P E R F O R M A N C E P A R T S

PERFORMANCE PA R T S A History Of Excellence Cosworth has a legendary reputation for high performance racing engines and vehicle electronics systems...
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PERFORMANCE PA R T S

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 (through the 2006 season), Cosworth engines delivered 176 F1 wins, 13 Constructors’ Championships and 10 Drivers’ Championships. Its 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. From 1976 through 2002, Cosworth, sometimes in association with Ford, powered drivers to 305 race wins including 12 Indy 500 victories and 14 Series Championships. As the exclusive engine supplier to the Champ Car World Series (CCWS) from 2003 through 2007, it was the winning engine in 73 more races and claimed five more series championships. Cosworth has supplied the power to a significant cohort of respected F1 teams (Lotus, Tyrrell, Williams, McLaren), and drivers (Jim Clark, Graham Hill, Jackie Steward, Mario Andretti and Michael Schumacher), as well as providing engines for champions and Indy 500 winners in the United States (Andretti, Sebastien Bourdais, Nigel Mansell, Rick Mears, Bobby Rahal, Danny Sullivan, Paul Tracy, Al and Bobby Unser, and Jacques Villeneuve). Now Cosworth’s unique combination of advanced powertrain experience and state of the art electronics technologies has been employed to create a race-proven range of high performance components for some of the most popular performance production vehicles. The Cosworth range of high performance aftermarket components includes everything the serious enthusiast needs, designed to Cosworth’s superlative standards and manufactured to precise tolerances using high quality materials.

Contents Big Valve Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 High Performance Short Block Assemblies . . . . . . . . . . . . . . . . . . . 6 High Performance Long Block Assemblies. . . . . . . . . . . . . . . . . . . 8 Billet Crankshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Stroker Engine Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Forged Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ultra High Performance Head Studs . . . . . . . . . . . . . . . . . . . . . 13 Ultra High Performance Engine Bearings. . . . . . . . . . . . . . . . . . . 14 Forged Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Single Forged Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Spare Piston Pins and Circlips . . . . . . . . . . . . . . . . . . . . . . . . 19 Performance Ring Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Kevlar High Performance Timing Belts . . . . . . . . . . . . . . . . . . . . 21 High Performance Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . 22 High Performance Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . 24 High Performance Head Gaskets. . . . . . . . . . . . . . . . . . . . . . . 26 Thermal Composite Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . 28 High Flow Intake Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Oil Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ECPro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 High Flow Synthetic Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . 34 Induction/Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Intercooler Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 NGK High Performance Spark Plugs . . . . . . . . . . . . . . . . . . . . . 41 Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 High Performance Brake Kits - Sport . . . . . . . . . . . . . . . . . . . . . 44 High Performance Brake Kits - MAXSport. . . . . . . . . . . . . . . . . . . 45 Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Big Valve Cylinder Heads 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 a re-shaped combustion chamber to

CNC Ported Big Valve Cylinder Heads Part 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)

KK3672

Mitsubishi Evo VII-VIII 4G63 (2.0L) 2000-2005

KK3852

Mitsubishi Evo IX 4G63 (2.0L) -2006 MIVEC

Mitsubishi

20005685

Mitsubishi Evo X 4B11T (2.0L) 2008+ Others

20000691

Ford Duratec, 2.0L/2.3L

20000704

Mazda MZR, 2.0L/2.3L

CNC Ported Big Valve Cylinder Heads with Camshafts Part 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

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.

Nissan VQ35DE

Subaru EJ25

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Key Features: ■■ ■■ ■■

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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

Cylinder head development

Mitsubishi 4B11

Precision Newen® CNC Valve Seat Machining

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High Performance Short Block Assemblies 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 Blocks Part 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)

20000067

Nissan VQ35 Short Block (3.5L) Lo comp 8.8:1

CI8019

Nissan VQ35 Short Block (3.5L) Hi comp 11:1

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

Nissan

Mitsubishi

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.

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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

Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L The Cosworth 2.0L 4G63 is an excellent starting point for high performance and track day applications.

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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 2.2L 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.

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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

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

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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

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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

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High Performance Long Block Assemblies 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

High Performance Long Block Assemblies Part No.

Description Subaru - North American spec EJ25 “CS600 & CS600X”

20000162

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder heads and KK3766 Camshafts - 79mm Billet Crankshaft 8:2:1 cr

20000161

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft 8:2:1 cr

20002503

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts - 79mm Billet Crankshaft 8:2:1 cr

20002504 

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft 8:2:1 cr

20007705

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft 9.2:1 cr

20007706

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft 9.2:1 cr

20007709

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder heads and KK3766 Camshafts - 79mm Billet Crankshaft 9.2:1 cr

20007710

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts - 79mm Billet Crankshaft 9.2:1 cr

20003488

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder heads and KK3766 Camshafts- 81mm Billet Crankshaft 8:2:1 cr

20003489

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts- 81mm Billet Crankshaft 8:2:1 cr

Subaru - North American spec EJ25 “CS600 & CS600X” 81mm Stroke

20007711

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet Crankshaft 9.2:1 cr

20007712

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet Crankshaft 9.2:1 cr

20000160

EJ25 (2.5L) with Big Valve Cylinder heads and KK3920 Camshafts - Billet Crankshaft

SB8008

EJ25 (2.5L) with Big Valve Cylinder heads and KK3920 Camshafts - STD Crankshaft

Subaru - European/Asia spec EJ25 “CS600 & CS600X”

20002503

EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - Billet Crankshaft

20002504 

EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft

20007708

Subaru EJ25 (2.5) 2004-06 Big Valve Cylinder heads and KK3920 Camshafts - 79mm Billet Crankshaft 9.2:1 cr

20007707

Subaru EJ25 (2.5) 2004-06 Big Valve Cylinder heads and KK3920 Camshafts - STD Crankshaft 9.2:1 cr

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.

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

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Features ■■ ■■

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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 Assemblies Part No.

