PERFORMANCE TUNING COMPONENTS
High Performance Tuning Components for Fast Road and Track Applications
2011 A History Of Excellence
Cosworth has a legendary reputation for high performance racing engines and vehicle electronics systems in Formula One, the IndyCar Series, NASCAR, WRC and many more. In 40 years of F1 competition, Cosworth engines delivered 176 F1 wins, 13 Constructors’ Championships and 10 Drivers’ Championships. Cosworth’s results in American open- wheel racing, United States Auto Club (USAC), Championship Auto Racing Teams (CART) and the Indy Racing League (IRL), are equally impressive. Cosworth has now diversified to be one of the premier suppliers of high quality tuning components to the performance aftermarket. Our tuning portfolio of products and capabilities now extends throughout the vehicle, from the engine, to cooling, induction and fuel, thermal insulation, braking and filtration - with new, innovative products and extensions to ranges being added continually. Every one of our products is engineered to Cosworth’s exacting standards and all are designed to maximise the performance of the vehicle without compromising reliability, consistency and crucially the driving experience. Cosworth Aftermarket now design, manufacture and market an extensive range of tuning technologies for the enthusiast and motorsport professional alike including Japanese sport compact vehicles and luxury brand 4x4 vehicles. Our involvement in motorsport and road car tuning, latterly with the Cosworth Impreza STi CS400 has allowed our customers to share our experiences through our performance tuning products. New products and ranges are being added continuously. Please refer to www.cosworth.com Performance Tuning Components. Contents
Big Valve Cylinder Heads. 4 High Performance Short Block Assemblies. 6 High Performance Long Block Assemblies. 8 Forged Pistons . 10 Performance Ring Sets . 12 Spare Piston Pins and Circlips . 13 Billet Crankshafts. 14 Stroker Engine Kits. 15 Forged Connecting Rods. 16 High Performance Cylinder Head Stud Kits. 17 High Performance Camshafts. 18 Ultra High Performance Engine Bearings. 20 Kevlar High Performance Timing Belts. 22 Intercooler Systems. 23 High Flow Intake Systems. 26 Induction. 27 High Flow Synthetic Air Filters. 30 Brake Pads. 32 Big Brake Upgrade Kits . 35 Fuel. 36 Oil Control. 37 High Performance Valve Train. 40 High Performance Head Gaskets. 42 Thermal Composite Gaskets. 44 Cosworth Rhino Skin - Thermal Heat Protection. 45 Miscellaneous. 46 Disclaimer. 47
3 Big Valve Cylinder Heads
For over 40 years, Cosworth has been CNC Ported Big Valve Cylinder Heads the leader in innovative multi-valve cylinder head design for both racing Part No. Description and high performance production Subaru cars. The Cosworth CNC Ported Big KK3670 Subaru WRX STI EJ25 (2.5L) Pr. 2004-2006 Valve Cylinder head range is the latest 20001699 Subaru WRX STI EJ25 (2.5L) Pr. 2007 (with air injection ports) advancement. Modified from new OE 20004544 Subaru WRX STI EJ25 (2.5L) Pr. 2008-2009 (with dual AVCS) cylinder head castings, substantial gas flow Nissan improvements and upgraded valve train KK3918 Nissan VQ35 (3.5L) Pr. 2002-2006 (includes rev up version) components offer superior performance for Mitsubishi your high performance engine. KK3672 Mitsubishi Evo V-VIII -2005 4G63 2.0 Litre Each original cylinder head design is KK3852 Mitsubishi Evo IX 4G63 (2.0L) -2006 MIVEC carefully evaluated and tested to establish 20005685 Mitsubishi Evo X 2008 - 4B11T (2.0L) MIVEC the improvements required to meet Others the target performance level. Hours of 20000691 Ford Duratec, 2.0L/2.3L testing and flow bench validation are used to determine the best advanced port design yielding maximum usable CNC Ported Big Valve Cylinder Heads with Camshafts power and response. However, there Part No. Description is more to cylinder head design than Subaru just maximum flow. It is critical that port SB8010 Subaru WRX STI EJ25 (2.5L) Pr 2004-2006 w KK3766 Camshafts (USA & MY06 Japan/Euro) Electronic Throttle velocity is maintained to ensure drivability SB8012 Subaru WRX STI EJ25 (2.5L) Pr 2004-2006 w KK3920 Camshafts (Japan/Euro) Cable Throttle and valve train components are matched 20002024 Subaru WRX STI EJ25 (2.5L) Pr 2007 w KK3766 Camshafts (USA/Japan/Euro) to guarantee reliable performance. Once 20002026 Subaru WRX STI EJ25 (2.5L) Pr 2007 w KK3920 Camshafts (Special Applications Only) all of these factors have been tested 20010140 Subaru WRX STI EJ25 (2.5L) Pr 2008 w Dual AVCS Camshafts and validated, the final port contour is digitized. Using the digitized program, we then reshape both intake and exhaust a re-shaped combustion chamber to each cylinder head is ultrasonically ports using a 5 axis CNC mill producing un-shroud the valves increasing air flow cleaned, serialized and finally hand an accurate and consistent port shape and performance. After machining, each assembled with select high performance every time. In addition to re-shaping and cylinder head receives a multi-angle high valve train components, ready to install on enlarging the intake and exhaust ports, performance valve job on our precision your engine. most Big Valve Cylinder heads feature Newen® CNC valve seat cutter. Then
Nissan VQ35DE
Subaru EJ25
4 Key Features: ■■ All new OE Castings ■■ Enlarged intake and exhaust ports ■■ Large diameter stainless steel intake valves ■■ Large diameter inconel exhaust valves ■■ Hi-rev, dual valve springs ■■ Titanium retainers ■■ Hardened steel spring platforms ■■ Reshaped combustion chamber on most applications ■■ Flow bench proven design ■■ Dynamometer tested ■■ Machined Cosworth logo ■■ Precision multi-angle valve job ■■ Pre-assembled, ready to install ■■ Machined port bore finish ■■ Knife edge port divider
Cylinder head development
Mitsubishi 4B11
Precision Newen® CNC Valve Seat Machining
5 High Performance Short Block Assemblies
Cosworth high performance engine High Performance Short Blocks assemblies are the perfect basis for your high performance application. Each Part No. Description version has gone through countless Subaru hours of engineering and evaluation to SB8005 Subaru STI EJ25 Short Block (2.5L)-Forged Pistons, Rods 8:2:1 cr determine the best combination of parts SB8007 Subaru STI EJ25 Short Block(2.5L)-Forged Pistons, Rods W 79mm Billet Crank 8:2:1 cr and build specification, ensuring maximum 20003486 Subaru STI EJ25 Short Block(2.5L)-Forged Pistons, Rods W 81mm Billet Crank 8:2:1 cr reliable performance. Each Cosworth 20007702 Subaru STI EJ25 Short Block OE Crank 9.2:1 cr (High compression ratio) high performance engine assembly starts 20007697 Subaru STI EJ25 Short Block 81mm Crank 9.2:1 cr (High compression ratio) with all new select components as the 20007703 Subaru STI EJ25 Short Block 79mm BLT Crank 9.2:1 cr (High compression ratio) foundation of the performance build. Every Nissan block is thoroughly inspected before the 20000067 Nissan VQ35 Short Block (3.5L) Lo comp 8.8:1 cylinders are honed to perfection. We then CI8019 Nissan VQ35 Short Block (3.5L) Hi comp 11:1 balance the rotating assembly that includes Mitsubishi either a new factory forged crankshaft or CI8015 Mitsubishi Evo VIII/IX 4G63 Short Block (2.0L)-Forged Pistons, Rods Cosworth billet crank along with Cosworth forged connecting rods, Cosworth tri-metal CI8018 Mitsubishi Evo VII/IX 4G63 Short Block (2.2L)-Forged Pistons, Rods, Billet Crank bearings and Cosworth forged pistons. 20014144 Mitsubishi Evo X 4B11T Short Block (2.2L)-Forged Pistons, Rods, Billet Crank 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.
Subaru EJ25 High Performance Short Block 2.5/2.6L
The Cosworth EJ25 is an excellent starting ■■ New Subaru EJ25 STI EJ257 Block point for high performance and track day ■■ New Subaru EJ25 STI Forged applications. Crankshaft or Cosworth Billet Crank (79 or 81mm) ■■ Cosworth 79mm or 81mm Forged H-beam connecting rods ■■ Cosworth Forged Pistons (99.5mm) and rings ■■ Cosworth Tri-metal bearings ■■ Balanced to within 0.5 gram ■■ Complete blue-printed assembly ■■ Ring gap set ■■ Bearing clearance checked ■■ Deck height checked ■■ Connecting rod side clearance checked ■■ Crankshaft end float checked
6 Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L
The Cosworth 2.0L 4G63 is an excellent ■■ New Mitsubishi 4G63 Evolution Block starting point for high performance and ■■ New Mitsubishi forged crankshaft track day applications. (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 ■■ New Mitsubishi 4G63 Evolution Block combines the perfect bore to stroke ratio, ■■ New Cosworth Billet Crank (94mm) yielding potentially big gains in torque ■■ Cosworth Forged H-beam connecting while still allowing the engine to rotate and rods produce power at higher RPMs. ■■ 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 ■■ New Nissan forged crankshaft (81.4mm) ■■ Balanced to within 0.5 gram short block is the perfect foundation ■■ Cosworth Forged H-beam connecting ■■ Complete blue-printed assembly for your high performance application. rods ■■ Ring gap set Available in either high compression 11:1 ■■ Cosworth Forged Pistons (95.5mm) and ■■ Bearing clearance checked or low compression 8.8:1 for turbo or rings ■■ Deck height checked supercharged applications. ■■ Cosworth Tri-metal bearings ■■ Connecting Rod side clearance checked ■■ Cosworth Heavy Duty main studs ■■ Crankshaft end float checked ■■ Piston squirt jets
7 High Performance Long Block Assemblies
The Cosworth Subaru EJ25 CS600 series High Performance Long Block Assemblies is designed for extreme track day use and the demanding performance enthusiast. Part No. Description Each assembly is precision built by one Subaru - North American spec 2004-2006 EJ25 “CS600 & CS600X” of Cosworth’s skilled craftsmen using 20000161 Subaru EJ25 (2.5L) 2004-2006 w/ Big Valve Cylinder heads and KK3766 Cams-STD Crank 8.2:1cr the finest components from our parts 20000162 Subaru EJ25 (2.5L) 2004-2006 w/ Big Valve Cylinder heads and KK3766 Cams-Billet Crank 8.2:1cr catalogue to ensure maximum reliable 20003488 Subaru EJ25 (2.6L) 2004-06 w/ Big Valve Cylinder heads and KK3766 Cams-81mm Crank 8.2:1cr power and performance. Starting with 20007711 Subaru EJ25 (2.6L) 2004-06 w/ Big Valve Cylinder heads and KK3766 Cams-81mm Crank 9.2:1cr a new Subaru EJ257 semi closed deck Subaru - North American spec 2007 EJ25 “CS600 & CS600X” block, we meticulously diamond hone 20002504 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-STD Crankshaft 8.2:1cr each bore to guarantee perfect piston 20002503 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-Billet Crankshaft 8.2:1cr to cylinder wall clearance. The block is 20007706 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-STD Crank 9.2:1cr then assembled with our Forged Pistons, 20007705 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams-Billet Crank 9.2:1cr motorsport grade Forged H-Beam Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-STD Crankshaft 9.2:1cr connecting rods along with our high 20007710 performance rod and main bearings and a 20007709 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-Billet Crankshaft 9.2:1cr new STI forged crankshaft. For maximum 20003489 Subaru EJ25 (2.6L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-81mm Crank 8.2:1cr performance, an optional steel billet crank 20007712 Subaru EJ25 (2.6L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-81mm Crank 9.2:1cr is available (CS600X). Once the cylinder Subaru - European/Asia spec EJ25 Impreza 2004-2006 EJ25 “CS600 & CS600X” - Includes engine assembly with cylinder heads, camshafts, oil pump and cam covers block assembly is completed, we install a SB8008 Subaru EJ25 (2.5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-STD Crank 8.2:1cr pair of our CNC machine port-bored Big 20007707 Subaru EJ25 (2.5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-STD Crank 9.2:1cr Valve Cylinder heads with our proven “S2” camshafts complete with valve lash set to 20003490 Subaru EJ25 (2.6L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Cams 81mm Billet Crank 8.2:1cr our specifications. The cylinder heads are 20007708 Subaru EJ25 (2.5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-Billet Crank 9.2:1cr secured with our high performance 11mm 20000160 Subaru EJ25 (2.5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-Billet Crank 8.2:1cr steel studs and sealed with a Cosworth high performance stopper layer steel head gasket. Finally, we install one of our blue-printed, high pressure oil pumps for maximum lubrication. This proven engine combination has been used by top teams to win race and rally events in both North America, Asia and Europe.
