Cosworth Performance Tuning Components Catalogue 2011

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
Part No. Description
cylinder head design for both racing
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
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
CI8018 Mitsubishi Evo VII/IX 4G63 Short Block (2.2L)-Forged Pistons, Rods, Billet Crank
forged connecting rods, Cosworth tri-metal
20014144 Mitsubishi Evo X 4B11T Short Block (2.2L)-Forged Pistons, Rods, Billet Crank
bearings and Cosworth forged pistons.
The motorsport grade parts are then
professionally assembled by expert engine
builders in the Cosworth engine assembly
facility. Each high performance engine
assembly includes a complete specification
sheet listing all critical dimensions along
with a serialized plaque. For maximum
performance, combine with a Cosworth
CNC ported Big Valve Cylinder Head and
camshaft set.
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 Heavy Duty main studs
■■ Piston squirt jets
■■ Ring gap set
■■ Connecting Rod side clearance 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 Heavy Duty main studs
■■ Ring gap set
■■ Connecting Rod side clearance 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
7
High Performance Long Block Assemblies
The Cosworth Subaru EJ25 CS600 series
is designed for extreme track day use and
the demanding performance enthusiast.
Each assembly is precision built by one 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
20007710 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-STD Crankshaft 9.2:1cr
connecting rods along with our high
20007709 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-Billet Crankshaft 9.2:1cr
performance rod and main bearings and a
20003489 Subaru EJ25 (2.6L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-81mm Crank 8.2:1cr
new STI forged crankshaft. For maximum
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”
20003490 Subaru EJ25 (2.6L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Cams 81mm Billet Crank 8.2:1cr
camshafts complete with valve lash set to
20007708 Subaru EJ25 (2.5L) 2004-06 w/ Big Valve Cylinder heads and KK3920 Camshafts-Billet Crank 9.2:1cr
our specifications. The cylinder heads are
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
■■ New Subaru EJ25 STI Engine case
■■ New Subaru EJ25 STI Forged
Subaru - Impreza 2007 Sti EJ25 “CS600 & CS600X”
Crankshaft
20002504 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-STD Crank 8.2:1cr
■■ Optional Cosworth Billet Crankshaft
20002503 Subaru EJ25 (2.5L) 2007 w/ Big Valve Cylinder heads and KK3766 Camshafts-Billet Crank 8.2:1cr
(79/81mm stroke available)
■■ 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)

Subaru
10001430 Subaru WRX STI EJ25 (2.5L) 99.5mm 8.2:1cr
10001432 Subaru WRX STI EJ25 (2.5L) 100.mm 8.2:1cr
10001445 Subaru WRX EJ20 (2.0L) 92.mm 8.0:1cr
10001446 Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr
10001447 Subaru WRX EJ20 (2.0L) 93mm 8.0:1cr
10001433 Subaru WRX STI EJ25 (2.6L) 99.5mm 8.2:1cr (For use with 81mm crankshaft)
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)
Continued ->
10
Features Include:
Forged Piston Sets (Includes pistons, rings, pins and clips)
■■ Unique forgings for each application
■■ ‘Xylan’ anti scuff skirt coating
■■ Polished tops (reduces carbon build up
10001438 Subaru WRX STI EJ25 (2.5L) 100.mm 9.2:1cr
and relieves stress)
■■ 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
10001471 Nissan SR20DET 86.5mm 8.5:1cr

Cosworth Tech: Green Pistons
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
TBA Nissan RB26DETT 87.5mm 8.5:1cr-Stroker
components and fasteners. Cosworth
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
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

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
securely hold it in place while installing
the piston. Each tool is machined form
high grade aluminium and features a hard
anodised finish.
Cosworth Tech: Ring Sets

Cosworth Performance Ring Sets are comprised of a chrome top ring, an iron second
ring, and three-piece oil ring. Some Cosworth Performance Ring Sets offer upper
rings that are gas nitride treated for quicker break-in, lower wear, and improved
sealing. Manufacturing tolerances exceed OEM standards. Axial tolerance is +/-
0.0002” and radial tolerance is +/- 0.0005”.
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
high performance engines. Spare parts are PA2674 23mm Pin, Subaru EJ20 / EJ25 Piston
available for routine engine rebuilds. PA1846 22mm Pin, Mitsubishi 4G63 Piston
PA1251 22mm Pin, Nissan VQ Piston