Description Subaru - European/Asia spec EJ25 “CS600 & CS600X” 81mm Stroke

20003490

EJ25 (2.6L) 2004-06 with Big Valve Cylinder heads and KK3920 Camshafts - 81mm Billet Crankshaft

20003489

EJ25 (2.6L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet Crankshaft

20007713

Subaru EJ25 (2.5L) 2004-06 Big Valve Cylinder Heads and KK3920 Camshafts - 81mm Billet Crankshaft 9.2:1 cr

20007712

Subaru EJ25 (2.5L) 2007 Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet Crankshaft 9.2:1 cr

20007211

Subaru EJ25 (2.6L) 2004-06 Big Valve Cyl Head, KK3920 Cams, 81mm billet crank, H11 head studs, 12mm oil pump, 8.2:1 cr

20007212

Subaru EJ25 (2.6L) 2004-06 Big Valve Cyl Head, KK3766 Cams, 81mm billet crank, H11 head studs, 12mm oil pump, 8.2:1 cr

20007213

Subaru EJ25 (2.6L) 2007 Big Valve Cyl Head, KK3766 Cams, 81mm billet crank, H11 head studs, 12mm oil pump, 8.2:1 cr

20007714

Subaru EJ25 (2.6L) 2004-06 Big Valve Cyl Heads KK3920 Cams - 81mm Billet Crankshaft H11 head studs, 12mm oil pump, 9.2:1 cr

20007715

Subaru EJ25 (2.6L) 2004-06 Big Valve Cyl heads KK3766 Cams - 81mm Billet Crankshaft H11 head studs, 12mm oil pump, 9.2:1 cr

20007716

Subaru EJ25 (2.6L) 2007 Big Valve Cyl heads KK3766 Cams - 81mm Billet Crankshaft H11 head studs, 12mm oil pump, 9.2:1 cr

20010271

Subaru EJ25 (2.5L) 2008-2011 Big Valve Cylinder heads and 20007395 Camshafts 79mm STD Crankshaft 8:2:1 cr

20010272

Subaru EJ25 (2.5L) 2008-2011 Big Valve Cylinder heads and 20007395 Camshafts 79mm Billet Crankshaft 8:2:1 cr

20010273

Subaru EJ25 (2.5L) 2008-2011 Big Valve Cylinder heads and 20007395 Camshaft 79mm STD Crankshaft 9.2:1 cr

20010274

Subaru EJ25 (2.5L) 2008-2011 Big Valve Cylinder heads and 20007395 Camshafts 79mm Billet Crankshaft 9.2:1 cr

20010275

Subaru EJ25 (2.6L) 2008-2011 Big Valve Cylinder heads and 20007395 Camshafts 81mm Billet Crankshaft 8:2:1cr

20010276

Subaru EJ25 (2.6L) 2008-11 Big Valve Cylinder heads and 20007395 Camshafts 81mm Billet Crankshaft 9:2:1cr

Subaru CS600 MAX (Includes H11 head studs and High volume oil pump, 81mm crankshaft)

Subaru 2008~2011 “CS600 & CS600X”

Subaru Engine Testing

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Billet Crankshafts 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 Superfinish.

Billet Crankshafts Part No.

Description Mitsubishi

20020632

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

Features Include: ■■ ■■ ■■ ■■

Superior lubrication Profiled counterweights High strength Light weight

Cosworth Tech: Isotropic Superfinish 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

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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

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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.

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.

Stroker Kits Part No.

Description Mitsubishi

KK3831

Mitsubishi Evo 4G63 (2.2L) - 94mm Crank

20007783

Mitsubishi Evo 4B11T (2.2L) - 94mm Crank

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

Subaru

Subaru EJ25 2.6L ■■ ■■

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Cosworth Forged Pistons (99.5mm) Cosworth Fully Counterweighted Billet Crankshaft (81mm) Forged Cosworth Connecting Rods Cosworth Rod and Main Bearings Cosworth Piston Rings

Mitsubishi 4G63 (Evolution VII-IX) 2.2L ■■ ■■

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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 ■■ ■■

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Cosworth Forged Pistons (86mm) Cosworth Fully Counterweighted Billet Crankshaft (94mm) Forged Cosworth Connecting Rods Cosworth Rod and Main Bearings Cosworth Piston Rings

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Forged Connecting Rods 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: ■■

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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

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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 EJ25 (2.5L) set of four

130.48

23.03

55.01

530

20002587

Subaru WRX 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

20020201

Mitsubishi Evo 4G63 (2.2L) set of four for use with Cosworth crankshaft 20020632

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

22.03

51.02

430

Honda

20002590

Honda K20 (2.0L) set of four H-Beam

139.03

Ultra High Performance Head Studs 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.

Ultra High Performance Head Stud Kits Part No.

Description

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

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

13

Ultra High Performance Engine Bearings Engine bearings are one of the most vital components within an engine and are often overlooked when considering high performance

upgrades.

Performance

High Performance Engine Bearings Part 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

friction. Cosworth race bearing sets feature

PR7889

Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal

Size 1

unique combinations of design, metallurgy

SB0006

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

Size 2

and engineering to deliver performance

SB0007

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

Size 2

engineered, multi-layer bearings generate less heat than normal bearings by reducing

in extreme conditions. Cosworth race bearings sets are available in three sizes to accommodate most applications. 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

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

20007173

Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal

Size 1

20007176

Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal

Size 1

20007174

Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal

Size 2 Size 2

■■

Tight consistent wall tolerances

20007177

Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal

■■

Oversize chamfers where applicable

20007178

Mitsubishi Evo X 4B11T Thrust Bearing Set

■■

Flash plating eliminated for improved heat transfer

20002725

Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal

Size 0

20002724

Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal

Size 0

■■

Tested to over 1000 horsepower!

14

Nissan VG35DE

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

Cosworth High Performance Engine Bearings are available in 3 sizes: 0, 1, 2. It is imperative that bearing clearances are measured before selecting the the appropriate bearing size. ■■

■■ ■■

■■

■■

All three sizes are within the nominal “standard” range. We do not offer undersized bearings for ground crankshafts. Size 1 is in the middle of the range 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

High Performance Engine Bearings Part 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

15

Forged Pistons 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.

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

Polished crown

Anti-detonation bands

Optimised forging

Xylan skirt coating

Subaru EJ25, 9.2:1

16

Mitsubishi 4G63

Subaru EJ25

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

Forged Piston Sets (Includes pistons, pins and circlips - rings not included) Part No.