Includes engine assembly with cylinder heads, camshafts, oil pump and cam covers
8 Features High Performance Long Block Assemblies ■■ New Subaru EJ25 STI Engine case Part No. Description ■■ New Subaru EJ25 STI Forged Crankshaft Subaru - Impreza 2007 Sti EJ25 “CS600 & CS600X” 20002504 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-STD Crank 8.2:1cr ■■ Optional Cosworth Billet Crankshaft (79/81mm stroke available) 20002503 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-Billet Crank 8.2:1cr ■■ Cosworth forged H-beam Connecting 20003489 Subaru EJ25 (2.6L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams 81mm Billet Crank 8.2:1cr rods 20007713 Subaru EJ25 (2.6L) 2007 w/ Big Valve Cylinder heads and KK3766 Cams 81mm Billet Crank 9.2:1cr ■■ Cosworth Forged Pistons and rings Subaru Impreza 2008+ Sti EJ25 “CS600 & CS600X” ■■ Cosworth motorsport Tri-metal bearings 20010271 Subaru EJ25 (2.5L) 2008-09 Big Valve heads & 20007395 Camshafts- 79mm STD Crankshaft 8:2:1 cr ■■ Balanced to within 0.5 gram 20010272 Subaru EJ25 (2.5L) 2008-09 Big Valve heads & 20007395 Camshafts-79mm Billet Crankshaft 8:2:1 cr ■■ Complete blue-printed assembly 20010273 Subaru EJ25 (2.5L) 2008-09 Big Valve heads & 20007395 Camshaft -79mm STD Crankshaft 9.2:1 cr ■■ Enlarged intake and exhaust ports 20010274 Subaru EJ25 (2.5L) 2008-09 Big Valve heads & 20007395 Camshafts - 79mm Billet Crankshaft 9.2:1 cr ■■ Large diameter stainless steel intake 20010275 Subaru EJ25 (2.6L) 2008-09 Big Valve heads & 20007395 Camshafts- 81mm Billet Crankshaft 8:2:1cr valves 20010276 Subaru EJ25 (2.6L) 2008-09 Big Valve heads & 20007395 Camshafts- 81mm Billet Crankshaft 9:2:1cr ■■ 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
Subaru Engine Testing
9 Forged Pistons
With 50 years of world class engine design Features & Benefits: and manufacturing experience, Cosworth’s ■■ Skirt profile & oval technology - reduces engine noise, increases life & performance intimate knowledge of the interaction ■■ F1 quality forgings - proprietary CosAl 010 for high stress applications between the piston and other engine ■■ Oil and combustion gas control features - reduced blow-by and oil consumption components gives the us the distinct ■■ Offset pin bores - for reduced engine noise advantage in piston design resulting in the finest piston available.
The piston is one of the most important Polished crown 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. Anti-detonation bands 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, Optimised forging polished top and patented anti-detonation bands. Additionally, each application uses a unique forging to minimize weight and ensure the strongest possible piston.
Xylan skirt coating
Subaru EJ25, 9.2:1 Mitsubishi 4G63 Subaru EJ25
Forged Piston Sets (Includes pistons, rings, pins and clips)
Part No. Description
Subaru
10001430 Subaru WRX STI EJ25 (2.5L) 99.5mm 8.2:1cr 10001431 Subaru WRX STI EJ25 (2.5L) 99.75mm 8.2:1cr 10001432 Subaru WRX STI EJ25 (2.5L) 100.mm 8.2:1cr 10001445 Subaru WRX EJ20 (2.0L) 92.mm 8.0:1cr 10001446 Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr 10001447 Subaru WRX EJ20 (2.0L) 93mm 8.0:1cr 10001433 Subaru WRX STI EJ25 (2.6L) 99.5mm 8.2:1cr (For use with 81mm crankshaft) 10001434 Subaru WRX STI EJ25 (2.6L) 99.75mm 8.2:1cr (For use with 81mm crankshaft) 10001435 Subaru WRX STI EJ25 (2.6L) 100.mm 8.2:1cr (For use with 81mm crankshaft) 10001442 Subaru WRX EJ20 (2.2L) 92.mm 8.0:1cr (For use with 79mm crankshaft) 10001443 Subaru WRX EJ20 (2.2L) 92.25mm 8.0:1cr (For use with 79mm crankshaft) 10001444 Subaru WRX EJ20 (2.2L) 92.5mm 8.0:1cr (For use with 79mm crankshaft) 10001436 Subaru WRX STI EJ25 (2.5L) 99.5mm 9.2:1cr Continued -> 10 Features Include: Forged Piston Sets (Includes pistons, rings, pins and clips) ■■ Unique forgings for each application Part No. Description ■■ ‘Xylan’ anti scuff skirt coating 10001437 Subaru WRX STI EJ25 (2.5L) 99.75mm 9.2:1cr ■■ Polished tops (reduces carbon build up and relieves stress) 10001438 Subaru WRX STI EJ25 (2.5L) 100.mm 9.2:1cr ■■ Manufactured from proprietary alloy 10001439 Subaru WRX STI EJ25 (2.6L) 99.5mm 9.2:1cr (For use with 81mm crankshaft) (CosAl 010) 10001440 Subaru WRX STI EJ25 (2.6L) 99.75mm 9.2:1cr (For use with 81mm crankshaft) ■■ Ultra strong pin 10001441 Subaru WRX STI EJ25 (2.6L) 100.mm 9.2:1cr (For use with 81mm crankshaft)
■■ Patented anti-detonation bands Nissan ■■ Supplied with full ring pack 10001466 Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr (Left and right hand bank) 10001467 Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr (Left and right hand bank) 10001468 Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application) 10001469 Nissan VQ35 (3.5L) Low CR 96.mm 8.8:1cr (Turbo application) 10001470 Nissan SR20DET 86mm 8.5:1cr Cosworth Tech: Green Pistons 10001471 Nissan SR20DET 86.5mm 8.5:1cr TBA Nissan RB26DETT 86.5mm 8.5:1cr-Stroker Xylan is a fluoropolymer coating TBA Nissan RB26DETT 87 mm 8.5:1cr-Stroker designed for use on various engine components and fasteners. Cosworth TBA Nissan RB26DETT 87.5mm 8.5:1cr-Stroker pistons use xylan coating to provide 20023158 Nissan VR38DETT 95.5mm 9.0:1cr lubrication and control friction, wear Mitsubishi resistance, heat resistance, nonstick 10001448 Mitsubishi Evo IV-IX 4G63 (2.0L) 85mm 8.8:1cr and release properties and, at the 10001449 Mitsubishi Evo IV-IX 4G63 (2.0L) 85.5mm 8.8:1cr same time, can also protect from 10001450 Mitsubishi Evo IV-IX 4G63 (2.0L) 86mm 8.8:1cr corrosion. This is the same coating 10001451 Mitsubishi Evo IV-IX 4G63 (2.2L) 85mm 8.8:1cr use with 94mm crank (PA2701+100) we use on many of our ultra-high 10001452 Mitsubishi Evo IV-IX 4G63 (2.2L) 85.5mm 8.8:1cr use with 94mm crank (PA2701+100) performance race engines. 10001453 Mitsubishi Evo IV-IX 4G63 (2.2L) 86mm 8.8:1cr use with 94mm crank (PA2701+100) 10001454 Mitsubishi 4B11T (2.0L) 86mm 9.2:1cr 10001455 Mitsubishi 4B11T (2.0L) 86.5mm 9.2:1cr 10001456 Mitsubishi 4B11T (2.0L) 87mm 9.2:1cr 10001457 Mitsubishi 4B11T (2.2L) 86mm 9.2:1cr Stroker for use with 94mm crankshaft 10001458 Mitsubishi 4B11T (2.2L) 86.5mm 9.2:1cr Stroker for use with 94mm crankshaft 10001459 Mitsubishi 4B11T (2.2L) 87mm 9.2:1cr Stroker for use with 94mm crankshaft 10001460 Mitsubishi 4B11T (2.2L) 86mm 10:1cr Stroker for use with 94mm crankshaft 10001461 Mitsubishi 4B11T (2.2L) 86.5mm 10:1cr Stroker for use with 94mm crankshaft 10001462 Mitsubishi 4B11T (2.2L) 87mm 10:1cr Stroker for use with 94mm crankshaft
Honda
10001463 Honda K20A 86mm 12:1cr 10001464 Honda K20A 86.25mm 12:1cr 10001465 Honda K20A 86.5mm 12:1cr 20006695 Honda K20A 86mm 9:1cr (for forced induction applications) 20006696 Honda K20A 86.5mm 9:1cr (for forced induction applications) 20006697 Honda K20A 87mm 9:1cr (for forced induction applications)
Toyota
TBA Toyota 2JZ-GTE 87mm 8.5:1cr
Nissan VQ35 High Compression
11 Performance Ring Sets
Developed using the latest technologies, Performance Ring Sets for Cosworth Pistons and highest quality materials, Cosworth Performance Ring Sets are designed Part No. Description to meet the demands of modern high Subaru performance engines for higher power 20001515 Subaru WRX STI EJ25 (2.5L) 99.5mm output, improved sealing, lower friction, 20001516 Subaru WRX STI EJ25 (2.5L) 99.75mm and longer life. 20001517 Subaru WRX STI EJ25 (2.5L) 100.mm 20005160 Subaru WRX EJ20 (2.0L) 92.mm 20005161 Subaru WRX EJ20 (2.0L) 92.5mm 20003605 Subaru WRX EJ20 (2.0L) 92.mm (Use with Stroker pistons 20002489/ 20003685) 20003607 Subaru WRX EJ20 (2.0L) 92.5mm (Use with Stroker pistons 20002491/ 20003687)
Nissan
20001512 Nissan VQ35 (3.5L) 95.5mm 20001514 Nissan VQ35 (3.5L) 96.mm
Mitsubishi
PR7317 Mitsubishi Evo 4G63 (2.0L) 85mm 20002246 Mitsubishi Evo 4G63/4B11 86mm 20005705 Mitsubishi Evo 4B11 86.5mm 20005706 Mitsubishi Evo 4B11 87mm
Tool
20008832 Tool -85.00Mm Ring Compressor 20007717 Tool -86.00Mm Ring Compressor 20007751 Tool -86.25Mm Ring Compressor 20007761 Tool -86.50Mm Ring Compressor Piston Ring Compressor 20007782 Tool -87.00Mm Ring Compressor Cosworth Cylindrical Ring Compressors 20007784 Tool -87.50Mm Ring Compressor are precision machined to exact tolerance 20007785 Tool -92.00Mm Ring Compressor to ensure easy piston installation on most 20007786 Tool -92.50Mm Ring Compressor engines. They feature a smooth, tapered 20007787 Tool -95.50Mm Ring Compressor bore along with a knurled top ring to 20007788 Tool -96.00Mm Ring Compressor securely hold it in place while installing 20007793 Tool -99.50Mm Ring Compressor the piston. Each tool is machined form high grade aluminium and features a hard 20007794 Tool -99.75Mm Ring Compressor anodised finish. 20007795 Tool -100.0Mm Ring Compressor
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”.
