nissan RB26 49 30 41 9 359 81 29 9 941 212 12 0 28 4

20000168 Nissan SR20 46 00 39 0 365 82 27 5 964 217 11 5 25 4

20000163 Nissan VQ35DE 46 00 38 0 289 65 24 5 775 175 13 5 22 9

20002550 Nissan VQ35DE 47 00 38 0 378 85 23 9 1183 266 14 1 22 6

20000166 Subaru EJ 2 0/2 5 42 00 36 0 275 62 25 0 780 175 11 0 23 2

KK3839 Subaru EJ 2 0/2 5 46 10 36 0 356 80 22 1 1019 229 13 9 20 8

All dimensions are in millimetres unless otherwise specified

High Performance Valve Train

High Performance Valves

Large diameter valves are essential for improved air flow. Cosworth high performance intake valves are produced from high quality stainless steel for maximum durability. Exhaust valves are machined from Inconel for high temperature (2400° F) reliability. Each valve features a swirl polished back for improved air flow and dished face for additional weight reduction. Some Cosworth High Performance Valves are only compatible with Cosworth Ultra Race Valve Spring Kits. Please confirm application before ordering.

High Performance Valve TrainPart No. Description

Subaru

SB0034 Valve, Inlet +1 0mm Subaru EJ25-Stainless Steel (37 0mm)

SB0033 Valve, EX +1 0mm Subaru EJ25-Inconel (33 0mm)

PR7710 Subaru EJ25 (2 5L) Graded Cam bucket 4 50






















NiSSaN

PR7602 Valve, Inlet +1 0mm Nissan VQ35-Stainless Steel (38 15mm)

PR7603 Valve, Ex +1 0mm Nissan VQ35-Inconel (32 35mm)

MitSubiShi

CI0113 Valve, Inlet +1 0mm Mitsubishi 4G63 Stainless Steel (35 0mm)

CI0112 Valve, Ex +1 0mm Mitsubishi 4G63-Inconel (31 5mm)

20007107 Valve, Inlet +1 0mm Mitsubishi 4B11T Stainless Steel (36 0mm)

20007082 Valve, Ex +1 0mm Mitsubishi 4B11T-Inconel (30 0mm)

40

Note: Cosworth Subaru valves require Cosworth retainer kits. We recommend Cosworth retainers with all other valves.

Mitsubishi 4G63 Subaru EJ20/EJ25

Nissan VQ35DE

Mitsubishi 4B11

High RPM Valve Spring SetsPart No. application

MitSubiShi

20000164 High RPM Single Valve Spring set (16) Mitsubishi Evo VII-IX 4G63

20004844 High RPM Single Valve Spring set (16) Mitsubishi Evo X 4B11T

Subaru

20000166 High RPM Single Valve Spring set (16) Subaru WRX STI EJ25 (2 5L) EJ20 (2 0L)

NiSSaN

20000163 High RPM Single Valve Spring set (24) Nissan VQ35 (3 5L)

20000168 High RPM Single Valve Spring set (16) Nissan SR20DET (2 0L)

20000169 High RPM Single Valve Spring set (24) Nissan RB26 (2 6L)

High RPM Valve Springs

Cosworth High RPM Valve Springs are the result of countless hours of engineering, testing and validation ensuring the best possible spring for high performance applications. Cosworth High RPM Valve Springs are wound from the world’s finest Japanese Kobe steel and feature dual chamfered ends to reduce wear on seats and retainers. Each spring has been engineered with increased seat pressure along with higher lift capability for optimum performance potential and improved valve control. Single spring design allows easy installation with no machining required and is perfect for typical high performance use.

■ Manufactured from the finest Japanese Kobe steel

■ Single spring design for easy installation ■ Dual chamfered ends ■ Increased performance

Ultra-High RPM Valve Spring SetsPart No. application

KK3813 Mitsubishi Evo 4G63 (2 0L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

KK3839 Subaru EJ25 STI (2 5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

20002550 Nissan VQ35 (3 5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

20007182 Mitsubishi Evo 4B11T Ultra-High RPM Dual Valve Spring / Titanium Retainer set

Ultra Race Valve Spring Kits

Cosworth Ultra Race Valve Spring Kits are engineered for use in situations that require valve control in extreme conditions. Each kit consists of dual valve springs with matched lightweight titanium retainers, keepers, and hardened steel spring seats. Cosworth Ultra Race Valve Springs are

wound from the highest quality chrome silicone steel with chamfered ends and are heat treated and stress relieved for long term reliability. Ultra Race Valve Spring kits are compatible with Cosworth high performance valves.

