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

Transcription

P E R F O R M A N C E
E N G I N E
C O M P O N E N T S
A History Of Excellence
Since it was formed in 1958 by Mike Costin and the late Keith Duckworth in a small workshop
in Acton, England, Cosworth has become the most successful engine manufacturer in
the history of Formula One. In addition it has achieved enormous success in IndyCars,
Champ Cars, rallying, sports cars and touring cars.
The company soon outgrew its little workshop in Acton and moved to north London, where
the Ford 105E engine was developed. Cosworth’s first race win followed – at Goodwood
in 1960, a Formula Junior win for the young Jim Clark.
By the mid 1960s the company had moved again, to Northampton, and in 1966 a contract
was signed with Ford to develop a new three-litre Formula One engine. The legendary
DFV was born. Jim Clark again provided the maiden victory, first time out at the Dutch
Grand Prix in 1967. The DFV went on to dominate F1 for 15 years with 155 race wins.
In the 1970s the Cosworth DFX ruled the US Indycar scene with an incredible 151 race
wins in a 14-year reign, including 10 driver’s championships and 10 Indianapolis 500
victories.
Through the 1980s and ‘90s, Cosworth continued to provide race-winning power with three
World Touring Car titles in 1987, ‘93 and ‘94. In Formula 1 the HB engine won 11 races,
while in the US Nigel Mansell’s CART championship in 1993 and Jacques Villeneuve’s in
1995 were both powered by Cosworth XBs. In 1994 the Zetec V8 F1 engine took Michael
Schumacher to his first world driver’s title. In rallying the Ford Escort Cosworth and the
Duratec-R powered Focus WRC gave Ford yet more success.
In 2004 Cosworth still provided the power to 30% of the F1 grid, as well as to the entire
Champ Car World Series and the Ford Focus WRC cars. In 2005 Cosworth powered Red
Bull’s impressive debut F1 season. In 2006, Cosworth powered the Williams F1 car with
a brand new V8 engine which was later acknowledged as the most powerful and highest
revving engine on the 2006 grid.
Today, Cosworth continues to enjoy racing success in various series including Formula
Atlantic and Super GT. The engineering expertise gained over the last 5 decades have
enabled Cosworth to launch a broad array of high performance engine components for
the aftermarket. With the product range increasing on a continual basis, Cosworth power
is now accessible to everyone.
Contents
Big Valve Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Performance Short Block Assemblies . . . . . . . . . . . . . . . . . . . 6
High Performance Long Block Assemblies. . . . . . . . . . . . . . . . . . . 8
Billet Crankshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Stroker Engine Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Forged Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Ultra High Performance Head Studs . . . . . . . . . . . . . . . . . . . . .
13
Ultra High Performance Engine Bearings. . . . . . . . . . . . . . . . . . . 14
Forged Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Single Forged Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Spare Piston Pins and Circlips . . . . . . . . . . . . . . . . . . . . . . . .
19
Performance Ring Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Kevlar High Performance Timing Belts. . . . . . . . . . . . . . . . . . . .
21
High Performance Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . 22
High Performance Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . 24
High Performance Head Gaskets. . . . . . . . . . . . . . . . . . . . . . . 26
Oil Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
High Flow Synthetic Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . 31
Mazda MX5 Supercharger system 2006-2008 . . . . . . . . . . . . . . . .
32
Induction / Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Subaru Intercooler System . . . . . . . . . . . . . . . . . . . . . . . . . .
36
NGK High Performance Spark Plugs . . . . . . . . . . . . . . . . . . . . . 37
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3
Big Valve Cylinder Heads
For over 40 years, Cosworth has been
Modified
the
head
leader
in
innovative
multi-valve
from
new
castings,
OE
cylinder
substantial
gas
flow
Each original cylinder head design is
carefully evaluated and tested to establish
cylinder head design for both racing and
improvements and upgraded valve train
the
high performance production cars.
components offer superior performance
the target performance level. Hours of
for your high performance engine.
testing and flow bench validation are
The
Cosworth CNC Ported Big Valve Cylinder
improvements
required
to
meet
used to determine the best advanced
head range is the latest advancement.
port design yielding maximum usable
power and response. However, there
CNC Ported Big Valve Cylinder Heads
Part No.