12 Spare Piston Pins and Circlips
Cosworth Pistons feature heavy duty, ultra Spare Piston Pins and Circlips strong piston pins designed for the higher stress and elevated load levels found in Part No. Description high performance engines. Spare parts are PA2674 23mm Pin, Subaru EJ20 / EJ25 Piston available for routine engine rebuilds. PA1846 22mm Pin, Mitsubishi 4G63 Piston For ease of circlip installation on Subaru PA1251 22mm Pin, Nissan VQ Piston engines, we offer an exclusive installation PP5433 Circlip, 23mm Subaru EJ20 / EJ25 Piston. 2 req per piston tool engineered to simplify the task. This PP2371 Circlip, 22mm Nissan / Mitsubishi Piston. 2 req per piston high quality tool is machined from steel to SB8004 Circlip install tool, Subaru ensure years of trouble free use.
13 Billet Crankshafts
Increased engine performance often Billet Crankshafts means increased engine speed and load. Original factory crankshafts may not Part No. Description be able to withstand the added stress, Mitsubishi resulting in catastrophic engine failure. Mitsubishi EVO 4G63 (2.2L conversion) 94mm stroke - Fully counter-weighted Billet Steel, F1 Rod Bearing type 20004138 (must use with Cosworth connecting rod 20020201) Additionally, many OE crankshafts rod 20006577 Mitsubishi EVO 4B11T (2.2L conversion) 94mm stroke - Fully counter-weighted Billet Steel journals are lubricated from only one main oil feed. Cosworth billet crankshafts 20002315 Subaru WRX STI EJ25 (2.5L) 79mm stroke - Light weight version Billet Steel feature full-flow oiling whereby each 20002316 Subaru WRX STI EJ25 (2.5L) 81mm stroke - Light weight version Billet Steel rod journal is lubricated from two main sources. This provides superior lubrication during sustained high rpm use preventing rod bearing failure. Cosworth Subaru crankshafts are manufactured entirely from high grade steel in a light-weight, high strength design with a unique Isotropic Super Finish (ISF®). Features Include: ■■ Superior lubrication ■■ Profiled counterweights ■■ High strength ■■ Light weight
Cosworth Tech: Isotropic Super Finish (ISF®) The ISF® process is a chemically process improves the life and efficiency the most power output possible. With the accelerated vibratory mass finishing of moving metal parts. Increased life ISF® process, the energy normally lost process. Any time two metal parts come translates into lower operating costs as to friction is now available in the form of into contact with each other, the resulting well as better performance. In extreme increased power output. Once friction friction causes heat build up. These high environments, such as automobile or is reduced, the engine will run cooler temperatures cause wear and over time motorcycle racing, every component allowing for longer durability of parts and reduce efficiency and eventually create must work in harmony at 100% capacity. fewer failures. the need for replacement. By creating Races are won and lost by fractions of a a smooth and shiny finish, the ISF® second, so it all comes down to getting
■■ 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
ISF® - ISF is a registered trademark of REM Chemical Inc. All Rights Reserved. 14 Stroker Engine Kits
Cosworth stroker kits are the perfect way Stroker Kits to add displacement, torque and power to your engine. Each kit includes select Part No. Description matched components from our parts list Mitsubishi ensuring reliable performance. KK3831 Mitsubishi Evo 4G63 (2.2L) - 94mm Crank 20007783 Mitsubishi Evo 4B11T (2.2L) - 94mm Crank
Subaru
20002500 Subaru EJ25 (2.6L) w 81mm Billet Crankshaft 20002501 Subaru EJ20 (2.2L) w 79mm Forged Crankshaft (92mm Pistons) 20004359 Subaru EJ20 (2.2L) w 79mm Forged Crankshaft (92.5mm Pistons) 20002502 Subaru EJ20 (2.2L) w 79mm Billet Crankshaft (92mm Pistons)
Subaru EJ25 2.6L ■■ 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 ■■ Cosworth Forged Pistons (86mm) ■■ Cosworth Fully Counterweighted Billet Crankshaft (94mm) ■■ Forged Cosworth Connecting Rods ■■ Cosworth Rod and Main Bearings ■■ Cosworth Piston Rings
Mitsubishi 4B11T (Evolution X) 2.2L ■■ Cosworth Forged Pistons (86mm) ■■ Cosworth Fully Counterweighted Billet Crankshaft (94mm) ■■ Forged Cosworth Connecting Rods ■■ Cosworth Rod and Main Bearings ■■ Cosworth Piston Rings
15 Forged Connecting Rods
The connecting rod is the vital link between Forged Connecting Rods the piston and power. When engine output Total is increased, the demands placed on the Ctr. to Ctr. P.E. Bore B.E. Bore Part No. Description Nominal (mm) (mm) (mm) connecting rod increase as well. To ensure Weight (g) engine reliability in all conditions, original Subaru connecting rods should be replaced with 20002587 Subaru WRX STI EJ20 (2.0L) set of four 130.48 23.03 55.01 530 heavy duty specification parts. Cosworth Mitsubishi
Forged Connecting Rods are manufactured 20002632 Mitsubishi Evo 4G63 (2.0L) set of four 150.01 22.03 48.00 568 from high strength 4340 (EN24) steel and Mitsubishi Evo 4G63 (2.2L) set of four for 20015908 150.01 22.03 52.89 565 machined to exacting tolerances. use with Cosworth crankshaft 20004138 20002596 Mitsubishi 4B11T (2.0L) set of four 143.74 23.03 55.01 565 Features: Mitsubishi 4B11T (2.2L) 94mm Stroker Rod 20007184 142.72 21.03 55.01 556 ■■ Rods include genuine Cosworth H11 set of four tool steel rod bolts (260,000psi). Nissan ■■ Proprietary forging made in the USA. 20002585 Nissan VQ35 (3.5L) set of six 144.17 22.03 55.01 547 ■■ Detailed machined work to maintain 20007115 Nissan VQ35 (3.8L) Stroker Rod set of six 141.71 22.03 55.01 538 optimum weight and strength. 20002588 Nissan RB26 (2.6L) set of six 121.51 21.02 51.02 507 ■■ Solid beam design for high power 20002589 Nissan SR20 (2.0L) set of four 136.30 22.03 51.02 564 applications 20011563 Nissan VR38 (3.8L) set of six 164.99 23.03 59.00 629 ■■ “Radial Truss” small end for superior Honda strength and reduced reciprocating 20002590 Honda K20 (2.0L) set of four H-Beam 139.03 22.03 51.02 430 mass ■■ Manufactured from 4340 (EN24) steel
16 High Performance Cylinder Head Stud Kits
Essential for high performance engine High Performance Cylinder Head Stud Kits (180,000psi tensile strength) builds, heavy duty head studs reduce cylinder head movement in high boost Part No. Description or high compression engines optimising PR7243 Subaru WRX STI EJ25/EJ20 (2.5L) 11mm cylinder head to block sealing. Cosworth PR7420 Nissan VQ35 (3.5L) Ultra High Performance Head Studs PR7767 Nissan SR20DET (2.0L) are manufactured from H11 tool steel PR7843 Mitsubishi Evo 4G63 (2.0L) with 260,000psi tensile strength and PR7422 BMW MINI Cooper/Cooper S (1.6L) come complete with nuts and washers. Manufactured with hex broach end for ease of installation. Ultra High Performance Head Stud Kits (260,000psi tensile strength) Additionally, genuine Cosworth head studs Part No. Description utilize a base seating feature to evenly 20002440 Subaru WRX STI EJ25/EJ20 (2.5L) 11mm distribute maximum load on the stud and 20002442 Mitsubishi Evo 4G63 (2.0L) 11mm not the threads. This feature is typically 20006025 Mitsubishi Evo X 4B11T Head Stud Kit found only in high level race engines. 20002444 Nissan SR20DET (2.0L) 11mm 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
17 High Performance Camshafts
Cosworth has been engineering camshafts Performance Camshafts for nearly 50 years. That coupled with years of innovative multi valve cylinder head Part No. Description Specification design ensures our camshaft designs are Subaru the most efficient in providing maximum Subaru WRX STI EJ25 (2.5L) Set of four (AVCS Type) S2 Grind Int."278" deg. 10.7mm lift / Exh. "274" KK3766 (Electronic throttle) - North American spec deg. 10.mm lift usable power across the widest power Subaru WRX EJ20 (2.0L) Set of four 9/99 - 8/05 non AVCS JDM band. KK3765 EJ205 ~ 9/01 - 8/05 non AVCS USDM WRX EJ205 engines - Euro/ "272" deg. 10mm lift Asian spec
Each cam is ground from a new blank Subaru WRX STI EJ25/EJ20 Set of four (AVCS Type) S2 Grind (Cable Int."278" deg. 10.7mm lift / Exh. "274" KK3920 and finished using the same procedures throttle) - Japan / European spec deg. 10.mm lift we use in our extreme level race engines. Subaru WRX STI EJ257B Set of four (Dual AVCS) S2D Grind - North Int."278" deg. 10.7mm lift / Exh. "274" 20007395 American , Asian and European spec deg. 10.mm lift Cosworth camshafts are the perfect Subaru WRX EJ20 (2.0L) Set of four. Compatible with GC8 Version IV "270" deg. 10.4mm lift compliment to our CNC Ported Big Valve 20005187 (09/1997) - Euro/Asian spec