Description Subaru

20003674

Subaru WRX STI EJ25 (2.5L) 99.5mm 8.2:1cr

20003675

Subaru WRX STI EJ25 (2.5L) 99.75mm 8.2:1cr

20003676

Subaru WRX STI EJ25 (2.5L) 100.mm 8.2:1cr

20003677

Subaru WRX EJ20 (2.0L) 92.mm 8.0:1cr

20003678

Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr

20003682

Subaru WRX STI EJ25 (2.6L) 99.5mm 8.2:1cr (For use with 81mm crankshaft)

20003683

Subaru WRX STI EJ25 (2.6L) 99.75mm 8.2:1cr (For use with 81mm crankshaft)

20003684

Subaru WRX STI EJ25 (2.6L) 100.mm 8.2:1cr (For use with 81mm crankshaft)

20004531

Subaru WRX STI EJ25 (2.5L) 99.5mm 9.2:1cr

20004532

Subaru WRX STI EJ25 (2.5L) 99.75mm 9.2:1cr

20004533

Subaru WRX STI EJ25 (2.5L) 100.mm 9.2:1cr

20004534

Subaru WRX STI EJ25 (2.6L) 99.5mm 9.2:1cr (For use with 81mm crankshaft)

20004535

Subaru WRX STI EJ25 (2.6L) 99.75mm 9.2:1cr (For use with 81mm crankshaft)

20004536

Subaru WRX STI EJ25 (2.6L) 100.mm 9.2:1cr (For use with 81mm crankshaft)

20003685

Subaru WRX EJ20 (2.2L) 92.mm 8.5:1cr (For use with 79mm crankshaft)

20003687

Subaru WRX EJ20 (2.2L) 92.5mm 8.5:1cr (For use with 79mm crankshaft)

20003223

Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr

20003225

Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr

20003679

Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application)

20003681

Nissan VQ35 (3.5L) Low CR 96.mm 8.8:1cr (Turbo application)

20003688

Mitsubishi Evo IV-IX 4G63 (2.0L) 85mm 8.8:1cr

20003690

Mitsubishi Evo IV-IX 4G63 (2.0L) 86mm 8.8:1cr

20003693

Mitsubishi Evo IV-IX 4G63 (2.2L) 86mm 8.8:1cr (For use with 94mm crank)

20005129

Mitsubishi 4B11 (2.0L) 86mm 9.0:1cr

20005130

Mitsubishi 4B11 (2.0L) 86.5mm 9.0:1cr

20005131

Mitsubishi 4B11 (2.0L) 87mm 9.0:1cr

20005856

Mitsubishi 4B11 (2.2L) 86mm 9.0:1cr (For use with 94mm crank)

20005859

Mitsubishi 4B11 (2.2L) 86.5mm 9.0:1cr (For use with 94mm crank)

20005860

Mitsubishi 4B11 (2.2L) 87mm 9.0:1cr (For use with 94mm crank)

20009276

Mitsubishi 4B11 (2.2L) 86mm 10.0:1cr For use with 94mm crank

20009277

Mitsubishi 4B11 (2.2L) 86.5mm 10.0:1cr For use with 94mm crank

20009278

Mitsubishi 4B11 (2.2L) 87mm 10.0:1cr For use with 94mm crank

20005865

Honda K20A 86mm 12:1cr

20005866

Honda K20A 86.25mm 12:1cr

20005867

Honda K20A 86.5mm 12:1cr

Nissan

Mitsubishi

Honda

Nissan VQ35 High Compression

17

Single Forged Pistons Single Forged Pistons (Includes pins and circlips) Part No.

Description Subaru

20000897

Subaru WRX STI EJ25 (2.5L) 99.5mm 8.2:1cr

20000898

Subaru WRX STI EJ25 (2.5L) 99.75mm 8.2:1cr

20000899

Subaru WRX STI EJ25 (2.5L) 100.mm 8.2:1cr

20002111

Subaru WRX EJ20 (2.0L) 92.mm 8.0:1cr

20002112

Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr

20002431

Subaru WRX STI EJ25 (2.6L) 99.5mm 8.2:1cr (For use with 81mm crankshaft)

20002432

Subaru WRX STI EJ25 (2.6L) 99.75mm 8.2:1cr (For use with 81mm crankshaft)

20002433

Subaru WRX STI EJ25 (2.6L) 100.mm 8.2:1cr (For use with 81mm crankshaft)

20002489

Subaru WRX EJ20 (2.2L) 92.mm 8.5:1cr (For use with 79mm crankshaft)

20002491

Subaru WRX EJ20 (2.2L) 92.5mm 8.5:1cr (For use with 79mm crankshaft)

20004522

Subaru WRX STI EJ25 (2.5L) 99.5mm 9.2:1cr

20004523

Subaru WRX STI EJ25 (2.5L) 99.75mm 9.2:1cr

20004524

Subaru WRX STI EJ25 (2.5L) 100.mm 9.2:1cr

20004528

Subaru WRX STI EJ25 (2.6L) 99.5mm 9.2:1cr (For use with 81mm crankshaft)

20004529

Subaru WRX STI EJ25 (2.6L) 99.75mm 9.2:1cr (For use with 81mm crankshaft)

20004530

Subaru WRX STI EJ25 (2.6L) 100.mm 9.2:1cr (For use with 81mm crankshaft)

20002036

Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr (Left hand bank)

20002038

Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr (Left hand bank)

20002039

Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr (Right hand bank)

20002041

Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr (Right hand bank)

20002132

Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application)

20002134

Nissan VQ35 (3.5L) Low CR 96.mm 8.8:1cr (Turbo application)

Nissan

18

Single Forged Pistons (Includes pins and circlips) Part No.

Description Mitsubishi

20000832

Mitsubishi Evo IV-IX 4G63 (2.0L) 85mm 8.8:1cr

20000834

Mitsubishi Evo IV-IX 4G63 (2.0L) 86mm 8.8:1cr

20000971

Mitsubishi Evo IV-IX 4G63 (2.2L) 86mm 8.8:1cr For use with 94mm crank

20004488

Mitsubishi 4B11 (2.0L) 86mm 9.0:1cr

20004675

Mitsubishi 4B11 (2.0L) 86.5mm 9.0:1cr

20004676

Mitsubishi 4B11 (2.0L) 87mm 9.0:1cr

20005783

Mitsubishi 4B11 (2.2L) 86mm 9.0:1cr (For use with 94mm crank)

20005784

Mitsubishi 4B11 (2.2L) 86.5mm 9.0:1cr (For use with 94mm crank)

20005785

Mitsubishi 4B11 (2.2L) 87mm 9.0:1cr (For use with 94mm crank)

20009273

Mitsubishi 4B11 (2.2L) 86mm 10.0:1cr For use with 94mm crank

20009274

Mitsubishi 4B11 (2.2L) 86.5mm 10.0:1cr For use with 94mm crank

20009275

Mitsubishi 4B11 (2.2L) 87mm 10.0:1cr For use with 94mm crank

20005799

Honda K20A 86mm 12:1cr

20005800

Honda K20A 86.25mm 12:1cr

20005801

Honda K20A 86.5mm 12:1cr

Honda

Cosworth Tech: Green Pistons Xylan 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.