Application
Specification
is more to cylinder head design than
just maximum flow. It is critical that port
Subaru
KK3670
Subaru WRX STI EJ25 (2.5L)
Pair 2004-2006
velocity is maintained to ensure drivability
20001699
Pair 2007 with air injection ports
and valve train components are matched
20004544
Pair 2008 with dual AVCS
to guarantee reliable performance. Once
all of these factors have been tested
Nissan
KK3918
Nissan VQ35 (3.5L)
Pair 2006-2007 including Rev-Up version
Mitsubishi
digitized. Using the digitized program,
KK3672
Mitsubishi Evo VII-VIII 4G63 (2.0L)
KK3852
Mitsubishi Evo IX 4G63 (2.0L)
2006 MIVEC
TBA
Mitsubishi Evo X 4B11T (2.0L)
2008 MIVEC
2000-2005
we then reshape both intake and exhaust
ports using a 5 axis CNC mill producing
an accurate and consistent port shape
Others
KK3673
every time. In addition to re-shaping and
BMW MINI Cooper/Cooper S (1.6L)
20000691
Ford Duratec, 2.0L/2.3L
20000704
Mazda MZR, 2.0L/2.3L
enlarging the intake and exhaust ports,
most Big Valve Cylinder heads feature a
re-shaped combustion chamber to unshroud the valves increasing air flow
CNC Ported Big Valve Cylinder Heads with Camshafts
Part No.
Application
and performance. After machining, each
Specification
cylinder head receives a multi-angle high
Subaru
SB8010
Pair with KK3766 Camshafts and valve lash set
with cam bucket (USA)
SB8012
Pair with KK3920 Camshafts and valve lash set
with cam bucket (Japan/Euro)
20002024
Pair 2007 with KK3766 Camshafts (USA)
20002026
Pair 2007 with KK3920 Camshafts (Japan/Euro)
Mitsubishi 4G63
4
and validated, the final port contour is
Subaru EJ25
performance valve job on our precision
CNC valve seat cutter. Then each cylinder
head is ultrasonically cleaned, serialized
and finally hand assembled with select
high performance valve train components,
ready to install on your engine.
Nissan VQ35DE
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
CNC Valve seat cutter
5
High Performance Short Block Assemblies
Cosworth
engine
foundation of the performance build. Every
builders in the Cosworth engine assembly
assemblies are the perfect basis for
high
block is thoroughly inspected before the
facility. Each high performance engine
your high performance application. Each
cylinders are honed to perfection. We then
assembly includes a complete specification
version
countless
balance the rotating assembly that includes
sheet listing all critical dimensions along
hours of engineering and evaluation to
either a new factory forged crankshaft or
with a serialized plaque. For maximum
determine the best combination of parts
Cosworth billet crank along with Cosworth
performance, combine with a Cosworth
and build specification, ensuring maximum
forged connecting rods, Cosworth tri-metal
CNC ported Big Valve Cylinder Head and
reliable
Cosworth
bearings and Cosworth forged pistons.
camshaft set.
high performance engine assembly starts
The motorsport grade parts are then
with all new select components as the
professionally assembled by expert engine
has
performance
gone
through
performance.
Each
High Performance Short Blocks
Part No.
Application
Specification
Subaru
SB8005
Subaru STI EJ25 Short Block (2.5L)
Forged Pistons, Rods
SB8007
Forged Pistons, Rods with 79mm Billet Crank
20003486
Nissan
20000067
Nissan VQ35 Short Block (3.5L)
Lo comp 8.8:1
KK3879
Nissan VQ35 Short Block (3.5L)
Hi comp 11:1
CI8015
Mitsubishi Evo VIII/IX 4G63 Short Block (2.0L)
Forged Pistons, Rods
CI8018
Mitsubishi Evo VII/IX 4G63 Short Block (2.2L)
Mitsubishi
Subaru EJ25 High Performance Short Block 2.5L
The Cosworth EJ25 is an excellent starting point for high performance and track day
applications.