Cylinder Heads. Our cams are profiled to Subaru WRX STI EJ25 (2.5L) Set of four (AVCS Type) North American Int.”260” deg. 9.6mm lift / Exh. “260” KK3814 increase boost response thereby increasing spec - North American spec deg. 9.6mm lift engine torque and power and are fully Mitsubishi compatible with our CNC Ported Big Valve KK3805 Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M1 Grind "264" deg. 10.2 mm lift Cylinder Heads. KK3806 Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M2 Grind "272" deg. 11 mm lift Intake"280" deg. 11.6mm / Exhaust Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M3 Grind 20002513 "272" deg. 11mm lift
Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M2 MIVEC Intake/Exhaust "272" deg. 11 KK3921 Grind mm lift
Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M3 MIVEC Intake "280" deg. 11.6mm lift / 20002517 Grind Exhaust "272" deg. 11 mm lift
Mitsubishi Evo X 4B11 (2.0L) Pr (1 intake and 1 exhaust cam) MX1 MIVEC Intake "266" deg. 10.8mm / 20004124 Grind Exhaust "266" deg. 10.4mm lift
Mitsubishi “SWB” Race Camshafts
20002698 Mitsubishi Evo 4G63 (2.0L) "280" Intake cam 280 deg. / 11.6 mm 20016008 Mitsubishi Evo 4G63 (2.0L) "290" Intake cam 290 deg. / 11.6 mm 20004722 Mitsubishi Evo IX 4G63 MIVEC (2.0L) "280" Intake cam 280 deg. / 11.6 mm 20016009 Mitsubishi Evo IX 4G63 MIVEC (2.0L) "290" Intake cam 290 deg. / 11.6 mm 20016006 Mitsubishi Evo 4-9 4G63 (2.0L) "280" Exhaust cam 280 deg. / 11.6 mm 20016007 Mitsubishi Evo 4-9 4G63 (2.0L) "290" Exhaust cam 290 deg. / 11.6 mm
Nissan
Intake "268" deg. 10.4mm lift / Nissan VQ35 "287hp" Set (2 intake and 2 Exhaust cams) "ZK1" Grind 20002507 Exhaust "268" deg. 9.5mm lift
Intake “270” deg. 10.65mm lift / Nissan VQ35 “287hp” Set (2 intake and 2 Exhaust cams) “ZK2” Grind 20002508 Exhaust “270” deg. 10.65mm lift
Intake “268” deg. 10.4mm lift / Nissan VQ35 “Rev up” Set (2 intake and 2 Exhaust cams) “ZK1” Grind 20002510 Exhaust “268” deg. 9.5mm lift
Intake “270” deg. 10.65mm lift / Nissan VQ35 “Rev up” Set (2 intake and 2 Exhaust cams) “ZK2” Grind 20002511 Exhaust “270” deg. 10.65mm 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 Japanese/European
18 Features Include: ■■ Ground from new blanks ■■ Engineered and tested profiles ■■ Broad power band ■■ Compatible with Cosworth CNC ported Big Valve Cylinder Heads
Subaru AVCS
Mitsubishi EVO 4G63 Mivec
Mitsubishi 4B11T
Subaru WRX STi EJ257B
Nissan VQ35
19 Ultra High Performance Engine Bearings
Engine bearings are one of the most vital High Performance Engine Bearings components within an engine and are Part No. Description Specification often overlooked when considering high Subaru EJ25 / EJ20 performance upgrades. Performance 20002720 Subaru WRX/STI EJ25/ EJ20 Main Bearing Set - Tri Metal Size 0 engineered, multi-layer bearings generate 20002721 Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal Size 0 less heat than normal bearings by reducing 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 in extreme conditions. Cosworth race Mitsubishi Evo 4G63 “Evo” 1992-2006 bearings sets are available in three sizes 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 to accommodate most applications. PR7894 Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal Size 1 Engineered with the following features: 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 ■■ High strength overlay plate with PR7428 Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal Size 2 reduced thickness for better oil control Mitsubishi Evo 4G63 (2.0L) Thrust Bearing set and less friction PR7429 Mitsubishi 4B11T Evo X ■■ Hardened steel backing on all 20007172 Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal Size 0 connecting rod bearings 20007175 Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal Size 0 ■■ Increased crush for better retention 20007173 Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal Size 1 ■■ 3/4 grooving on main bearings 20007176 Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal Size 1 providing optimum oil supply 20007174 Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal Size 2 ■■ Tight consistent wall tolerances 20007177 Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal Size 2 ■■ Oversize chamfers where applicable 20007178 Mitsubishi Evo X 4B11T Thrust Bearing Set ■■ Flash plating eliminated for improved Nissan VG35DE heat transfer 20002725 Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal Size 0 ■■ Tested to over 1000 horsepower! 20002724 Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal Size 0 PR7911 Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal Size 1 PR7910 Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal Size 1 PR7853 Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal Size 2 PR7854 Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal Size 2 PR7859 Nissan VQ35 (3.5L) Thrust Bearing Set
20 Our bearings are available in 3 sizes: 0 , 1, High Performance Engine Bearings 2. We do not offer undersized bearings for ground crankshafts. Part No. Description Specification Nissan SR20DET (except RNN14 Pulsar Gti-R) ■■ Size 1 is what we used to call “STD” 20002727 Nissan SR20 (2.0L) Main Bearing Set - Tri Metal Size 0 ■■ Size 2 is what we used to call “RACE” 20002726 Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal Size 0 ■■ Size 0 provides .025mm or .001” less oil PR7896 Nissan SR20 (2.0L) Main Bearing Set - Tri Metal Size 1 clearance than our size 1 bearing Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal Size 1 ■■ Size 2 provides .025mm or .001” more PR7895 oil clearance than our size 1 bearing PR7851 Nissan SR20 (2.0L) Main Bearing Set - Tri Metal Size 2 PR7852 Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal Size 2 Bearing half shells can be mixed and match PR7937 Nissan SR20 (2.0L) Thrust Bearing Set to provide the incremental changes in oil Nissan RB25/26 clearance However it is imperative that 20002729 Nissan RB25/26 Main Bearing Set - Tri Metal Size 0 bearing clearances are measured before selecting the appropriate bearing size. 20002728 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 0 PR7892 Nissan RB25/26 Main Bearing Set - Tri Metal Size 1 PR7891 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 1 PR7655 Nissan RB25/26 Main Bearing Set - Tri Metal Size 2 PR7656 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 2
Honda K20/K23/K24 (except A3)
20002731 Honda K20 (2.0L) Main Bearing Set - Tri Metal Size 0 20002730 Honda K20 (2.0L) Rod Bearing Set - Tri Metal Size 0 PR7914 Honda K20 (2.0L) Main Bearing Set - Tri Metal Size 1 PR7912 Honda K20 (2.0L) Rod Bearing Set - Tri Metal Size 1 PR7915 Honda K20 (2.0L) Main Bearing Set - Tri Metal Size 2 PR7913 Honda K20 (2.0L) Rod Bearing Set - Tri Metal Size 2 PR7916 Honda K20 (2.0L) Thrust Bearing Set
21 Kevlar High Performance Timing Belts
Cosworth Kevlar High Performance Timing Cosworth Kevlar High Performance Timing Belts belts are 300% stronger than original equipment timing belts and are the perfect Part No. Description compliment when installing Cosworth 20004950 Timing Belt – Mitsubishi 4G63 Heavy Duty, All camshafts or cylinder heads. 20004952 Balance Belt - Mitsubishi 4G63 Heavy Duty, All 20004953 Timing Belt – Subaru EJ20/25 Heavy Duty, All ■■ High saturation HNBR elastomeric composites ensure durability and heat 20019487 Timing Belt - Nissan Skyline RB25/26 resistance ■■ Durable nylon fibre provides extra wear resistance and increased tooth strength ■■ Kevlar backing improves strength
22 Intercooler Systems
Subaru front-mount Intercooler Intercooler Upgrade System 2008+ STI - 20005378 Part No. Description Front mounted intercoolers offer improved performance potential for Subaru 20014525 Mitsubishi EVO X Front Mount Intercooler (Uses factory piping) applications. The Cosworth front mount 20019677 Mitsubishi EVO X Intercooler Hard Pipe Kit intercooler for the 2008+ Subaru STI 20005378 Subaru STI 2008+ Front Mount Intercooler System replaces the restrictive, heat-soak prone original top mounted core. The engineered system features an efficient large aluminium core with mandrel bent aluminium tubing for maximum performance up to and exceeding 600hp. The intercooler core is rubber mounted on a secure bracket system to help eliminate cracking and breakage. Installation is simplified as no cutting of vehicle is required Features ■■ Large efficient core available in anodised black finish for subtle appearance ■■ Large diameter mandrel bent aluminium tubing with grey powder coated finish CAD Assembly ■■ 4-ply heavy duty silicone coupling hoses ■■ Isolated mounting system ■■ Liner hose clamps
Large efficient intercooler core
Large diameter aluminium tubing
23 Mitsubishi EVO X Front Mount Intercooler Upgrade - PN 20014525 The Cosworth front mount intercooler for 2008 and newer Mitsubishi Evolution X features cast end tanks and an efficient large core to ensure maximum charge air cooling capability. Steel brackets with rubber vibration isolators for optimal resistance to the fatigue failure common with hard mounted aluminium brackets. Installation does not require any vehicle modifications.