Spare Piston Pins and Circlips 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.

Spare Piston Pins and Circlips Part 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

19

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.

Performance Ring Sets for Cosworth Pistons Part 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

20003607

Subaru WRX EJ20 (2.0L) 92.5mm (Use with Stroker pistons 20002491/ 20003687)

20001512

Nissan VQ35 (3.5L) 95.5mm

20001514

Nissan VQ35 (3.5L) 96.mm

(Use with Stroker pistons 20002489/ 20003685)

Nissan

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

20008832

Tool -85.00Mm Ring Compressor

20007717

Tool -86.00Mm Ring Compressor

20007751

Tool -86.25Mm Ring Compressor

20007761

Tool -86.50Mm Ring Compressor

20007782

Tool -87.00Mm Ring Compressor

20007784

Tool -87.50Mm Ring Compressor

20007785

Tool -92.00Mm Ring Compressor

20007786

Tool -92.50Mm Ring Compressor

20007787

Tool -95.50Mm Ring Compressor

20007788

Tool -96.00Mm Ring Compressor

20007793

Tool -99.50Mm Ring Compressor

20007794

Tool -99.75Mm Ring Compressor

20007795

Tool -100.0Mm Ring Compressor

Tool

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 aluminum and features a hard anodized finish.

Cosworth Tech: Ring Sets Cosworth 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”.

20

Kevlar High Performance Timing Belts 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 fiber provides extra wear resistance and increased tooth strength Kevlar backing improves strength

Cosworth Kevlar High Performance Timing Belts Part 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 RB25/26

21

High Performance Camshafts 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 Camshafts Part No.

Description

Specification Subaru

KK3766

Subaru WRX STI EJ25 (2.5L) Set of four (AVCS Type) S2 Grind (Electronic throttle)

Int."278" deg. 10.7mm lift / Exh. "274" deg. 10.mm lift

KK3765

Subaru 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

"272" deg. 10mm lift

KK3920

Subaru WRX STI EJ25/EJ20 Set of four (AVCS Type) S2 Grind (Cable throttle)

Int."278" deg. 10.7mm lift / Exh. "274" deg. 10.mm lift

20007395

Subaru WRX STI EJ257B Set of four (Dual AVCS) S2D Grind

Int."278" deg. 10.7mm lift / Exh. "274" deg. 10.mm lift

20005187

Subaru WRX EJ20 (2.0L) Set of four. Compatible with GC8 Version IV (09/1997)

"270" deg. 10.4mm lift

Mitsubishi

KK3805

Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M1 Grind

KK3806

Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M2 Grind

"272" deg. 11 mm lift

Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M3 Grind

Intake"280" deg. 11.6mm / Exhaust "272" deg. 11mm lift

20002513

"264" deg. 10.2 mm 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

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

Mitsubishi “SWB” Race Camshafts

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

Mazda MZR

20002515

Mazda MZR (1 intake and 1 exhaust cam) “MZ1” Grind

Intake “264” deg. 9.8mm lift / Exhaust “244” deg. 8.5mm lift

Cosworth Tech - Subaru Cams Our 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

22

Japanese/European

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 EVO 4G63 Mivec Mitsubishi 4B11T

Subaru WRX STi EJ257B

Nissan VQ35

23

High Performance Valve Train High Performance Valves

High Performance Valve Train

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.

Part 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

PR7711

Subaru EJ25 (2.5L) Graded Cam bucket 4.52

PR7712

Subaru EJ25 (2.5L) Graded Cam bucket 4.54

PR7713

Subaru EJ25 (2.5L) Graded Cam bucket 4.56

PR7714

Subaru EJ25 (2.5L) Graded Cam bucket 4.58

PR7715

Subaru EJ25 (2.5L) Graded Cam bucket 4.60

PR7716

Subaru EJ25 (2.5L) Graded Cam bucket 4.62

PR7717

Subaru EJ25 (2.5L) Graded Cam bucket 4.64

PR7718

Subaru EJ25 (2.5L) Graded Cam bucket 4.66

PR7719

Subaru EJ25 (2.5L) Graded Cam bucket 4.68

PR7720

Subaru EJ25 (2.5L) Graded Cam bucket 4.70

PR7721

Subaru EJ25 (2.5L) Graded Cam bucket 4.72

PR7722

Subaru EJ25 (2.5L) Graded Cam bucket 4.74

PR7723

Subaru EJ25 (2.5L) Graded Cam bucket 4.76

PR7724

Subaru EJ25 (2.5L) Graded Cam bucket 4.78

PR7725

Subaru EJ25 (2.5L) Graded Cam bucket 4.80

PR7726

Subaru EJ25 (2.5L) Graded Cam bucket 4.82

PR7727

Subaru EJ25 (2.5L) Graded Cam bucket 4.84

PR7728

Subaru EJ25 (2.5L) Graded Cam bucket 4.86

PR7729

Subaru EJ25 (2.5L) Graded Cam bucket 4.88

PR7730

Subaru EJ25 (2.5L) Graded Cam bucket 4.90

PR7731

Subaru EJ25 (2.5L) Graded Cam bucket 4.91

PR7602

Valve, Inlet +1.0mm Nissan VQ35-Stainless Steel (38.15mm)

PR7603

Valve, Ex +1.0mm Nissan VQ35-Inconel (32.35mm)

CI0113

Valve, Inlet +1.0mm Mitsubishi 4G63 Stainless Steel (35.0mm)

CI0112

Valve, Ex +1.0mm Mitsubishi 4G63-Inconel (31.5mm)

Nissan

Mitsubishi

20007107

Valve, Inlet +1.0mm Mitsubishi 4B11T Stainless Steel (36.0mm)

20007082

Valve, Ex +1.0mm Mitsubishi 4B11T-Inconel (30.0mm)

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

L1 mm

F1 N

F1 lbs

L2 mm

F2 N

F2 lbs

Max Lift

Coil Bind

20000164

Part No.