Install Height “F1”

*Seal clearance

41

Stopper Layer

Gasket LayerFolded

Gasket Layer

Cosworth High Performance Head Gaskets are engineered to seal in power under the most demanding conditions. Constructed from stainless steel with a folded stopper layer, each application features superior sealing compared to conventional multi-layer steel gaskets. Additionally, Cosworth High Performance Head Gaskets are manufactured from pre-coated die cut stainless steel resulting in uniform coating distribution and consistent shape.

Each gasket is carefully engineered with the following features:

■ Individual die cut layers of stainless steel with superior consistency compared to laser cut gaskets

■ Pre-coated stainless steel with a 0.25 micron layer of nitrile rubber ensures consistent distribution of coating with no high or low areas

■ Manufacturing dimensional tolerance of +/- 0.001”

■ Die cut manufacturing process ensures smooth edges, unlike laser cut gaskets

■ Cosworth gaskets feature a “folded stopper” layer for additional clamping force around each cylinder. The width of sealing area is specific for each application thereby providing ultimate sealing properties

■ Available in a range of thicknesses for specific applications

High Performance Head Gaskets

High Performance Head GasketsPart No. Description

NiSSaN

20013292 Nissan GTR VR38DETT (3 8L) Bore = 96mm T ~ 0 8mm (Pr)

20004667 Nissan VQ35HR / VQ37VHR Bore = 96mm T ~ 0 6mm (Pr)

20000900 Nissan VQ35DE (3 5L) Bore = 96mm T ~ 0 6mm (Pr)



20000924 Nissan SR20DET (2 0L) Bore = 87mm T ~ 1 1mm





20000927 Nissan RB26DETT (2 6L) Bore = 87mm T ~ 1 1mm



20000930 Nissan RB25DET (2 5L) Bore = 87mm T ~ 1 1mm

20000931 Nissan RB25DET (2 5L) Bore = 87mm T ~ 1 5mm

MitSubiShi

20001689 Mitsubishi Evo IX 4G63 (2 0L) Bore = 86mm T ~ 1 3mm

20001690 Mitsubishi Evo IX 4G63 (2 0L) Bore = 86mm T ~ 1 5mm

20000909 Mitsubishi Evo IV-VIII 4G63 (2 0L) Bore = 86mm T ~ 1 3mm

20000910 Mitsubishi Evo IV-VIII 4G63 (2 0L) Bore = 86mm T ~ 1 5mm

20004122 Mitsubishi Evo X 4B11T (2 0L) Bore = 87mm T ~ 1 1mm

20004123 Mitsubishi Evo X 4B11T (2 0L) Bore = 87mm T ~ 1 3mm

Subaru

20000913 Subaru WRX STI EJ25 (2 5L) Bore = 101mm T ~ 0 78mm each



20010706 2008+ Subaru WRX STI EJ25 (2 5L) Bore = 101mm T ~ 0 78mm each



20000919 Subaru WRX EJ20 (2 0L) Bore = 93mm T ~ 0 78mm each

20000922 Subaru WRX EJ20 (2 0L) Bore = 93mm T ~ 1 1mm each

hONDa

20010904 Honda S2000 F20/22C Bore = 88mm, T ~ 0 38mm




20003127 Honda K20/24 Bore = 87mm T ~ 0 8mm for use with RAA, RAC, RBB, and RBC cylinder heads



20010903 Honda K20/24 Bore = 87mm T ~ 0 38mm for use with PRB, PNC, and PPA cylinder heads




tOyOta

TBA Toyota 2JZ - GTE Bore = 87mm T ~ 1 1mm



42

Nissan VQ35DE

Mitsubishi 4G63

Mitsubishi 4b11t

Subaru EJ25

Uniform nitrile rubber coating

Die cut edges

Stopper sealing layerWithout folded stopper layer, clamping force is limited resulting in incomplete sealing around