Features ■■ Smooth transition cast aluminium end tanks for optimum airflow. Purposeful airflow management without the compromises of fabricated sheet metal end tanks. ■■ Large, efficient intercooler core ensure low restriction and high-efficiency heat transfer. ■■ Easy installation - under 30 minutes with simple hand tools, no modification to car needed ■■ Heavy duty steel brackets with rubber isolated mounting ■■ 4-ply heavy duty silicone couplers with liner hose clamps ■■ Made in USA ■■ Core size: 20” x 12.3” x 3.5” ■■ 55% increased flow over the factory OE intercooler ■■ Optional large-diameter hard intercooler pipe kit - Part number 20019677 Robust mounting system
24 EVO X Intercooler Pipe Upgrade Kit - PN 20019677 The Cosworth Intercooler Pipe Upgrade for the Mitsubishi EVO X features large diameter single piece mandrel bent aluminium tubes with 4-ply silicone couplers and stainless steel liner type hose clamps and is designed to decrease turbo lag and increase power in your Mitsubishi Evolution X. The mounting location of the bypass valve has been optimised for reduced turbocharger lag and is compatible with both the original component and many aftermarket versions. Engineered to work with the factory intercooler or Cosworth intercooler kit (Cosworth part # 20014525) but may be compatible with other brands. Features ■■ Bright Silver, durable powder coated finish ■■ Relocated bypass valve for reduced turbocharger lag ■■ 2.5” / 63.5mm diameter tubing (hot side) ■■ 2.75” / 69.85mm diameter tubing (cold side) ■■ 4-ply silicone couplers ■■ Robust mounting system
25 High Flow Intake Systems
Cosworth’s High Flow Intake Systems High Flow Intake Systems feature increased diameter, large smooth radius bent aluminium inlet tubes for Part No. Description superior air flow management coupled with 20019421 2001-2007 Subaru Impreza WRX, 2004-2007 Subaru Impreza WRX STI a high flow air filter for maximum air flow 20019422 2008-2010 Subaru Impreza WRX and performance. 20019423 2008-2010 Subaru Impreza WRX STI Each kit includes an integrated heat shield 20019424 2008-2010 Mitsubishi Lancer EVO X designed to isolate the air intake from engine heat - delivering cold air into the engine for superior power conversion. The filter element is large, conical in shape and engineered to dramatically reduce intake restriction resulting in additional power and torque. Up to 15% More Performance ■■ Lightweight aluminium mandrel shaped inlet tube for maximum airflow ■■ Conical Cosworth blue cotton gauze cleanable air filter with Cosworth embossed dry carbon composite end cap ■■ Integrated heat shield for cold air isolation ■■ Hardware kit included for easy, perfect fit ■■ Made in USA
26 Induction
VQ35 Twin Plenum Intake Manifold - Induction PN 20000063 Part No. Description The Cosworth Twin Plenum Inlet Manifold for the Nissan VQ35DE has been designed Nissan to enhance mid-range and high RPM 20000063 Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with Carbon plenum covers power. It features increased plenum volume 20005779 Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with Carbon plenum covers "Bright Polish Finish" for improved high RPM power while torque Subaru enhancing velocity stacks improve mid- 20006438 Subaru High Volume Inlet Manifold range power. With performance derived 20015678 TGV Delete Kit - Subaru EJ25 Top Feed Injectors from countless hours of development Mitsubishi including computational fluid dynamics, TBA 4B11T Intake Manifold the Cosworth Twin Plenum Inlet Manifold is perfect for both normally aspirated and forced induction applications. Cast from lightweight aluminium alloy with carbon fibre end caps and includes all required mounting hardware. Will fit with original strut tower brace. Can be used with the factory fuel rail system or the Cosworth High Volume Fuel Rail kit.
High-polished finish optional
Mitsubishi 4B11T Intake Manifold The Cosworth Intake Manifold for the engineered top Cosworth’s high standards larger plenum volume and larger tapered 4B11T engine is designed for high of excellence and has been tested for runners with airhorn inlets for improved performance and maximum horsepower maximum performance as well as durability. airflow. The Cosworth manifold is designed and torque. The design has been This intake manifold features a significantly with stock throttle body location.
27 Subaru High Volume Air Intake Manifold - PN 20006438 The Cosworth Subaru High Volume Inlet ■■ Substantially increased plenum volume of brake booster, boost gauge, MAP Manifold is cast from aluminium featuring ■■ Large, tapered runners with radiused sensor, boost controller, etc. large tapered runners with radiused inlets inlets ■■ Will work with standard or forward for improved air flow. Plenum volume has ■■ Tuned plenum volume and runner mount throttle body configurations been substantially increased and tuned for length/taper ■■ Stock throttle body location for power. Engineered for easy installation and ■■ Over 10% increase in flow compatibility with most aftermarket FMIC is the key to making big power. ■■ Integral vacuum manifold for connection kits
28 TGV Delete Kit - PN 20015678 The Cosworth Tumble Generating Valve (TGV) Delete Kit is designed to maximize airflow to your engine by eliminating the obstructions inherent to the OEM TGV intake ports. The TGV deletes are made of a fibre reinforced polymer to insulate the cylinder head from the intake tract, providing your engine with a cooler, denser charge of air. To further increase performance, the Cosworth TGV deletes are port matched to our CNC cylinder heads and intake manifold. This product is a direct fit for the 07+ Subaru STi due to the top feed injector design and due to a revision to the upper bolt pattern of the TGV, specifically moving the centre two M6 holes. With our manifold and top feed injectors, the TGV delete kit will work without issue on most WRX/STi applications
■■ 07+ Subaru STi specific, top feed injector specific ■■ Produced from fibre reinforced polymer to lower intake air temperatures ■■ Deletes factory Tumble Generating Valve for increased airflow ■■ Free flowing design, port matched to Cosworth CNC Cylinder head & intake manifold ■■ Includes high temp o-rings, shoulder bolts, and shims. ■■ New OEM Subaru injector o-rings included
29 High Flow Synthetic Air Filters
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 Nissan 350Z / Subaru Impreza Toyota Tundra a true cold air supply to the engine. Cosworth Performance Air Filters also provide increased air flow when compared to original equipment air filters.
■■ Improved performance ■■ Superior filtration ■■ Exceptional dust holding capacity ■■ Reduced restriction (10%+ compared to OE filters) ■■ Over 98% efficiency (ISO5011:200 Fine Dust Test) Mazda 3 Subaru Legacy 2008+ STI
Lexus IS250/350 Mitsubishi Evo 8/9 Honda Fit
Honda S2000
30 Performance Air Filters Performance Air Filters Performance Air Filters
Part No. Description Year Part No. Description Year Part No. Description Year
ACURA (Honda) MITSUBISHI OPEL / VAUXHALL
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
CITROEN Astra (1.7L) with Isuzu Diesel 20006783 Lancer (1.5/1.8/2.0L) 2008-2010 1991-1992 20002270 Engine 20006783 C-Crosser 2008-2009 20002277 Lancer (1.3/1.6/2.0L) 1999-2008 Cavalier with Isuzu Diesel 20002270 1992-1995 FORD 20006783 Outlander (2.0/2.4L) Diesel 2007-2009 Engine 20002270 Maverick (2.4L) 1993-1998 Nova (1.5L) Incl. Diesel & 20002277 Outlander (2.0/2.4L) 2003-2007 20002270 1989-1992 HONDA Novavan 20002277 Colt (1.3/1.6L) 1996-2005 20002271 S2000 (2.0/2.2L) 1999-2009 20002270 Kadett (1.5L) 1989 20002277 Mirage (1.5/1.8L) 1997-2004 PEUGEOT 20005380 Integra Type R (2.0L) JDM 2001-2006 NISSAN 20006783 4007 2007-2009 Civic Type R (2.0L) 2000-2006 20005380 20002270 350Z 2003-2006 PONTIAC Civic Type R (2.0L) JDM 2001-2005 20005380 20005381 350Z (Twin Air Box) 2007-2010 20002282 Vibe 2003-2009 Civic (2.0L) 2001-2006 20005380 20002270 R34 Skyline Gtr (2.6L) 1999-2002 SCION Fr-V 2005-2008 20005380 R33 Skyline Gtr (2.6L) 1995-1998 20002270 20002282 Tc (2.4L) 2007-2009 20005380 Cr-V 2002-2006 20002270 R32 Skyline Gtr (2.6L) 1989-1994 SUBARU 20002272 Jazz (1.4L) 2007-2008 Skyline Coupe V35 2001-2006 20002278 Impreza WRX STi 2008-2010 20002270 (2.5/3.0/3.5L) 20002273 Fit (1.5L) 2007-2009 20002278 Impreza WRX 2008-2010 20002270 R34 Skyline (2.0/2.5L) 1998-2001 20002273 Fit JDM (1.3/1.5L) 2001-2006 20002278 Impreza 2.5L 2008-2009 20002270 R33 Skyline (2.0/2.5L) 1993-1998 20005380 Stream (2.0L) 2001-2005 20002278 Impreza 2.0L 2008-2009 20002270 R32 Skyline (2.0/2.5L) 1989-1993 20005380 Stepwagon (2.0L) 2001-2005 20002270 Impreza WRX STi 1997-2007 20002270 R31 Skyline (2.0L) 1985-1989 20002273 Mobilio JDM (1.5L) 2001-2007 20002270 Impreza WRX 1993-2007 20002270 R30 Skyline (2.0/2.8L) 1981-1990 20002273 Mobilio Spike JDM (1.5L) 2002-2007 20002270 Impreza 1993-2007 HOLDEN 20002270 Stagea (2.0/2.5/3.0/3.5L) 1996-2006 20002278 Legacy (2.5L/3.0L/GT) 2005-2009 2002270 Calais (3.8L) 2002 20002270 300Zx (3.0L) 1987-1990 Legacy B4 (2.0/2.5/3.0L) 20002278 2003-2008 2002270 Commodore (3.8/5.0L) 1988-1996 20002270 200Sx (1.8/2.0L) 1988-1999 JDM
