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