combustion chamber

Folded stopper layer provides complete sealing around entire combustion chamber

Honda F20C

43

Thermal Composite Gaskets

Thermal Composite GasketsPart No. Description

20013283 Thermal Intake Manifold Gasket - EJ25 2004+ all (Pair)

20013286 Thermal Intake Manifold Gasket - 4G63 EVO 4-9

20013287 Thermal Intake Manifold Gasket - 4B11T EVO X

20013288 Thermal Intake Manifold Gasket - 2ZZ-GE

20013289 Thermal Plenum Gasket - VQ35DE

20013290 Thermal Plenum Gasket - VR38DETT

The Cosworth Thermal Guard Composite Intake Gasket is designed to aid in the reduction of inlet air temperature by isolating the intake manifold from the heat generated by the engine’s cylinder head. By reducing the temperature of the inlet manifold the temperature of the intake air charge is also reduced. The density of cooler air is greater than that of warm air. A denser intake air charge contains more oxygen which results in the potential for increased power and torque.

Each Cosworth Thermal Guard Composite Intake Gasket is precision manufactured from an engineering grade composite phenolic material that resists deformation common with plastic gaskets. As an added feature Cosworth Thermal Guard Composite Intake Gaskets are reusable and include a tube of “Hylomar Universal Blue Racing Formula” sealant. The use of OE inlet manifold gaskets is not required with the Cosworth Thermal Guard Composite Intake Gasket.

■ Isolates inlet manifold from engine and cylinder head

■ Reduces inlet air temperature ■ Reusable with no deformation ■ Higher temperature resistance than

plastic gaskets (+500º F) ■ Precision CNC manufactured ■ Includes Hylomar Universal Blue Racing

Formula sealant ■ Race proven ■ Safe with all fuel types

Nissan VQ35

Mitsubishi 4B11

Mitsubishi 4G63

Subaru EJ25

44

Cosworth Rhino Skin - Thermal Heat Protection

Cosworth Rhino Skin – Thermal Heat ProtectionPart No. Description

20019507 Subaru EJ25 STi 2008 - exhaust manifold heat shield

20019574 Subaru EJ25 STi 2008 - Up-pipe heat shield

20019952 Subaru EJ25 STi 2008 - Down-pipe heat shield

CRS003 Subaru EJ20 STi ‘98 - exhaust manifold heat shield

CRS004 Nissan SR20DET exhaust manifold (low mount) heat shield

CRS005 Nissan RB25 exhaust manifold (low mount) heat shield

CRS006 Nissan RB26 exhaust manifold (top mount) heat shield

CRS006 Mitsubishi 4G63 exhaust manifold (low mount) heat shield

CRS007 Mitsubishi 4B11T exhaust manifold (low mount) heat shield

CRS008 Honda K20A EP3 exhaust manifold heat shield

Cosworth Rhino Skin is a simple yet highly effective way of restraining heat from penetrating and destroying thermally sensitive areas of the engine bay - a re-occurring challenge for fast road and motorsport vehicles.

Cosworth Rhino Skin heat protection uses leading thermal protection technology to restrain heat to the area of generation. Each application is individually developed by Cosworth so there is no trim to fit and making for an easier installation.

Cosworth Rhino Skin has been initially developed as thermal protection for two key areas: turbochargers and exhaust manifolds where temperatures typically exceed 900°C/1650°F, making the need for predictable, rugged and reliable thermal armour a real one.

Cosworth Rhino skins are designed for street performance to hardcore motorsport applications. Branded in Cosworth image, each skin has a Teflon style surface effectively repelling grease and dirt they are capable of withstanding upto 1250°C/1800°F continuously.

Wrapping the exhaust header with Rhino Skin maintains hotter exhaust gases, decreases the density, and allows the

exhaust gas to accelerate from the system quicker. Thus, greater exhaust scavenging is produced lowering intake temperatures and in-turn contributing to an increase in power.

Benefits to power are also demonstrated in vehicles like the Subaru Impreza where the intercooler sits on top of the engine, rather than down at the front by the radiator. The “Up-Pipe” that brings hot exhaust gases to power the turbo and the “Down-Pipe” that takes them away, are both located directly beneath the intercooler - clearly generating significant radiant heat, particularly when the car is stationary.

To overcome this, a solution successfully developed and employed on the Cosworth Impreza CS400, was the Rhino Skin application – using the Rhino Skin to prevent the exhaust transferring heat to the intercooler, keeping the charge cool and improving the car’s performance and also increasing the engine’s responsiveness.