Mitsubishi EVO 7-9

47.00

38.1

381

85

26.1

900

202

12.0

24.3

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

20000166

Subaru EJ 2.0/2.5

42.00

36.0

275

62

25.0

780

175

11.0

23.2

KK3813

Mitsubishi EVO 7-9

50.00

38.1

512

115

26.9

1268

285

12.0

25.7

Nissan VQ35DE

47.00

38.0

378

85

23.9

1183

266

14.1

22.6

Subaru EJ 2.0/2.5

46.10

36.0

356

80

22.1

1019

229

13.9

20.8

20002550 KK3839

Application

All dimensions are in millimetres unless otherwise specified

24

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. ■■

■■ ■■ ■■

High RPM Valve Spring Sets Part 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

20000166

High RPM Single Valve Spring set (16) Subaru WRX STI EJ25 (2.5L) EJ20 (2.0L)

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)

Subaru

Nissan

Manufactured from the finest Japanese Kobe steel Single spring design for easy installation Dual chamfered ends Increased performance

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.

Ultra-High RPM Valve Spring Sets Part 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

*Seal clearance Install Height “F1”

Nissan VQ35DE

Mitsubishi 4B11

Mitsubishi 4G63

Subaru EJ20/EJ25

25

High Performance Head Gaskets 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 multilayer 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

Folded Stopper Layer

Gasket Layer

High Performance Head Gaskets Part 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)

20000903

Nissan VQ35DE (3.5L) Bore = 98mm T ~ 0.6mm (Pr)

20000906

Nissan VQ35DE (3.5L) Bore = 100mm T ~ 0.6mm (Pr)

20000924

Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.1mm

20000925

Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.5mm

20000926

Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.8mm

20003395

Nissan SR20DET (2.0L) Bore = 90mm T ~ 1.1mm

20003396

Nissan SR20DET (2.0L) Bore = 90mm T ~ 1.5mm

20000927

Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.1mm

20000928

Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.5mm

20000929

Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.8mm

20000930

Nissan RB25DET (2.5L) Bore = 87mm T ~ 1.1mm

20000931

Nissan RB25DET (2.5L) Bore = 87mm T ~ 1.5mm

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

20000913

Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 0.78mm each

20000916

Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.1mm each

20002145

Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.5mm each

20010706

2008+ Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 0.78mm each

20010707

2008+ Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.1mm each

20010708

2008+ Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.5mm 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

Mitsubishi

Subaru

Honda

Gasket Layer

26

20010904

Honda S2000 F20/22C Bore = 88mm, T ~ 0.38mm

20010905

Honda S2000 F20/22C Bore = 88mm, T ~ 0.80mm

20010906

Honda S2000 F20/22C Bore = 88mm, T ~ 1.1mm

20010907

Honda S2000 F20/22C Bore = 90mm, T ~ 1.1mm

20003127

Honda K20/24 Bore = 87mm T ~ 0.8mm for use with RAA, RAC, RBB, and RBC cylinder heads.

20003128

Honda K20/24 Bore = 87mm T ~ 1.1mm for use with RAA, RAC, RBB, and RBC cylinder heads.

20003129

Honda K20/24 Bore = 89mm T ~ 1.1mm 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.

20005454

Honda K20/24 Bore = 87mm T ~ 0.8mm for use with PRB, PNC, and PPA cylinder heads.

20005455 

Honda K20/24 Bore = 87mm T ~ 1.1mm for use with PRB, PNC, and PPA cylinder heads.

20005456

Honda K20/24 Bore = 89mm T ~ 1.1mm for use with PRB, PNC, and PPA cylinder heads.

Folded stopper layer provides complete sealing around entire combustion chamber

Without folded stopper layer, clamping force is limited resulting in incomplete sealing around combustion chamber

Honda F20C

Nissan VQ35DE

Stopper sealing layer

Uniform nitrile rubber coating

Mitsubishi 4G63

Mitsubishi 4b11t

Die cut edges

Subaru EJ25

27

Thermal Composite Gaskets 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.

Thermal Composite Gaskets Part 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

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

28

High Flow Intake Systems Cosworth’s High Flow Intake Systems feature increased diameter, large smooth radius bent aluminum 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.

High Flow Intake Systems Part 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

Up to 15% More Performance ■■

■■

■■

■■ ■■

Lightweight aluminum 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

29

Oil Control 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 stabilize oil temperatures. Cosworth oil control components are engineered to combat several problem areas experienced in high performance engines. 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.

Oil Control Part 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)

20009175

Nissan (VQ35) High Pressure Oil Pump Kit

20008841

Nissan (VQ35) Oil Control Baffle

20008632

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

20001382

Mitsubishi Evo VII-IX 4G63 (2.0L) Crankshaft Oil Scraper

20007845

Mazda Miata NC Oil Cooler Kit

Nissan

Mitsubishi

Mazda

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 maneuvers to help maintain constant oil pressure. Manufactured from stainless steel. Model Year 2003-2004 require fit kit PN 20008632 for proper installation.

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, oneway 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.

30

Nissan Baffle Install Kit

Subaru Oil Control Baffle

Nissan Oil Control Baffle

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.

Heavy duty mounting bracket / pump manifold

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

Internal baffling

Required to complete the installation: ■■ ■■ ■■

■■

Oil Tank Hoses/Hose Ends 2004-2007 Subaru STI Alternator Bracket Cosworth High Volume/Pressure Oil Pump 20001185

Low profile design

Twin Scavenge Ports

31

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

Subaru EJ20/25 Oil pump - High Volume - 20001185 Increasing oil volume will help to prevent bearing damage and engine failure.

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.

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

Pump Gear: 10mm vs 12mm

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

32

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.

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.

ECPro Cosworth’s professional motorsport ECUs are engineered by the team responsible for developing the Pectel Control Systems range. They are the only ECUs with “Plug & Perform” in mind, offering an out-of-thebox base calibration to immediately run your engine so its ready for dyno tuning to your desired specification. ■■

■■

■■

■■

■■

■■

■■

■■

■■ ■■

Professional motorsport design - machined aluminum case and motorsport specification electronics Complete integration with OEM vehicle CAN bus for seamless installation 56Mhz processor - higher performance timing and control 4MB of memory - pre-configured internal logging for 2000 samples per second on 54 channels of data (RPM, boost, sensors, fuel multipliers etc.) Knock Monitoring and Control - OEM MIL lamp indication of detonation levels; industry leading control technology Calibration Select - ability to access multiple complete maps (calibration selectable for boost, fuelling, ignition, rev limit, ALS setting, VCAM target, Fly-By-Wire pedal mapping, and overrun fuelling cut-off) e.g. Intelligent, Sports and Sports-Sharp with the SI-drive on the STi 08) Pectel Anti-lag System (ALS) - off throttle, low rpm boost enhancement AVCS & MIVEC - preconfigured fully variable quad / dual cam control Optional ECPro Dash Display Comprehensive configured worksheets software suite

ECPro Part No.