■■
New Subaru EJ25 STI EJ257 Block
■■
Balanced to within 0.5 gram
■■
New Subaru EJ25 STI Forged
Crankshaft or Cosworth Billet Crank
(79mm)
■■
Complete blue-printed assembly
■■
Ring gap set
■■
Bearing clearance checked
■■
Deck height checked
■■
Connecting Rod side clearance
checked
■■
Crankshaft end float checked
■■
Cosworth Forged H-beam connecting
rods
■■
Cosworth Forged Pistons (99.5mm)
and rings
■■
Cosworth Tri-metal bearings
6
Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L
The Cosworth 2.0L 4G63 is an excellent starting point for high performance and track day
applications.
■■
New Mitsubishi 4G63 Evolution Block
■■
Piston squirt jets
■■
New Mitsubishi forged crankshaft
(88mm)
■■
■■
■■
rods
■■
Ring gap set
■■
■■
Deck height checked
■■
checked
■■
■■
Cosworth Forged Pistons (85mm) and
rings
■■
■■
Cosworth Heavy Duty main studs
Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.2L
The Cosworth 4G63 2.2L stroker engine combines the perfect bore to stroke ratio, yielding
potentially big gains in torque while still allowing the engine to rotate and produce power
at higher RPMs.
■■
New Mitsubishi 4G63 Evolution Block
■■
■■
New Cosworth Billet Crank (94mm)
■■
■■
rods
■■
Ring gap set
■■
■■
Deck height checked
■■
checked
■■
■■
Cosworth Forged Pistons (86mm) and
rings
■■
■■
■■
Piston squirt jets
Nissan VQ35DE (350Z-G35) High Performance Short Block 3.5L
The Cosworth VQ35DE high performance short block is the perfect foundation for your high
performance application. Available in either high compression 11:1 or low compression
8.8:1 for turbo or supercharged applications.
■■
New Nissan forged crankshaft
(81.4mm)
■■
checked
■■
rods
■■
■■
and rings
■■
■■
■■
Piston squirt jets
■■
■■
■■
Ring gap set
■■
■■
Deck height checked
7
High Performance Long Block Assemblies
The Cosworth Subaru EJ25 CS600 series
steel studs and sealed with a Cosworth
maximum lubrication. This proven engine
is designed for extreme track day use and
high performance stopper layer steel
combination has been used by top teams
the demanding performance enthusiast.
head gasket. Finally, we install one of our
to win events in both North America and
Each assembly is precision built by one
blue-printed, high pressure oil pumps for
Europe.
of Cosworth’s skilled craftsmen using
the finest components from our parts
catalogue to ensure maximum reliable
power and performance. Starting with
a new Subaru EJ257 semi closed deck
block, we meticulously diamond hone
each bore to guarantee perfect piston
to cylinder wall clearance. The block is
then assembled with our Forged Pistons,
motorsport
grade
Forged
H-Beam
connecting rods along with our high
performance rod and main bearings and a
new STI forged crankshaft. For maximum
performance, an optional steel billet crank
is available (CS600X). Once the cylinder
block assembly is completed, we install a
pair of our CNC machine port-bored Big
Valve Cylinder heads with our proven “S2”
camshafts complete with valve lash set to
our specifications. The cylinder heads are
secured with our high performance 11mm
High Performance Long Block Asse
Part No.