INIFINITI Silvia JDM (1.8./2.0L) Legacy B4 (2.0/2.5/3.0L) 20002270 1980-2002 1998-2005 S12/13/14/15 20002270 JDM 20005381 G37 (3.7L) (Twin Air Box) 2008-2010 20002270 Primera (1.6/1.8/2.0L) 1990-2007 20002270 Legacy (1.8/2.0/2.5L/3.0L) 1989-2003 20005381 G35 (3.5L) 2007-2008 20002270 Xtrail (2.0/2.2/2.5L) 2001-2006 20002278 Forester (2.0L/2.5L) 2008-2009 20002270 G35 (3.5L) 2003-2007 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 G20 (2.0L) 1991-2002 20002270 Altima (2.4/2.5/3.5L) 1993-2008 20002278 Tribeca (3.0/3.6L) 2006-2008 20005381 Ex35 (3.5L) 2008-2009 Almera (1.5/1.8/2.0/2.2L) 20002270 1995-2007 20002279 Tribeca (3.0/3.6L) 2006-2009 20002270 Fx35 (3.5L) 2003-2008 Incl.Tino 20002270 Alcione Svx (3.3L) JDM 1991-1996 20002270 I35 (3.5L) 2002-2004 20002270 Quest (3.5L) 2004-2008 20002278 Exiga (2.0L) JDM 2006-2008 20002270 I30 (3.0L) 1996-2001 20002270 Sentra (1.6/1.8/2.0/2.5L) 1991-2006 TOYOTA 20002270 J30 (3.0L) 1993-1997 20002270 Terrano (2.4L) 1992-2005 20002281 Rav4 (2.2L) Diesel 2006-2010 20002270 Q45 (4.5L) 2001 20002270 Navarra (3.0L) 2004-2005 20002282 Corolla T Sport 2002 20002270 Qx4(3.3/3.5L) 1997-2003 20002270 Xterra (3.3L) 2000-2004 20002282 Corolla (1.4/1.6/1.8L) 2002-2009 20002270 M30 (3.0L) 1990-1992 20002270 Pathfinder (2.7/3.0/3.3/3.5L) 1990-2004 20002282 Matrix Xrs/Xr (1.8L) 2003-2009 ISUZU 20002270 Frontier (3.3L) 1999-2004 20002282 Avensis (1.6/1.8/2.0/2.4L) 2003-2007 20002270 Gemini (1.5/1.7L) 1985 20002270 Patrol (4.2L) 1988-1997 20002282 Altis (1.6/1.8/2.0L) 2001 LEXUS 20002270 Serena (1.6/2.0/2.3L) 1992-2001 20002270 Lexcen (3.8L) 1989-1997 20002281 IS250 2005-2009 20002270 Prairie (2.0/2.4L) 1989-1996 20002282 Premio JDM 2001-2007 20002281 IS350 2006-2009 20002270 Pickup (3.0L) 1990-1996 20002282 Noah JDM 2001-2008 20002281 IS220 2005-2009 20002270 QX (2.0/3.0L) 1995 20002282 Opa JDM 2000-2008 20002281 GS350 2005-2009 20002270 Sunny (1.5/1.6/1.7/1.8/2.0L) 1985-1993 20002282 Isis JDM 2004-2008 20002281 GS430 2006 20002270 NX (1.6/1.8/2.0L) 1987-1993 20002282 Allion JDM 2001-2007 LOTUS 20002270 Stanza (2.4L) 1990-1992 20002282 Elise 1.8L (Toyota Engine) 2004-2007 20002282 Ipsum JDM 2001-2008 20002270 Axxess (2.4L) 1990-1991 MAZDA 20002282 Wish JDM 2003-2008 20002270 Bluebird (1.9/2.0L) 1982-1990 20002273 RX-8 2003-2009 20002282 Voxy JDM 2001-2007 20002270 Laurel (2.0/2.4/2.8/3.0L) 1980-1989 20002275 MX-5 (1.8/2.0L) 2005-2008 20002282 Volt JDM 2008-2009 20002270 Cedric (2.8L) 1983 20002274 Mazda 3 (2.0/2.3L) 2003-2008 20002282 Caldina (Non-Turbo) JDM 2002-2008 20002270 810 (2.4/2.8L) 1981 20002274 Mazda 3 Mazdaspeed 2007-2008
31 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. ■■ Medium-hard sports pad suitable for With two grades of friction material, the heavy duty/fast road StreetMaster and TrackMaster ranges ■■ ECE R90 approval deliver exceptional levels of stopping power ■■ Superior bite - 0.5µ friction coefficient - specifically tailored for fast road and track virtually from first pedal applications respectively. ■■ Strong brake effect up to 650°C ■■ Chamfered edge – avoid lifting Manufactured in the United Kingdom, ■■ Fitted with premium quality shim Cosworth brake pads feature a 1.5mm hardware - silent braking technology granulated interlayer which not only serves ■■ Durability factor 6.5 with rotor minimal to act as a shock absorber, helping to disc abrasion reduce stress on the rotor surface but ■■ Produces consistent, predictable braking triples bonding strength so diminishing performance edge lifting. To reduce the “bedding-in” or “seating- in” time - this is the time it takes for the pad and disc to adapt to each other - all Cosworth brake pads are heat seared. This process heats the friction material to in excess of 600°C “toasting” the ■■ Track day driving surface greatly enhancing the performance ■■ Extremely high friction level 0.7µ friction the first time that the driver applies the coefficient brakes. Scorching pads also significantly ■■ Strong brake effect through 800°C reduces initial fading. Fading increases the ■■ “Vee” line expansion groove technology - necessary force and pressure required to superb debris clearance maintain the deceleration of the vehicle. ■■ Fitted with premium quality shim Cosworth’s brake pads range offer hardware - silent braking technology exceptional performance with no ■■ Durability Factor 9.5 with minimal disc compromise. abrasion ■■ Super fast “bed-in” typically under 2 laps Why choose Cosworth Brake Pads? ■■ Heat stable, predictable & heat cycle exceptionally well ■■ Heat seared for reduced “bedding-in” ■■ This track formulation CAN be safely time used on highways except in Europe ■■ Superior bite from cold where ECE R90 approvals are required. ■■ Exceptional stopping performance - 0.7µ This pad has too much brake effect to braking coefficient be compliant with these regulations. ■■ Silent running technology ■■ “Vee” groove for fast debris clearance ■■ Fade resistant ■■ Premium grade friction material ■■ Consistent & predictable braking patterns
32 Vehicle Application List StreetMaster TrackMaster StreetMaster TrackMaster Model Year Front Pads Front Pads Rear Pads 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
Subaru
Impreza 2.0 Turbo (Not UK) 98-2002 CFS3003 CFT3003 CFS3023 CFT3023
Impreza 2.0 Turbo (UK) 98-2002 CFS3003 CFT3003 CFS3007
Impreza 2.0 Turbo P1 2000-2002 CFS3003 CFT3003 CFS3007
Impreza 2.0 Turbo WRX 2001-2005 CFS3003 CFT3003 CFS3023 CFT3023
Impreza 2.2 Turbo (22B) 98-2000 CFS3003 CFT3003 CFS3023 CFT3023
Impreza 2.5 Turbo WRX 2006-2007 CFS3003 CFT3003 CFS3023 CFT3023
Impreza 2.0 Turbo WRX STi 2002-2005 CFS3004 CFT3004 CFS3008 CFT3008
Impreza 2.5 Turbo WRX STi 2006-2007 CFS3004 CFT3004 CFS3008 CFT3008
Impreza 2.5 Turbo WRX STi 2007- CFS3004 CFT3004 CFS3008 CFT3008
Toyota
Toyota Supra 3.0ltr Twin Turbo 17" wheel 93 - 2002 CFS3025 CFT3025 CFS3026 CFT3026 See next page for brake pad applications to fit AP Racing callipers
33 Cosworth Brake Pads to Fit AP Racing Calipers Cosworth SKU Cosworth SKU Model Year Position Caliper Type APR Caliper Ref StreetMaster TrackMaster
Ford
Civic Type R 2002 -2006 Front 4 Piston CP5200 CFSA001 CFTA001
Civic Type R 2002 -2006 Front 6 Piston CP5570 CFSA002 CFTA002
Civic Type R 2007 on Front 4 Piston CP6637 CFSA005 CFTA005
S2000 1999 on Front 4 Piston CP6637 CFSA005 CFTA005
Evo 7 - 8 & 9 2001 on Front 6 Piston CP7040 CFSA003 CFTA003
Evo 7 - 8 & 9 2001 on Front 6 Piston CP5555 CFSA002 CFTA002
Evo 4 - 5 & 6 1997 on Front 6 Piston CP5570 CFSA002 CFTA002
Evo 4 - 5 & 6 1997 on Front 4 Piston CP5200 CFSA001 CFTA001
350Z 2005 on Front 6 Piston CP7040 CFSA003 CFTA003
GTR32 1992 on Front 4 Piston CP5200 CFSA001 CFTA001
GTR33 1995 on Front 6 Piston CP5555 CFSA002 CFTA002
GTR34 1999 on Front 6 Piston CP5555 CFSA002 CFTA002
WRX,STI 2001 - 2007 Front 4 Piston CP5200 CFSA004 CFTA004
WRX,STI 1994 - 2007 Front 6 Piston CP5570 CFSA002 CFTA002
WRX,STI 2001 - 2007 Front 6 Piston CP7040 CFSA003 CFTA003
WRX,STI 2008- Front 6 Piston CP7048 CFSA006 CFTA006
Escort Cosworth 1991 on Front 6 Piston CP5570 CFSA002 CFTA002
Escort Cosworth 1991 on Front 4 Piston CP5200 CFSA001 CFTA001
Sierra Cosworth 1987 on Front 4 Piston CP5200 CFSA001 CFTA001
Sierra Sapphire Cosworth 4x4 1990 on Front 4 Piston CP5200 CFSA001 CFTA001
Fiesta ST 2005 Front 4 Piston CP6637 CFSA005 CFTA005
Focus RS 2002 on Front 6 Piston CP7040 CFSA003 CFTA003
Focus ST170 2001 on Front 4 Piston CP5200 CFSA001 CFTA001
The Cosworth brake pad range is constantly expanding and a full list of applications can be found at www.cosworth.com, Performance Tuning Components section
34 Big Brake Upgrade Kits
Cosworth has combined over 50 years of Big Brake Upgrade Kits motorsport heritage and technology with the unrivalled experience of AP Racing Part No. Description to develop a range of joint branded high 20017603 Subaru 2008 on (to fit 17 and 18 inch wheels) performance Big Brake Upgrade kits. CBK3002 EVO X (to fit 17 and 18 inch wheels) 350z (to fit 17 and 18 inch wheels) The Cosworth AP Racing brake kit delivers CBK3003 ultimate stopping power consistently and quickly from cold whilst offering corner weight reduction over the OEM brakes of 1.58Kg. The Cosworth BBK calipers are 6 piston, with differential bores to eliminate “pad taper”. The trailing pistons have a larger bore than the leading ones to compensate for mechanical end load & to even out the wear on the pads. All our performance brake calipers use conventional seals in conjunction with a dirt seal and are finished with an eye-catching high gloss black PTFE based paint coating which is impervious to normal brake fluids & high brake temperatures. The 2-piece discs features Cosworth technology embedded within the pair of 48 vaned discs together with lightweight high grade aluminium mounting bells designed to deliver enhanced airflow than the original brakes. The discs have been developed to produce optimum braking bite, as well as thermal stability and durability. The upgrade kits also contain a set of high performance brake pads, mounting brackets individually designed for each application, brake hoses, a complete set of fixings and two bottles of AP Racing Formula DOT 5.1 brake and clutch fluid. Cosworth Big Brake Upgrade Kits are a stylish and effective way of up-rating your cars braking performance. Detailed Specification:
■■ 2 x Ø355 x 32mm 2 piece brake discs ■■ 2 x 6 piston brake calipers ■■ High performance brake pad friction material* ■■ Braided brake hoses ■■ 2 x Dot 5.1 high temperature brake fluid ■■ 2 x Mounting brackets ■■ 2 x Aluminium mounting bells ■■ Steel braided hoses ■■ Fixings
*Braking material is not R90 approved for road use
35 Fuel
Mitsubishi EVO X High Volume Fuel Fuel Rail System - 20005241 Part No. Description The Cosworth High Volume Fuel Kit features a machined from solid, hard Nissan anodised aluminium fuel rail with o-ringed KK3905 Nissan VQ35DE (3.5L) High Volume Fuel rail system fittings and a pre-shaped inlet pipe. The Mitsubishi Cosworth High Volume Fuel Rail Kit can be 20005241 Mitsubishi EVO X High Volume Fuel rail kit used with original or various aftermarket injectors and PRV’s.