For ease of circlip installation on Subaru
PP5433 Circlip, 23mm Subaru EJ20 / EJ25 Piston. 2 req per piston
engines, we offer an exclusive installation
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
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
20002315 Subaru WRX STI EJ25 (2.5L) 79mm stroke - Light weight version Billet Steel
main oil feed. Cosworth billet crankshafts
20002316 Subaru WRX STI EJ25 (2.5L) 81mm stroke - Light weight version Billet Steel
feature full-flow oiling whereby each
rod journal is lubricated from two main
sources. This provides superior lubrication
during sustained high rpm use preventing
rod bearing failure. Cosworth Subaru
crankshafts are manufactured entirely from
high grade steel in a light-weight, high
strength design with a unique Isotropic
Super Finish (ISF®).
Features Include:
■■ Superior lubrication
■■ Profiled counterweights
■■ High strength
■■ Light weight
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
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)
Crankshaft (94mm)
Mitsubishi 4B11T (Evolution X) 2.2L

■■ Cosworth Forged Pistons (86mm)
Crankshaft (94mm)
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 Part No. Description
Ctr. to Ctr. P.E. Bore B.E. Bore
Nominal
connecting rod increase as well. To ensure (mm) (mm) (mm)
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
Part No. Description Specification
years of innovative multi valve cylinder head
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 throttle) - Japan / European spec deg. 10.mm lift
and finished using the same procedures
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
compliment to our CNC Ported Big Valve 20005187 (09/1997) - Euro/Asian spec
"270" deg. 10.4mm lift
Cylinder Heads. Our cams are profiled to KK3814

Subaru WRX STI EJ25 (2.5L) Set of four (AVCS Type) North American Int.”260” deg. 9.6mm lift / Exh. “260”
spec - North American spec deg. 9.6mm lift
increase boost response thereby increasing
Mitsubishi
engine torque and power and are fully
KK3805 Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M1 Grind "264" deg. 10.2 mm lift
compatible with our CNC Ported Big Valve
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

20002513 Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 exhaust cam) M3 Grind
"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 /

20002507 Nissan VQ35 "287hp" Set (2 intake and 2 Exhaust cams) "ZK1" Grind
Exhaust "268" deg. 9.5mm lift
Intake “270” deg. 10.65mm lift /

20002508 Nissan VQ35 “287hp” Set (2 intake and 2 Exhaust cams) “ZK2” Grind
Exhaust “270” deg. 10.65mm lift

20002510 Nissan VQ35 “Rev up” Set (2 intake and 2 Exhaust cams) “ZK1” Grind

20002511 Nissan VQ35 “Rev up” Set (2 intake and 2 Exhaust cams) “ZK2” Grind
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
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
20002723 Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal Size 0
bearings sets are available in three sizes
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
PR7429 Mitsubishi Evo 4G63 (2.0L) Thrust Bearing set
and less friction
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
20002724 Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal Size 0
■■ Tested to over 1000 horsepower!
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.
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
PR7895 Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal Size 1
■■ Size 2 provides .025mm or .001” more
PR7851 Nissan SR20 (2.0L) Main Bearing Set - Tri Metal Size 2
oil clearance than our size 1 bearing
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
20002728 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 0
selecting the appropriate bearing size.
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
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
20019487 Timing Belt - Nissan Skyline RB25/26
composites ensure durability and heat
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
Front mounted intercoolers offer improved
20014525 Mitsubishi EVO X Front Mount Intercooler (Uses factory piping)
performance potential for Subaru
20019677 Mitsubishi EVO X Intercooler Hard Pipe Kit
applications. The Cosworth front mount
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
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
20019424 2008-2010 Mitsubishi Lancer EVO X