From the turbo perspective, the benefit of the shield is that it stops the turbo cooling down too quickly, preventing rapid temperature change which can cause turbine damage.

45

Miscellaneous

MiscellaneousPart No. application

Subaru

SB0001 Subaru (EJ20/EJ25) Billet Timing Belt Guide

SB0002 Subaru Billet Cam Angle Sensor Bracket (for mounting cam angle sensor on front of head)

20004539 Subaru (EJ20/EJ25) Air pump delete plate set

Subaru Billet Timing Belt Guide - Part number SB0001

The original sheet metal timing belt guide can flex from belt deflection when subjected to extreme RPM causing the timing belt to skip one or more teeth on the crankshaft sprocket. The Cosworth Billet Timing Belt Guide was developed to control this problem and is machined from solid aluminium with a hard anodised finish. Includes mounting hardware.

Subaru Billet Cam Angle Sensor Bracket - Part number SB0002

Used for mounting the cam angle sensor to the front of non North American Spec STI cylinder heads. Useful for adapting our cylinder heads to Japanese and European market engines.

Air Pump Delete - Part number 20004539

Used to eliminate the air pump and related valves found on 2006-2008 Subaru Engines. Used for high performance applications or adapting later cylinder heads to early engines. Seals off the air injection ports at the cylinder heads. Saves weight, reduces complexity, cleans up engine compartment. Machined from solid aluminium with a “Cosworth blue” anodised finish. Mounting hardware included.

Oil Filler CapsPart No. Description

20014944 Mitsubishi Evo X 4B11T Oil Filler Cap (Red)

20015827 Mitsubishi Evo X 4B11T Oil Filler Cap (Natural)

20014380 All Subaru vehicles from 1990 to current model years (Blue)

Oil Filler Caps

The Cosworth Oil Filler Cap is machined from solid aluminium with the traditional Cosworth “three prong” ergonomic style. This light weight oil filler cap includes a an oil ring sealing feature , preinstalled to ensure leak free operation on your engine. Each cap features a durable anodised finish.

■ Machined from solid aluminium ■ Durable anodised finish ■ Includes pre-installed O-ring for leak free

operation ■ Ergonomic, Classic Cosworth three

prong design

46

Disclaimer

The products in this catalogue require professional installation to ensure correct operation. Cosworth will not accept responsibility for damage to vehicles as a result of improper installation of our products.

The performance and power gained from installing products from this catalogue may place vehicles within an “off road use only” category in certain counties and states around the world. Cosworth will not accept responsibility for any restrictions placed on vehicles.

Product Disclaimer: A vehicle modified with Cosworth competition and or racing performance products may not meet the legal requirements for operation on public roads and highways. It is the purchaser’s responsibility to check and comply with all local, state and federal laws prior to operating vehicle. Installation and use of performance products may also affect/ void vehicle warranty and insurance policy.

Warranty: In general, Cosworth Performance Parts carry no warranty. Cosworth Ltd and Cosworth LLC shall not be liable for direct, indirect, incidental or consequential damage or injury to persons or property that might be claimed as a result from the installation, improper installation and failure of part including claims for delay, loss of profits or labour. There are no warranties expressed or implied.

SOME PRODUCTS MAY NOT BE LEGAL FOR SALE OR USE ON POLLUTION CONTROLLED MOTOR VEHICLES OPERATING IN CERTAIN COUNTRIES INCLUDING THE US STATE OF CALIFORNIA.

European Office

Cosworth LtdThe Octagon

St James Mill RoadNorthampton

NN5 5RAUnited Kingdom

Tel: +44 (0)1604 598300Fax: +44 (0)1604 598301Email: clsales@cosworth com

www.cosworth.comPerformance tuning components

US Office

Cosworth LLC3031 Fujita Street

TorranceCA 90505

USA

Tel: +1 310 534 1390Fax: +1 310 534 2631Email: sales@cosworth com

© Copyright 2011, Cosworth (UK) - v3 0

PERFORMANCE TUNING - Tunehouse · Subaru KK3670 Subaru WRX STI EJ25 (2 5L) Pr 2004-2006 20001699 Subaru WRX STI EJ25 (2 5L) Pr 2007 (with air injection ports) 20004544 Subaru WRX

Documents