■■ Direct fit replacement- includes all necessary components for a complete bolt-on installation ■■ Designed with expansion in mind, facilitating installation of custom fuel systems including AN fuel lines and remote mounted fuel pressure regulators ■■ Full-flow ½” bore will support upwards of 600hp worth of fuelling ■■ Hard anodised finish is methanol compatible. (upgraded fittings and seals required)
Mitsubishi Evo Fuel Rail System
Nissan VQ35 High Volume Fuel Rail System - KK3905 The original factory VQ35DE fuel rail arrangement is limited in performance. The Cosworth VQ35 High Volume Fuel System features high volume anodised fuel rails, with o-ringed fittings and is fully configurable for various applications. Each system includes sleeved high pressure fuel lines along with a CNC machined distribution block that includes an additional port for various sensors. The Cosworth High Volume Fuel Rail System can be used with original or various aftermarket injectors. VQ35 Fuel Rail System
36 Fuel Oil Control
Subaru Dry Sump - 20004463 The Cosworth Dry Sump Setup Kit for the improved scavenging, and increased Subaru EJ series engine is a must for race ring seal due to greater pan vacuum. and performance applications. Dry sump The Cosworth Dry Sump System for the oiling systems offer an unparalleled level of Subaru EJ20/EJ25 replaces the original safety and reliability compared to factory oil sump with a machined from solid, low wet sump systems. Complete crankcase profile alloy pan with twin scavenge ports, oil scavenging reduces excessive and internal baffling and o-ring sealing. A two residual oil that can cause blow-by and stage scavenge pump driven by a HTD power loss. A dry sump also offers more belt, mounted to a heavy duty bracket consistent oil pressure to the engine, 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
37 High performance engines reject a Oil Control substantial amount of heat through the oil system. Maintaining oil pressure and Part No. Application control along with an increase in actual Subaru volume will help dissipate heat and stabilise 20001238 Subaru (EJ20/EJ25) High Volume Oil Pan oil temperatures. Cosworth oil control 20002499 Subaru (EJ20/EJ25) Oil Control Baffle components are engineered to combat KK3928 Subaru (EJ20/EJ25) Blueprinted Oil Pump with high pressure mod & install kit several problem areas experienced in high 20001185 Subaru (EJ20/EJ25) High Volume/Pressure Blueprinted Oil Pump & install kit performance engines. 20009093 Subaru 2008+ STI (EJ25) Blueprinted Oil Pump with high pressure mod .& install kit
Dry Sump Kit, Subaru EJ (Includes pan, 2 stage scav pump, brackets and pump drive-fluid lines / tank are not 20004463 included) Mitsubishi 4G63 Crankscraper Nissan 20009175 Nissan (VQ35) High Pressure Oil Pump Kit The Cosworth 4G63 Crankscraper is 20008841 Nissan (VQ35) Oil Control Baffle engineered to reduce parasitic drag on the Nissan (VQ35) Oil Control Baffle 03-04 Install kit crankshaft caused by oil accumulation that 20008632 surrounds the crankshaft during rotation. Mitsubishi This oil buildup causes additional drag and 20001382 Mitsubishi Evo VII-IX 4G63 (2.0L) Crankshaft Oil Scraper can reduce power output. Additionally, Mazda overall oil control is improved by keeping 20007845 Mazda Miata NC Oil Cooler Kit oil in the sump. Especially useful in high rpm and race applications. Mounts to main bearing girdle. Designed from 2.6 mm Nissan Oil Control Baffle (12gauge) steel plate and includes required The Cosworth Oil Control Baffle for the mounting hardware. Nissan VQ35 has been engineered to stop oil from surging away from the oil pick up during hard driving conditions. The unique Cosworth one-way control valves allow oil to flow towards the pickup but restrict oil from migrating to the back of the sump during aggressive manoeuvres to help maintain constant oil pressure. Manufactured from stainless steel. Model Year 2003-2004 require fit kit PN 20008632 for proper installation.
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 Nissan Baffle Install Kit Oil Pan Baffle has been engineered with diverters to control oil returning from the cylinder heads to the pan directing it away from the crankshaft. Additionally, one- way valves prevent oil from re-entering the upper crankcase chamber thereby limiting blow by and preventing oil starvation during hard driving. Manufactured from stainless steel and installs easily between the block and oil pan on both EJ20/EJ25 series engines. Use with our High Volume Oil Pan for maximum oil control. Subaru Oil Control Baffle Nissan Oil Control Baffle
38 Subaru EJ20/25 High Volume Oil Pan - 20001238 Sustained high RPM or prolonged high speed driving will result in elevated oil temperatures. Additional oil volume along with improved oil control will reduce damaging oil temperatures. The Cosworth EJ20/EJ25 High Volume Oil Pan is fabricated from both custom and original components resulting in an additional 2qts oil capacity when compared to standard oil pan. Each kit includes powder coated oil pan, mounting hardware, oil pickup and spacer. Will not work with some equal length exhaust manifolds.
Subaru EJ20/25 Oil pump - High Volume, High Pressure - 20001185 Increasing oil volume will help to prevent bearings. The Cosworth High Volume Suggested applications include drag, track bearing damage and engine failure. Subaru EJ20/EJ25 series oil pump day and race use. Each kit includes all Additionally, sustained high RPM use may utilizes a completely new inner and outer required mounting hardware and seals. cause oil starvation at the rod and main 12mm rotor to increase volume by 20%.
Pump Gear: 10mm vs 12mm
Subaru EJ20/25 Oil pump - High Pressure - KK3928 High performance engines require increase oil pressure helping to ensure additional oil pressure because of the superior lubrication. Each pump is carefully increased demand placed upon various inspected and de-burred for unobstructed components within the engine. The oil flow. Perfect for high performance Cosworth High Pressure Subaru EJ20/ daily use. Each kit includes all required EJ25 series oil pump is modified to mounting hardware and seals.
Oil pump - 20009093 High performance engines require Perfect for high performance daily and additional oil pressure because of the track use. Each kit includes all required increased demand placed upon various mounting hardware and seals for quick and components within the engine. easy installation. The Cosworth High Pressure Oil Pump Features: for the Subaru 2008 and newer STI is ■■ 11mm oil pump gears modified to increase oil pressure helping to ■■ Essential for sustained high rpm ensure superior lubrication. applications Each pump is carefully inspected and de- ■■ Installation kit included burred for unobstructed oil flow. ■■ Maintain superior lubrication
39 High Performance Valve Train
High Performance Valves High Performance Valve Train Large diameter valves are essential Part No. Description for improved air flow. Cosworth high performance intake valves are produced Subaru from high quality stainless steel for SB0034 Valve, Inlet +1.0mm Subaru EJ25-Stainless Steel (37.0mm) maximum durability. Exhaust valves SB0033 Valve, EX +1.0mm Subaru EJ25-Inconel (33.0mm) are machined from Inconel for high PR7710 Subaru EJ25 (2.5L) Graded Cam bucket 4.50 temperature (2400° F) reliability. Each valve PR7711 Subaru EJ25 (2.5L) Graded Cam bucket 4.52 features a swirl polished back for improved PR7712 Subaru EJ25 (2.5L) Graded Cam bucket 4.54 air flow and dished face for additional PR7713 Subaru EJ25 (2.5L) Graded Cam bucket 4.56 weight reduction. Some Cosworth High PR7714 Subaru EJ25 (2.5L) Graded Cam bucket 4.58 Performance Valves are only compatible PR7715 Subaru EJ25 (2.5L) Graded Cam bucket 4.60 with Cosworth Ultra Race Valve Spring PR7716 Subaru EJ25 (2.5L) Graded Cam bucket 4.62 Kits. Please confirm application before PR7717 Subaru EJ25 (2.5L) Graded Cam bucket 4.64 ordering. 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
Nissan
PR7602 Valve, Inlet +1.0mm Nissan VQ35-Stainless Steel (38.15mm) PR7603 Valve, Ex +1.0mm Nissan VQ35-Inconel (32.35mm)
Mitsubishi
CI0113 Valve, Inlet +1.0mm Mitsubishi 4G63 Stainless Steel (35.0mm) CI0112 Valve, Ex +1.0mm Mitsubishi 4G63-Inconel (31.5mm) 20007107 Valve, Inlet +1.0mm Mitsubishi 4B11T Stainless Steel (36.0mm) 20007082 Valve, Ex +1.0mm Mitsubishi 4B11T-Inconel (30.0mm)
Valve Train Specification(L1=Install Height, F1=Force @ L1, L2=Max Lift, F2=Force @ Max Lift)
Part No. Application Free Height L1 mm F1 N F1 lbs L2 mm F2 N F2 lbs Max Lift Coil Bind 20000164 Mitsubishi EVO 7-9 47.00 38.1 381 85 26.1 900 202 12.0 24.3 KK3813 Mitsubishi EVO 7-9 50.00 38.1 512 115 26.9 1268 285 12.0 25.7 20000169 Nissan RB26 49.30 41.9 359 81 29.9 941 212 12.0 28.4 20000168 Nissan SR20 46.00 39.0 365 82 27.5 964 217 11.5 25.4 20000163 Nissan VQ35DE 46.00 38.0 289 65 24.5 775 175 13.5 22.9 20002550 Nissan VQ35DE 47.00 38.0 378 85 23.9 1183 266 14.1 22.6 20000166 Subaru EJ 2.0/2.5 42.00 36.0 275 62 25.0 780 175 11.0 23.2 KK3839 Subaru EJ 2.0/2.5 46.10 36.0 356 80 22.1 1019 229 13.9 20.8
Note: Cosworth Subaru valves require Cosworth retainer kits. We recommend Cosworth retainers with all other valves. All dimensions are in millimetres unless otherwise specified
40 High RPM Valve Springs High RPM Valve Spring Sets Cosworth High RPM Valve Springs are the Part No. Application result of countless hours of engineering, testing and validation ensuring the best Mitsubishi possible spring for high performance 20000164 High RPM Single Valve Spring set (16) Mitsubishi Evo VII-IX 4G63 applications. Cosworth High RPM Valve 20004844 High RPM Single Valve Spring set (16) Mitsubishi Evo X 4B11T Springs are wound from the world’s finest Subaru Japanese Kobe steel and feature dual 20000166 High RPM Single Valve Spring set (16) Subaru WRX STI EJ25 (2.5L) EJ20 (2.0L) chamfered ends to reduce wear on seats Nissan and retainers. Each spring has been 20000163 High RPM Single Valve Spring set (24) Nissan VQ35 (3.5L) engineered with increased seat pressure 20000168 High RPM Single Valve Spring set (16) Nissan SR20DET (2.0L) along with higher lift capability for optimum 20000169 High RPM Single Valve Spring set (24) Nissan RB26 (2.6L) performance potential and improved valve control. Single spring design allows easy installation with no machining required and Ultra-High RPM Valve Spring Sets is perfect for typical high performance use. Part No. Application ■■ Manufactured from the finest Japanese KK3813 Mitsubishi Evo 4G63 (2.0L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set Kobe steel KK3839 Subaru EJ25 STI (2.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set ■■ Single spring design for easy installation 20002550 Nissan VQ35 (3.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set ■■ Dual chamfered ends 20007182 Mitsubishi Evo 4B11T Ultra-High RPM Dual Valve Spring / Titanium Retainer set ■■ Increased performance
Ultra Race Valve Spring Kits Cosworth Ultra Race Valve Spring Kits wound from the highest quality chrome are engineered for use in situations that silicone steel with chamfered ends and are require valve control in extreme conditions. heat treated and stress relieved for long Each kit consists of dual valve springs with term reliability. Ultra Race Valve Spring matched lightweight titanium retainers, kits are compatible with Cosworth high keepers, and hardened steel spring seats. performance valves. Cosworth Ultra Race Valve Springs are
*Seal clearance
Install Height “F1”
Nissan VQ35DE
Mitsubishi 4B11
Mitsubishi 4G63 Subaru EJ20/EJ25
41 High Performance Head Gaskets
Cosworth High Performance Head Gaskets High Performance Head Gaskets are engineered to seal in power under the most demanding conditions. Constructed Part No. Description from stainless steel with a folded stopper Nissan layer, each application features superior 20013292 Nissan GTR VR38DETT (3.8L) Bore = 96mm T ~ 0.8mm (Pr) sealing compared to conventional multi- 20004667 Nissan VQ35HR / VQ37VHR Bore = 96mm T ~ 0.6mm (Pr) layer steel gaskets. Additionally, Cosworth 20000900 Nissan VQ35DE (3.5L) Bore = 96mm T ~ 0.6mm (Pr) High Performance Head Gaskets are 20000903 Nissan VQ35DE (3.5L) Bore = 98mm T ~ 0.6mm (Pr) manufactured from pre-coated die cut 20000906 Nissan VQ35DE (3.5L) Bore = 100mm T ~ 0.6mm (Pr) stainless steel resulting in uniform coating 20000924 Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.1mm distribution and consistent shape. 20000925 Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.5mm Each gasket is carefully engineered with 20000926 Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.8mm the following features: 20003395 Nissan SR20DET (2.0L) Bore = 90mm T ~ 1.1mm
■■ Individual die cut layers of stainless steel 20003396 Nissan SR20DET (2.0L) Bore = 90mm T ~ 1.5mm with superior consistency compared to 20000927 Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.1mm laser cut gaskets 20000928 Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.5mm ■■ Pre-coated stainless steel with a 0.25 20000929 Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.8mm micron layer of nitrile rubber ensures 20000930 Nissan RB25DET (2.5L) Bore = 87mm T ~ 1.1mm consistent distribution of coating with no 20000931 Nissan RB25DET (2.5L) Bore = 87mm T ~ 1.5mm
high or low areas Mitsubishi ■■ Manufacturing dimensional tolerance of 20001689 Mitsubishi Evo IX 4G63 (2.0L) Bore = 86mm T ~ 1.3mm +/- 0.001” 20001690 Mitsubishi Evo IX 4G63 (2.0L) Bore = 86mm T ~ 1.5mm ■■ Die cut manufacturing process ensures 20000909 Mitsubishi Evo IV-VIII 4G63 (2.0L) Bore = 86mm T ~ 1.3mm smooth edges, unlike laser cut gaskets 20000910 Mitsubishi Evo IV-VIII 4G63 (2.0L) Bore = 86mm T ~ 1.5mm ■■ Cosworth gaskets feature a “folded stopper” layer for additional clamping 20004122 Mitsubishi Evo X 4B11T (2.0L) Bore = 87mm T ~ 1.1mm force around each cylinder. The width 20004123 Mitsubishi Evo X 4B11T (2.0L) Bore = 87mm T ~ 1.3mm of sealing area is specific for each Subaru application thereby providing ultimate 20000913 Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 0.78mm each sealing properties 20000916 Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.1mm each ■■ Available in a range of thicknesses for 20002145 Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.5mm each specific applications 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 Gasket Layer Folded 20000919 Subaru WRX EJ20 (2.0L) Bore = 93mm T ~ 0.78mm each Stopper Layer 20000922 Subaru WRX EJ20 (2.0L) Bore = 93mm T ~ 1.1mm each Honda Gasket Layer 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.