Description

30C-550004

Cosworth ECPro Kit - Mitsubishi Evo 9 USDM

30C-550020

Cosworth ECPro Kit - Mitsubishi Evo X USDM

30C-550000

Cosworth ECPro Kit - Subaru USDM STI EJ257 (2.5L) 2008+

20009237

ECU Pin - Subaru STI EJ257 (2.5L) 2004+ Small Kit (10pcs.)

20009236

ECU Pin - Subaru STI EJ257 (2.5L) 2004+ Large Kit (10pcs.)

60C-550019

ECPro Ethernet Comms Lead (LEMO-RJ45) for 30C-550000 ECPro

01C-099500

ECPro Software CD

30C-550018

ECPro Dealer Dongle (requires pre-qualification and training course attendance)

30C-550017

ECPro Advanced User Dongle (with 1 year subscription)

30C-550035

ECPro Dash

ECPro - Subaru STi

ECPro

ECPro - Evo X

ECPro Dash Display (Alternate between red and blue backlight)

Pi CalTool

33

High Flow Synthetic Air Filters 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. ■■ ■■ ■■ ■■

■■

Nissan 350Z / Subaru Impreza

Improved performance Superior filtration Exceptional dust holding capacity Reduced restriction (10%+ compared to OE filters) Over 98% efficiency (ISO5011:200 Fine Dust Test)

Mazda 3

Mitsubishi Evo 8/9

Honda Fit

Subaru Legacy 2008+ STI

Honda S2000

34

Lexus IS250/350

Toyota Tundra

Performance Air Filters Part No.

Description

Performance Air Filters

Performance Air Filters Year

Part No.

Description

ACURA (Honda)

Year

Part No.

Description

Year

OPEL / VAUXHALL

MITSUBISHI

20005380

Acura Rsx

2002-2007

20006783

Lancer Evo X

2008-2010

20002270

Corsa (1.5L Diesel)

1988-1993

20005380

Acura Rsx Type S

2002-2006

20002277

Lancer Evo IX - IX

1996-2007

20002270

Vectra (1.7L) Turbo Diesel

1992-1995

20006783

Lancer (1.5/1.8/2.0L)

2008-2010

20002270

1991-1992

20002277

Lancer (1.3/1.6/2.0L)

1999-2008

Astra (1.7L) with Isuzu Diesel Engine

20006783

Outlander (2.0/2.4L) Diesel

2007-2009

20002270

Cavalier with Isuzu Diesel Engine

1992-1995

20002277

Outlander (2.0/2.4L)

2003-2007

20002270

Colt (1.3/1.6L)

1996-2005

Nova (1.5L) Incl. Diesel & Novavan

1989-1992

20002277 20002277

Mirage (1.5/1.8L)

1997-2004

20002270

Kadett (1.5L)

20002270

350Z

2003-2006

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

NISSAN

20005380

Civic Type R (2.0L) JDM

2001-2005

20005381

350Z (Twin Air Box)

2007-2010

20005380

Civic (2.0L)

2001-2006

20002270

R34 Skyline Gtr (2.6L)

1999-2002

20005380

Fr-V

2005-2008

20002270

R33 Skyline Gtr (2.6L)

1995-1998

20005380

Cr-V

2002-2006

20002270

R32 Skyline Gtr (2.6L)

1989-1994

20002272

Jazz (1.4L)

2007-2008

20002273

Fit (1.5L)

2007-2009

20002270

Skyline Coupe V35 (2.5/3.0/3.5L)

2001-2006

20002273

Fit JDM (1.3/1.5L)

2001-2006

20002270

R34 Skyline (2.0/2.5L)

1998-2001

20005380

Stream (2.0L)

2001-2005

20002270

R33 Skyline (2.0/2.5L)

20005380

Stepwagon (2.0L)

2001-2005

20002270

R32 Skyline (2.0/2.5L)

1989-1993

20002273

Mobilio JDM (1.5L)

2001-2007

20002270

R31 Skyline (2.0L)

1985-1989

20002273

Mobilio Spike JDM (1.5L)

2002-2007

20002270

R30 Skyline (2.0/2.8L)

20002270

Stagea (2.0/2.5/3.0/3.5L)

2002

20002270

300Zx (3.0L)

1987-1990

1988-1996

20002270

200Sx (1.8/2.0L)

20002270

HOLDEN

2002270

Calais (3.8L)

2002270

Commodore (3.8/5.0L) INIFINITI

2008-2009

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

1988-1999

20002278

Legacy B4 (2.0/2.5/3.0L) JDM

2003-2008

Silvia JDM (1.8./2.0L) S12/13/14/15

1980-2002

20002270

Legacy B4 (2.0/2.5/3.0L) JDM

1998-2005

20002270

Primera (1.6/1.8/2.0L)

1990-2007

20002270

Legacy (1.8/2.0/2.5L/3.0L)

1989-2003

20002270

Xtrail (2.0/2.2/2.5L)

2001-2006

20002278

Forester (2.0L/2.5L)

2008-2009

20002270

Maxima (2.0/2.4/2.8/3.0/3.5L)

1982-2009

20002278

Outback (2.0/2.5/3.0L)

2005-2009

20002270

Altima (2.4/2.5/3.5L)

1993-2008

20002278

Tribeca (3.0/3.6L)

2006-2008

20002270

Almera (1.5/1.8/2.0/2.2L) Incl.Tino

1995-2007

20002279

Tribeca (3.0/3.6L)

2006-2009

2004-2008

20002270

Alcione Svx (3.3L) JDM

1991-1996

20002278

Exiga (2.0L) JDM

2006-2008

1981-1990 1996-2006

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

Quest (3.5L)

20002270

I30 (3.0L)

1996-2001

20002270

Sentra (1.6/1.8/2.0/2.5L)

20002270

J30 (3.0L)

1993-1997

20002270

Terrano (2.4L)

1992-2005

20002270

Q45 (4.5L)

2001

20002270

Navarra (3.0L)

2004-2005

20002270

Qx4(3.3/3.5L)

1997-2003

20002270

Xterra (3.3L)

2000-2004

20002270

M30 (3.0L)

1990-1992

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

1991-2006

20002281

IS250

2005-2009

20002270

Prairie (2.0/2.4L)