Each kit includes an integrated heat shield
designed to isolate the air intake from
engine heat - delivering cold air into the
engine for superior power conversion. The
filter element is large, conical in shape and
engineered to dramatically reduce intake
restriction resulting in additional power and
torque.
Up to 15% More Performance
■■ Lightweight aluminium mandrel shaped
inlet tube for maximum airflow
■■ Conical Cosworth blue cotton gauze
cleanable air filter with Cosworth
embossed dry carbon composite end
cap
■■ Integrated heat shield for cold air
isolation
■■ Hardware kit included for easy, perfect fit
■■ Made in USA
26
Induction
VQ35 Twin Plenum Intake Manifold -
Induction
PN 20000063
The Cosworth Twin Plenum Inlet Manifold
Nissan
for the Nissan VQ35DE has been designed
20000063 Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with Carbon plenum covers
to enhance mid-range and high RPM
20005779 Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with Carbon plenum covers "Bright Polish Finish"
power. It features increased plenum volume
Subaru
for improved high RPM power while torque
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 20006783 Lancer (1.5/1.8/2.0L) 2008-2010 Astra (1.7L) with Isuzu Diesel
20002270 Engine
1991-1992
20006783 C-Crosser 2008-2009 20002277 Lancer (1.3/1.6/2.0L) 1999-2008
Cavalier with Isuzu Diesel
FORD 20002270 1992-1995
20006783 Outlander (2.0/2.4L) Diesel 2007-2009 Engine
20002270 Maverick (2.4L) 1993-1998
20002277 Outlander (2.0/2.4L) 2003-2007 Nova (1.5L) Incl. Diesel &
20002270 Novavan
1989-1992
HONDA
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
20005380 Civic Type R (2.0L) 2000-2006
20002270 350Z 2003-2006
PONTIAC
20005380 Civic Type R (2.0L) JDM 2001-2005
20005381 350Z (Twin Air Box) 2007-2010
20002282 Vibe 2003-2009
20005380 Civic (2.0L) 2001-2006
20002270 R34 Skyline Gtr (2.6L) 1999-2002
SCION
20005380 Fr-V 2005-2008
20002270 R33 Skyline Gtr (2.6L) 1995-1998
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
20002270 2001-2006 20002278 Impreza WRX STi 2008-2010
(2.5/3.0/3.5L)
20002273 Fit (1.5L) 2007-2009
20002278 Impreza WRX 2008-2010
20002273 Fit JDM (1.3/1.5L) 2001-2006
20002270 R34 Skyline (2.0/2.5L) 1998-2001
20002278 Impreza 2.5L 2008-2009
20005380 Stream (2.0L) 2001-2005
20002270 R33 Skyline (2.0/2.5L) 1993-1998
20002278 Impreza 2.0L 2008-2009
20005380 Stepwagon (2.0L) 2001-2005
20002270 R32 Skyline (2.0/2.5L) 1989-1993
20002270 Impreza WRX STi 1997-2007
20002273 Mobilio JDM (1.5L) 2001-2007
20002270 R31 Skyline (2.0L) 1985-1989
20002270 Impreza WRX 1993-2007
20002273 Mobilio Spike JDM (1.5L) 2002-2007
20002270 R30 Skyline (2.0/2.8L) 1981-1990
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)
20002270 200Sx (1.8/2.0L) 1988-1999 20002278 2003-2008
2002270 Commodore (3.8/5.0L) 1988-1996 JDM
INIFINITI Silvia JDM (1.8./2.0L) Legacy B4 (2.0/2.5/3.0L)

20002270 S12/13/14/15
1980-2002 20002270 1998-2005
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) 20002279 Tribeca (3.0/3.6L) 2006-2009
20002270 1995-2007
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
LOTUS
20002282 Allion JDM 2001-2007
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 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
350Z 2005 on Front 6 Piston CP7040 CFSA003 CFTA003
GTR32 1992 on Front 4 Piston CP5200 CFSA001 CFTA001
WRX,STI 2001 - 2007 Front 4 Piston CP5200 CFSA004 CFTA004
WRX,STI 2008- Front 6 Piston CP7048 CFSA006 CFTA006
Escort Cosworth 1991 on Front 6 Piston CP5570 CFSA002 CFTA002
Escort Cosworth 1991 on Front 4 Piston CP5200 CFSA001 CFTA001
Sierra Cosworth 1987 on Front 4 Piston CP5200 CFSA001 CFTA001
Sierra Sapphire Cosworth 4x4 1990 on Front 4 Piston CP5200 CFSA001 CFTA001
Fiesta ST 2005 Front 4 Piston CP6637 CFSA005 CFTA005
Focus RS 2002 on Front 6 Piston CP7040 CFSA003 CFTA003
Focus ST170 2001 on Front 4 Piston CP5200 CFSA001 CFTA001
The Cosworth brake pad range is constantly expanding and a full list of applications can be found at www.cosworth.com,
Performance Tuning Components section
34
Big Brake Upgrade Kits
Cosworth has combined over 50 years of
Big Brake Upgrade Kits
motorsport heritage and technology with
the unrivalled experience of AP Racing
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)
CBK3003 350z (to fit 17 and 18 inch wheels)