Specification
Subaru - North American spec EJ25 “CS600 & CS600X”
20000162
EJ25 (2.5L) with Big Valve Cylinder heads and KK3766 Camshafts - Billet Crankshaft
20000161
EJ25 (2.5L) with Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft
20002503
EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - Billet Crankshaft
20002504 EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft
20003488
EJ25 (2.5L) 2004-06 with Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet
Crankshaft
20003489
EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet
Crankshaft
20000160
EJ25 (2.5L) with Big Valve Cylinder heads and KK3920 Camshafts - Billet Crankshaft
SB8008
EJ25 (2.5L) with Big Valve Cylinder heads and KK3920 Camshafts - STD Crankshaft
Subaru - North American spec EJ25 “CS600 & CS600X” 81mm Stroke
Subaru - European/Asia spec EJ25 “CS600 & CS600X”
20002503
EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - Billet Crankshaft
20002504 EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - STD Crankshaft
20003490
EJ25 (2.5L) 2004-06 with Big Valve Cylinder heads and KK3920 Camshafts - 81mm Billet
Crankshaft
20003489
EJ25 (2.5L) 2007 with Big Valve Cylinder heads and KK3766 Camshafts - 81mm Billet
Crankshaft
Subaru - European/Asia spec EJ25 “CS600 & CS600X” 81mm Stroke
Includes engine assembly with cylinder heads, camshafts, oil pump and cam covers
8
Features
■■
Cosworth forged H-beam Connecting
rods
■■
New Subaru EJ25 STI Engine case
■■
New Subaru EJ25 STI Forged
Crankshaft
■■
Cosworth Forged Pistons and rings
■■
Cosworth motorsport Tri-metal bearings
Optional Cosworth Billet Crankshaft
(79/81mm stroke available)
■■
■■
■■
Enlarged intake and exhaust ports
■■
Large diameter stainless steel intake
valves
■■
Large diameter inconel exhaust valves
■■
Hi-rev, dual valve springs
■■
Titanium retainers
■■
Hardened steel spring platforms
■■
Multi angle valve job
■■
CNC machined port finish
■■
Knife edge port divider
■■
Cosworth S2 High lift camshafts
■■
Valve lash set
■■
Cosworth high pressure oil pump
■■
Cam covers
■■
Cosworth serial number
■■
9
Billet Crankshafts
Increased
often
rod journals are lubricated from only one
rod bearing failure. Cosworth Subaru
means increased engine speed and load.
engine
performance
main oil feed. Cosworth billet crankshafts
crankshafts are manufactured entirely
Original factory crankshafts may not
feature full-flow oiling whereby each
from high grade steel in a light-weight, high
be able to withstand the added stress,
rod journal is lubricated from two main
strength design with a unique Isotropic
resulting in catastrophic engine failure.
sources. This provides superior lubrication
Superfinish.
Additionally, factory Subaru crankshaft
during sustained high rpm use preventing
Features Include:
■■
Superior lubrication
■■
Profiled counterweights
■■
High strength
■■
Light weight
Billet Crankshafts
Part No.
Application
Specification
Mitsubishi
PR7863
Mitsubishi EVO 4G63 (2.2L conversion)
94mm stroke - Fully counterweighted \ Billet Steel
Subaru
Cosworth Tech: Isotropic
Superfinish
20001414
79mm stroke - Light weight version \ Billet Steel
20001546
81mm stroke - Light weight version \ Billet Steel
the need for replacement. By creating a
by fractions of a second, so it all comes
smooth and shiny finish, the ISF Process
down to getting the most power output
chemically
improves the life and efficiency of moving
possible. With the ISF Process, the energy
finishing
metal parts. Increased life translates into
normally lost to friction is now available
process Any time two metal parts come
lower operating costs as well as better
in the form of increased power output.
into contact with each other, the resulting
performance. In extreme environments,
Once friction is reduced, the engine will
friction causes heat build up. These high
such as automobile or motorcycle racing,
run cooler allowing for longer durability of
temperatures cause wear and over time
every component must work in harmony
parts and fewer failures.
reduce efficiency and eventually create
at 100% capacity. Races are won and lost
The
ISF
accelerated
Process
is
vibratory
a
mass
■■
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
10
Stroker Engine Kits
Cosworth stroker kits are the perfect way
to add displacement, torque and power
to your engine. Each kit includes select
matched components from our parts list
ensuring reliable performance.
Stroker Kits
Part No.