1989-1996

20002281

IS350

2006-2009

20002270

Pickup (3.0L)

1990-1996 1995

20002281

IS220

2005-2009

20002270

QX (2.0/3.0L)

20002281

GS350

2005-2009

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

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

2007-2009 SUBARU

20002278

1993-1998

2003-2007

LOTUS

Tc (2.4L)

2008-2010

G35 (3.5L)

2006

20002282

Impreza 2.5L

20002270

GS430

2003-2009 SCION

Impreza WRX

2007-2008

20002281

Vibe

20002278

G35 (3.5L)

LEXUS

20002282

20002278

20005381

1985

2007-2009 PONTIAC

2008-2010

2008-2010

Gemini (1.5/1.7L)

4007

Impreza WRX STi

G37 (3.7L) (Twin Air Box)

20002270

20006783

20002278

20005381

ISUZU

1989

PEUGEOT

TOYOTA

20002281

Rav4 (2.2L) Diesel

20002282

Corolla T Sport

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)

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

2006-2010 2002

2001

35

Induction/Fuel Subaru High Volume Air Intake Manifold - PN 20006438 The Cosworth Subaru High Volume Inlet Manifold is cast from aluminum 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

36

Induction / Fuel Part 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"

KK3905

Nissan VQ35DE (3.5L) High Volume Fuel rail system Mitsubishi

20005241

Mitsubishi EVO X High Volume Fuel rail kit

20005378

Subaru STI 2008+ Front Mount Intercooler System

20006438

Subaru High Volume Inlet Manifold

20015678

TGV Delete Kit - Subaru EJ25 Top Feed Injectors

Subaru

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 fiber 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 center 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 fiber 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

37

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 midrange 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 aluminum 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.

High-polished finish optional

Mitsubishi EVO High Volume Fuel Rail System - 20005241

Nissan VQ35 High Volume Fuel Rail

The Cosworth High Volume Fuel Kit features a machined from solid, hard anodized aluminum 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.

The original factory VQ35DE fuel rail arrangement is limited in performance. The Cosworth VQ35 High Volume Fuel System features high volume anodized fuel rails, with o-ringed fittings and is fully

System - KK3905

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.

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 anodized finish is methanol compatible. (upgraded fittings and seals required) ■■

VQ35 Fuel Rail System

Mitsubishi Evo Fuel Rail System

38

Intercooler Upgrade 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 aluminum core with mandrel bent aluminum 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.

Intercooler Upgrade Part 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

Installation is simplified as no cutting of vehicle is required Features ■■

■■

■■ ■■ ■■

Large efficient core available in anodized black finish for subtle appearance Large diameter mandrel bent aluminum tubing with grey powder coated finish 4-ply heavy duty silicone coupling hoses Isolated mounting system Liner hose clamps

CAD Assembly

Large efficient intercooler core

Large diameter aluminum tubing

39

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 aluminum brackets. Installation does not require any vehicle modifications. Features ■■

■■

■■

■■

■■

■■ ■■ ■■

■■

Smooth transition cast aluminum 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

40

Robust mounting system

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 aluminum 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 optimized 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

NGK High Performance Spark Plugs NGK High Performance Spark Plugs are designed to withstand the severe mechanical and thermal shock associated with high revving, high-compression, and high boost engines. They feature a fine Iridium tip, which ensures high durability, and a consistently stable spark. Iridium alloy also has an extremely high melting point, perfect for today’s high-tech, high performance engines. They also feature Trivalent Metal Plating, which offers superior anti-corrosion and anti-seizing properties. Highly recommended for use in high-powered engines with increased compression ratios, and/or higher combustion chamber pressures. Available in different heat ranges to suit a variety of applications.

NGK High Performance Spark Plugs Part No.

Description

Specification

20005759

NGK R7438-8 VQ, EJ257, and 4G EVO9

Heat Range 8

20005760

NGK R7438-9 VQ, EJ257, and 4G EVO9

Heat Range 9

20005761

NGK TR7IX Duratec

Heat Range 7

20005762

NGK TR8IX Duratec

Heat Range 8

41

Brake Pads 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 “seatingin” 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

42

■■

■■ ■■

■■ ■■ ■■

■■

■■

■■ ■■

■■ ■■

■■

■■

■■ ■■

■■

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 Durability factor 6.5 with rotor minimal rotor abrasion Produces consistent, predictable braking performance

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 Durability Factor 9.5 with minimal rotor 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.

Vehicle Application List Model

Year

StreetMaster Front Pads

TrackMaster Front Pads

StreetMaster Rear Pads

TrackMaster Rear 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 7 2.0 Turbo

2000-2003

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 8 2.0 Turbo

2002-2005

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 9 2.0 Turbo

2005-2008

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 CFT3023

Subaru

Impreza 2.0 Turbo (Not UK)

98-2002

CFS3003

CFT3003

CFS3023

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

The Cosworth brake pad line is constantly expanding and update applications can be found at www.cosworthperformance.com

43

High Performance Brake Kits - Sport Cosworth Sport brake kits feature fully forged calipers for optimal strength and light weight. The bolt in bridge design allows for a super stiff caliper without sacrificing cooling. The end result is better performance with less vibration, noise, and pad taper.

High Performance Brake Kits - Sport Part No.

Description

Caliper/Rotor

Front/Rear

AUDI

20020666

S4 (B6, B7 Chassis) 2004-2009

4Piston / 355 x 32

Front

20020667

S4 (B6, B7 Chassis) 2004-2009

6Piston / 355 x 32

Front

20020668

S5 (Fits stock wheels) 2008-2009

6Piston / 355 x 32

Front

Cosworth 2-piece rotors are designed for 10-30% better airflow than directional vaned racing rotors. They were produced with a proprietary cast iron formula, which was specified with durability in mind. The hats and brackets are made with a special type of billet aerospace aluminum and are CNC machined in the USA to ISO standards.