The Cosworth AP Racing brake kit delivers
ultimate stopping power consistently and
quickly from cold whilst offering corner
weight reduction over the OEM brakes of
1.58Kg.
The Cosworth BBK calipers are 6 piston,
with differential bores to eliminate “pad
taper”. The trailing pistons have a larger
bore than the leading ones to compensate
for mechanical end load & to even out the
wear on the pads. All our performance
brake calipers use conventional seals
in conjunction with a dirt seal and are
finished with an eye-catching high gloss
black PTFE based paint coating which is
impervious to normal brake fluids & high
brake temperatures.
The 2-piece discs features Cosworth
technology embedded within the pair of 48
vaned discs together with lightweight high
grade aluminium mounting bells designed
to deliver enhanced airflow than the original
brakes. The discs have been developed to
produce optimum braking bite, as well as
thermal stability and durability.
The upgrade kits also contain a set of
high performance brake pads, mounting
brackets individually designed for each
application, brake hoses, a complete set
of fixings and two bottles of AP Racing
Formula DOT 5.1 brake and clutch fluid.
Cosworth Big Brake Upgrade Kits are a
stylish and effective way of up-rating your
cars braking performance.
Detailed Specification:
■■ 2 x Ø355 x 32mm 2 piece brake discs
■■ 2 x 6 piston brake calipers
■■ High performance brake pad friction
material*
■■ Braided brake hoses
■■ 2 x Dot 5.1 high temperature brake fluid
■■ 2 x Mounting brackets
■■ 2 x Aluminium mounting bells
■■ Steel braided hoses
■■ Fixings
*Braking material is not R90 approved for road use
35
Fuel
Mitsubishi EVO X High Volume Fuel
Fuel
Rail System - 20005241
The Cosworth High Volume Fuel Kit
Nissan
features a machined from solid, hard
KK3905 Nissan VQ35DE (3.5L) High Volume Fuel rail system
anodised aluminium fuel rail with o-ringed
Mitsubishi
fittings and a pre-shaped inlet pipe. The
20005241 Mitsubishi EVO X High Volume Fuel rail kit
Cosworth High Volume Fuel Rail Kit can be
used with original or various aftermarket
injectors and PRV’s.
■■ Direct fit replacement- includes all
necessary components for a complete
bolt-on installation
■■ Designed with expansion in mind,
facilitating installation of custom fuel

systems including AN fuel lines and
remote mounted fuel pressure regulators
■■ Full-flow ½” bore will support upwards of
600hp worth of fuelling

■■ Hard anodised finish is methanol
compatible.
(upgraded fittings and seals required)
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
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)
Nissan
Mitsubishi 4G63 Crankscraper
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
20008632 Nissan (VQ35) Oil Control Baffle 03-04 Install kit
crankshaft caused by oil accumulation that
Mitsubishi
surrounds the crankshaft during rotation.
20001382 Mitsubishi Evo VII-IX 4G63 (2.0L) Crankshaft Oil Scraper
This oil buildup causes additional drag and
Mazda
can reduce power output. Additionally,
20007845 Mazda Miata NC Oil Cooler Kit
overall oil control is improved by keeping
oil in the sump. Especially useful in high
rpm and race applications. Mounts to main
bearing girdle. Designed from 2.6 mm 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
Nissan Baffle Install Kit
and power loss. The Cosworth Subaru
Oil Pan Baffle has been engineered with
diverters to control oil returning from the
cylinder heads to the pan directing it away
from the crankshaft. Additionally, one-
way valves prevent oil from re-entering the
upper crankcase chamber thereby limiting
blow by and preventing oil starvation during
hard driving. Manufactured from stainless
steel and installs easily between the block
and oil pan on both EJ20/EJ25 series
engines. Use with our High Volume Oil Pan
for maximum oil control. 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
for improved air flow. Cosworth high
Subaru
performance intake valves are produced
SB0034 Valve, Inlet +1.0mm Subaru EJ25-Stainless Steel (37.0mm)
from high quality stainless steel for
SB0033 Valve, EX +1.0mm Subaru EJ25-Inconel (33.0mm)
maximum durability. Exhaust valves
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.
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,
Mitsubishi
testing and validation ensuring the best
20000164 High RPM Single Valve Spring set (16) Mitsubishi Evo VII-IX 4G63
possible spring for high performance
20004844 High RPM Single Valve Spring set (16) Mitsubishi Evo X 4B11T
applications. Cosworth High RPM Valve
Subaru
Springs are wound from the world’s finest
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
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
20003396 Nissan SR20DET (2.0L) Bore = 90mm T ~ 1.5mm