Toyota
TBA Toyota 2JZ - GTE Bore = 87mm T ~ 1.1mm TBA Toyota 2JZ - GTE Bore = 87mm T ~ 1.3mm TBA Toyota 2JZ - GTE Bore = 87mm T ~ 1.5mm
42 Without folded stopper layer, clamping force is Folded stopper layer provides complete sealing limited resulting in incomplete sealing around around entire combustion chamber Stopper sealing layer combustion chamber
Honda F20C Nissan VQ35DE
Uniform nitrile rubber coating
Mitsubishi 4G63
Mitsubishi 4b11t
Die cut edges
Subaru EJ25
43 Thermal Composite Gaskets
The Cosworth Thermal Guard Composite Thermal Composite Gaskets Intake Gasket is designed to aid in the reduction of inlet air temperature by Part No. Description isolating the intake manifold from the heat 20013283 Thermal Intake Manifold Gasket - EJ25 2004+ all (Pair) generated by the engine’s cylinder head. 20013286 Thermal Intake Manifold Gasket - 4G63 EVO 4-9 By reducing the temperature of the inlet 20013287 Thermal Intake Manifold Gasket - 4B11T EVO X manifold the temperature of the intake air 20013288 Thermal Intake Manifold Gasket - 2ZZ-GE charge is also reduced. The density of 20013289 Thermal Plenum Gasket - VQ35DE cooler air is greater than that of warm air. 20013290 Thermal Plenum Gasket - VR38DETT A denser intake air charge contains more oxygen which results in the potential for ■■ Isolates inlet manifold from engine and increased power and torque. cylinder head Each Cosworth Thermal Guard Composite ■■ Reduces inlet air temperature Intake Gasket is precision manufactured ■■ Reusable with no deformation from an engineering grade composite ■■ Higher temperature resistance than phenolic material that resists deformation plastic gaskets (+500º F) common with plastic gaskets. As an ■■ Precision CNC manufactured added feature Cosworth Thermal Guard ■■ Includes Hylomar Universal Blue Racing Nissan VQ35 Composite Intake Gaskets are reusable Formula sealant and include a tube of “Hylomar Universal ■■ Race proven Blue Racing Formula” sealant. The use of ■■ Safe with all fuel types OE inlet manifold gaskets is not required with the Cosworth Thermal Guard Composite Intake Gasket.
Mitsubishi 4B11
Mitsubishi 4G63
Subaru EJ25
44 Cosworth Rhino Skin - Thermal Heat Protection
Cosworth Rhino Skin is a simple yet Cosworth Rhino Skin – Thermal Heat Protection highly effective way of restraining heat from penetrating and destroying thermally Part No. Description sensitive areas of the engine bay - a 20019507 Subaru EJ25 STi 2008 - exhaust manifold heat shield re-occurring challenge for fast road and 20019574 Subaru EJ25 STi 2008 - Up-pipe heat shield motorsport vehicles. 20019952 Subaru EJ25 STi 2008 - Down-pipe heat shield Cosworth Rhino Skin heat protection uses CRS003 Subaru EJ20 STi ‘98 - exhaust manifold heat shield leading thermal protection technology to CRS004 Nissan SR20DET exhaust manifold (low mount) heat shield restrain heat to the area of generation. CRS005 Nissan RB25 exhaust manifold (low mount) heat shield Each application is individually developed CRS006 Nissan RB26 exhaust manifold (top mount) heat shield by Cosworth so there is no trim to fit and CRS006 Mitsubishi 4G63 exhaust manifold (low mount) heat shield making for an easier installation. CRS007 Mitsubishi 4B11T exhaust manifold (low mount) heat shield Cosworth Rhino Skin has been initially CRS008 Honda K20A EP3 exhaust manifold heat shield developed as thermal protection for two key areas: turbochargers and exhaust exhaust gas to accelerate from the system To overcome this, a solution successfully manifolds where temperatures typically quicker. Thus, greater exhaust scavenging developed and employed on the Cosworth exceed 900°C/1650°F, making the need is produced lowering intake temperatures Impreza CS400, was the Rhino Skin for predictable, rugged and reliable thermal and in-turn contributing to an increase in application – using the Rhino Skin to armour a real one. power. prevent the exhaust transferring heat to the Cosworth Rhino skins are designed for intercooler, keeping the charge cool and Benefits to power are also demonstrated in street performance to hardcore motorsport improving the car’s performance and also vehicles like the Subaru Impreza where the applications. Branded in Cosworth increasing the engine’s responsiveness. intercooler sits on top of the engine, rather image, each skin has a Teflon style than down at the front by the radiator. The From the turbo perspective, the benefit surface effectively repelling grease and “Up-Pipe” that brings hot exhaust gases to of the shield is that it stops the turbo dirt they are capable of withstanding upto power the turbo and the “Down-Pipe” that cooling down too quickly, preventing rapid 1250°C/1800°F continuously. takes them away, are both located directly temperature change which can cause Wrapping the exhaust header with Rhino beneath the intercooler - clearly generating turbine damage. Skin maintains hotter exhaust gases, significant radiant heat, particularly when decreases the density, and allows the the car is stationary.
45 Miscellaneous
Subaru Billet Timing Belt Guide - Part Miscellaneous number SB0001 Part No. Application The original sheet metal timing belt guide can flex from belt deflection when Subaru subjected to extreme RPM causing the SB0001 Subaru (EJ20/EJ25) Billet Timing Belt Guide timing belt to skip one or more teeth on SB0002 Subaru Billet Cam Angle Sensor Bracket (for mounting cam angle sensor on front of head) the crankshaft sprocket. The Cosworth 20004539 Subaru (EJ20/EJ25) Air pump delete plate set Billet Timing Belt Guide was developed to control this problem and is machined from solid aluminium with a hard anodised finish. Oil Filler Caps Includes mounting hardware. 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 The Cosworth Oil Filler Cap is machined from solid aluminium with the traditional Cosworth “three prong” ergonomic style. This light weight oil filler cap includes a Subaru Billet Cam Angle Sensor an oil ring sealing feature , preinstalled to Bracket - Part number SB0002 ensure leak free operation on your engine. Used for mounting the cam angle sensor Each cap features a durable anodised to the front of non North American Spec finish. STI cylinder heads. Useful for adapting our ■■ Machined from solid aluminium cylinder heads to Japanese and European ■■ Durable anodised finish market engines. ■■ Includes pre-installed O-ring for leak free operation ■■ Ergonomic, Classic Cosworth three prong design
Air Pump Delete - Part number 20004539 Used to eliminate the air pump and related valves found on 2006-2008 Subaru Engines. Used for high performance applications or adapting later cylinder heads to early engines. Seals off the air injection ports at the cylinder heads. Saves weight, reduces complexity, cleans up engine compartment. Machined from solid aluminium with a “Cosworth blue” anodised finish. Mounting hardware included.
46 Disclaimer
The products in this catalogue require professional installation to ensure correct operation. Cosworth will not accept responsibility for damage to vehicles as a result of improper installation of our products. The performance and power gained from installing products from this catalogue may place vehicles within an “off road use only” category in certain counties and states around the world. Cosworth will not accept responsibility for any restrictions placed on vehicles. Product Disclaimer: A vehicle modified with Cosworth competition and or racing performance products may not meet the legal requirements for operation on public roads and highways. It is the purchaser’s responsibility to check and comply with all local, state and federal laws prior to operating vehicle. Installation and use of performance products may also affect/ void vehicle warranty and insurance policy. Warranty: In general, Cosworth Performance Parts carry no warranty. Cosworth Ltd and Cosworth LLC shall not be liable for direct, indirect, incidental or consequential damage or injury to persons or property that might be claimed as a result from the installation, improper installation and failure of part including claims for delay, loss of profits or labour. There are no warranties expressed or implied. SOME PRODUCTS MAY NOT BE LEGAL FOR SALE OR USE ON POLLUTION CONTROLLED MOTOR VEHICLES OPERATING IN CERTAIN COUNTRIES INCLUDING THE US STATE OF CALIFORNIA. © Copyright 2011, Cosworth (UK) - v3.0
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