20020681

S5 (Fits stock wheels) 2008 - 2009

6Piston / 380 x 32

Front

20020682

TT 3.2L 2008-2009

4Piston / 355 x 32

Front

All parts are bench tested prior to shipment. Each caliper is 100% pressure tested to 2,500psi. Every brake line is 100% pressure tested to 4,500psi. Every assembled two-piece rotor is tested for runout. Each kit is optimized for specific vehicle application. ■■

■■ ■■

■■

■■

■■

■■

■■

■■

Bolt-in bridge minimizes caliper compliance 4 piston caliper weight: 3.6 kg (7.94 lbs) 2-piece rotor design allows 1030% better airflow greatly improving performance 4 piston caliper uses standard FMSI D372 pad DOT legal stainless brake lines with clear abrasion-resistance cover Piston sizes are optimized for each vehicle application to maintain bias Differential piston sizes minimize pad taper for longer pad life and a firmer pedal Dust boots are standard for reduced maintenance All finished parts are 100% leak down and pressure tested

44

BMW

20020684

325, 328 Series (E90, E92) 2006-2009

4 Piston / 345 x 28

Rear

20020685

325, 328 Series (E90, E92) 2006-2009

6 Piston / 355 x 32

Front

Volkswagen

20020710

Golf GTI 2.0T (Mk5) 2006-2009

4Piston / 328 x 28

Front

20020711

Golf GTI 2.0T (Mk5) 2006-2009

4Piston / 355 x 32

Front

20020712

Jetta 2.0T (Mk5)

4Piston / 355 x 32

Front

20020713

Jetta 2.5L & TDI (Mk5) 2006-2009

4Piston / 328 x 28

Front

Honda

20020687

Lancer EVOLUTION 7-9 2003-2006

4Piston / 328 x 28

Rear

20020688

Lancer EVOLUTION 7-9 2003-2006

4 Piston / 355 x 32

Front

20020689

Lancer EVOLUTION 7-9 2003-2006

6 Piston / 355 x 32

Front

20020690

Lancer EVOLUTION 7-9 (Fits Stock Wheels) 2003-2006

4 Piston / 332 x 32

Front

20020691

Lancer EVOLUTION 10 2008-2010

4 Piston / 345 x 28

Rear

20020692

Lancer EVOLUTION 10 2008-2010

6 Piston / 355 x 32

Front

Subaru

20020693

Impreza WRX 2002-2007

4 Piston / 328 x 28

Front

20020694

Impreza WRX 2002-2007

4 Piston / 332 x 32

Front

20020695

Impreza WRX 2002-2007

4 Piston / 355 x 32

Front

20020696

Impreza WRX 2002-2007

6 Piston / 355 x 32

Front

20020697

Impreza WRX; 266x10mm Rear Rotor; Sliding Rear Caliper 2002-2005

2 Piston / 328 x 28

Rear

20020698

Impreza WRX 2008-2009

2 Piston / 345 x 28

Rear

20020700

Impreza WRX 2008-2009

4 Piston / 328 x 28

Front

20020701

Impreza WRX 2008-2009

4 Piston / 355 x 32

Front

20020702

Impreza WRX STi v7-9 (5x100mm & 5x114.3mm Bolt Circle)

4 Piston / 355 x 32

Front

20020703

Impreza WRX STi v7-9 (5x100mm & 5x114.3mm Bolt Circle)

6 Piston / 355 x 32

Front

20020704

Impreza WRX STi v7-9 (Fits Stock Wheels; 5x100mm & 5x114.3mm Bolt Circle)

4 Piston / 332 x 32

Front

20020705

Impreza WRX STi 2008- 2010

2 Piston / 345 x 28

Rear

20020706

Impreza WRX STi 2008- 2010

4 Piston / 355 x 32

Front

20020707

Impreza WRX STi 2008- 2010

6 Piston / 355 x 32

Front

20020708

Legacy GT 2005-2009

2 Piston / 328 x 28

Rear

20020709

Legacy GT 2005-2009

4 Piston / 332 x 32

Front

High Performance Brake Kits - MAXSport Cosworth MAXSport brake kits feature lightweight machined and hard anodized fully forged calipers. They are engineered to provide a 20-percent reduction in weight without sacrificing stiffness or performance over our standard Sport kit. Cosworth 2-piece rotors are designed for 10-30% better airflow than directional vaned racing rotors. They were produced with a proprietary cast iron formula, which was specified with durability in mind. The hats and brackets are made with a special type of billet aerospace aluminum and are CNC machined in the USA.

High Performance Brake Kits - MAXSport Part No.

Description

Caliper/Rotor

Front/Rear

AUDI

20020659

Lancer EVOLUTION 7-9 2003-2006

2 Piston / 328 x 28

Rear

20020660

Lancer EVOLUTION 7-9 2003-2006

4 Piston / 355 x 32

Front

20020661

Lancer EVOLUTION 10 2008-2010

4 Piston / 345 x 28

Rear

20020662

Lancer EVOLUTION 10 2008-2010

6 Piston / 355 x 32

Front

Volkswagen

20020663

Impreza WRX STi v7-9 (5x100mm & 5x114.3mm Bolt Circle) 2004-2007

6 Piston / 355 x 32

Front

20020664

Impreza WRX STi 2008-2010

4 Piston / 355 x 32

Rear

20020665

Impreza WRX STi 2008-2010

6 Piston / 355 x 32

Front

All parts are bench tested prior to shipment. Each caliper is 100% pressure tested to 2,500psi. Every brake line is 100% pressure tested to 4,500psi. Every assembled two-piece rotor is tested for runout. Hats and brackets are CNC machined to ISO standards. Each kit is optimized for specific vehicle application. ■■

■■

■■

■■

■■

■■

■■

■■

■■

Bolt-in bridge minimizes caliper compliance 20% reduction in weight over the Cosworth Sport kit calipers 2-piece rotor design allows 1030% better airflow greatly improving performance 6 piston caliper uses standard FMSI D1247 pad DOT legal stainless brake lines with clear abrasion-resistance cover Piston sizes are optimized for each vehicle application to maintain bias Differential piston sizes minimize pad taper for longer pad life and a firmer pedal Dust boots are standard for reduced maintenance All finished parts are 100% leak down and pressure tested

Sport caliper fully forged for optimal strength

MAXSport caliper machined for lightness

45

Miscellaneous Subaru Billet Timing Belt Guide - Part number SB0001

Miscellaneous Part No.

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 aluminum with a hard anodized finish. Includes mounting hardware.

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

Oil Filler Caps Part 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

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.

The Cosworth Oil Filler Cap is machined from solid aluminum 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 anodized finish. ■■ ■■ ■■

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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 aluminum with a “Cosworth blue” anodized finish. Mounting hardware included.

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Machined from solid aluminum Durable anodized finish Includes pre-installed O-ring for leak free operation Ergonomic, Classic Cosworth three prong design

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 THE STATE OF CALIFORNIA

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