■■ Individual die cut layers of stainless steel
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
20004122 Mitsubishi Evo X 4B11T (2.0L) Bore = 87mm T ~ 1.1mm
stopper” layer for additional clamping
20004123 Mitsubishi Evo X 4B11T (2.0L) Bore = 87mm T ~ 1.3mm
force around each cylinder. The width
Subaru
of sealing area is specific for each
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 20000919
Folded 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
20003127 Honda K20/24 Bore = 87mm T ~ 0.8mm for use with RAA, RAC, RBB, and RBC cylinder heads.
20010903 Honda K20/24 Bore = 87mm T ~ 0.38mm for use with PRB, PNC, and PPA cylinder heads.
Toyota
TBA Toyota 2JZ - GTE Bore = 87mm T ~ 1.1mm
42
Without folded stopper layer, clamping force is
Folded stopper layer provides complete sealing
limited resulting in incomplete sealing around Stopper sealing layer
around entire combustion chamber
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
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
CRS003 Subaru EJ20 STi ‘98 - exhaust manifold heat shield

Cosworth Rhino Skin heat protection uses
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
Subaru
guide can flex from belt deflection when
SB0001 Subaru (EJ20/EJ25) Billet Timing Belt Guide
subjected to extreme RPM causing the
SB0002 Subaru Billet Cam Angle Sensor Bracket (for mounting cam angle sensor on front of head)
timing belt to skip one or more teeth on
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
Oil Filler Caps
solid aluminium with a hard anodised finish.
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
European Office
Cosworth Ltd
The Octagon
St James Mill Road
Northampton
NN5 5RA
United Kingdom
Tel: +44 (0)1604 598300

Fax: +44 (0)1604 598301
Email: clsales@cosworth.com
www.cosworth.com
Performance Tuning Components
US Office
Cosworth LLC
3031 Fujita Street
Torrance
CA 90505
USA
Tel: +1 310 534 1390

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

Cosworth Performance Tuning Components Catalogue 2011

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PERFORMANCE

High Performance Tuning Components

cylinder head castings, substantial gas flow Nissan

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

Cylinder head development

Precision Newen® CNC

Subaru EJ25 High Performance Short Block 2.5/2.6L

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

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

steel studs and sealed with a Cosworth

Subaru Engine Testing

Xylan skirt coating

Subaru EJ25, 9.2:1 Mitsubishi 4G63 Subaru EJ25

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

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

10001436 Subaru WRX STI EJ25 (2.5L) 99.5mm 9.2:1cr

10001468 Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application)

10001469 Nissan VQ35 (3.5L) Low CR 96.mm 8.8:1cr (Turbo application)

10001470 Nissan SR20DET 86mm 8.5:1cr

10001471 Nissan SR20DET 86.5mm 8.5:1cr

lubrication and control friction, wear Mitsubishi

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

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)

TBA Toyota 2JZ-GTE 87mm 8.5:1cr

Nissan VQ35 High Compression

20005160 Subaru WRX EJ20 (2.0L) 92.mm

20005161 Subaru WRX EJ20 (2.0L) 92.5mm

20001512 Nissan VQ35 (3.5L) 95.5mm

20001514 Nissan VQ35 (3.5L) 96.mm

PR7317 Mitsubishi Evo 4G63 (2.0L) 85mm

20002246 Mitsubishi Evo 4G63/4B11 86mm

20005705 Mitsubishi Evo 4B11 86.5mm

20005706 Mitsubishi Evo 4B11 87mm

20008832 Tool -85.00Mm Ring Compressor

20007717 Tool -86.00Mm Ring Compressor

20007751 Tool -86.25Mm Ring Compressor

20007761 Tool -86.50Mm Ring Compressor

Cosworth Cylindrical Ring Compressors 20007784 Tool -87.50Mm Ring Compressor

Cosworth Tech: Ring Sets

PA1251 22mm Pin, Nissan VQ Piston

ensure years of trouble free use.

Cosworth Tech: Isotropic Super Finish (ISF®)

■■ Allows a freer movement of parts with

20007783 Mitsubishi Evo 4B11T (2.2L) - 94mm Crank

20002500 Subaru EJ25 (2.6L) w 81mm Billet Crankshaft

20002501 Subaru EJ20 (2.2L) w 79mm Forged Crankshaft (92mm Pistons)

20004359 Subaru EJ20 (2.2L) w 79mm Forged Crankshaft (92.5mm Pistons)

20002502 Subaru EJ20 (2.2L) w 79mm Billet Crankshaft (92mm Pistons)