Application
Mitsubishi
KK3831
Mitsubishi Evo 4G63 (2.2L)
Subaru
20002500
Subaru EJ25 (2.6L)
20002501 Subaru EJ20 (2.2L) forged (79mm stroke) Crank
20002502 Subaru EJ20 (2.2L) Billet (79mm stroke) Crank
Subaru EJ25 2.6L
■■
■■
Cosworth Fully Counterweighted Billet
Crankshaft (81mm)
■■
Forged Cosworth Connecting Rods
■■
Cosworth Rod and Main Bearings
■■
Cosworth Piston Rings
Subaru EJ25 2.6L
Mitsubishi 4G63 (Evolution VII-IX) 2.2L
■■
Cosworth Forged Pistons (86mm)
■■
Cosworth Fully Counterweighted Billet
Crankshaft (94mm)
■■
Forged Cosworth Connecting Rods
■■
Cosworth Rod and Main Bearings
■■
Cosworth Piston Rings
Mitsubishi 4G63 2.2L
11
Forged Connecting Rods
The connecting rod is the vital link between
the piston and power. When engine output
is increased, the demands placed on the
connecting rod increase as well. To ensure
engine reliability in all conditions, original
connecting rods should be replaced with
heavy duty specification parts. Cosworth
Forged Connecting Rods are manufactured
from high strength 4340 (EN24) steel and
machined to exacting tolerances.
Features Include:
■■
Strong, light weight H-beam design
■■
Heavy duty rod bolt (260,000psi)
■■
Manufactured from 4340 (EN24) steel
■■
Small end bushed for floating pin
Forged Connecting Rods
Part No.
Application
Specification
Subaru
20002587
Subaru WRX STI EJ25 (2.5L) set of four
H-Beam
20002587
Subaru WRX EJ20 (2.0L) set of four
H-Beam
20002632
Mitsubishi Evo 4G63 (2.0L) set of four
H-Beam
20002596
Mitsubishi 4B11T (2.0L) set of four
H-Beam
20002585
Nissan VQ35 (3.5L) set of six
H-Beam
20002588
Nissan RB26 (2.6L) set of six
H-Beam
20002589
Nissan SR20 (2.0L) set of four
H-Beam
20002590
Honda K20 (2.0L) set of four
Mitsubishi
Nissan
Honda
12
H-Beam
Ultra High Performance Head Studs
Essential for high performance engine
are manufactured from H11 tool steel
Features:
builds, heavy duty head studs reduce
with 260,000psi tensile strength and
■■
Essential for high power applications
cylinder head movement
come complete with nuts and washers.
■■
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
■■
260ksi+ (260,000psi+) tensile strength
■■
Special heat treat process includes
heating in vacuum sealed furnace and
quenched in a nitrogen chamber for
precision control
in high boost
or high compression engines optimising
Manufactured with
cylinder head to block sealing. Cosworth
ease of installation.
hex broach end for
Ultra High Performance Head Studs
Ultra High Performance Head Stud Kits
Part No.
Application
20002440
Subaru WRX STI EJ25/EJ20 11mm
20002442
Mitsubishi Evo 4G63 11mm
20006025
Mitsubishi 4B11T 11mm
20002444
Nissan SR20DET 11mm
13
Ultra High Performance Engine Bearings
Engine bearings are one of the most vital
components within an engine and are
often overlooked when considering high
performance
upgrades.
Performance
engineered, multi-layer bearings generate
High Performance Engine Bearings
Part No.
Application
Specification
Subaru EJ25 / EJ20
20002720
Subaru WRX/STI EJ25/ EJ20 Main Bearing Set - Tri Metal
Size 0
20002721
Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal
Size 0
PR7940
Subaru WRX/STI EJ25/ EJ20 Main Bearing Set - Tri Metal
Size 1
PR7889
Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal
Size 1
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
less heat than normal bearings by reducing
friction. Cosworth race bearing sets feature
in extreme conditions.
Cosworth Race
Mitsubishi Evo 4G63 “Evo” 1992-2006
bearings sets are available in three sizes
20002723
Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal
Size 0
to accommodate most applications.
20002722
Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal
Size 0
PR7894
Size 1
Engineered with the following features:
PR7893
Size 1
High strength overlay plate with
reduced thickness for better oil control
and less friction
PR7427
Size 2
PR7428
Size 2
PR7429
Mitsubishi Evo 4G63 (2.0L) Thrust Bearing set
■■
■■
■■
■■
Hardened steel backing on all
connecting rod bearings
Increased crush for better retention
3/4 grooving on Main Bearings
providing optimum oil supply
■■
Tight consistent wall tolerances
■■
Oversize chamfers where applicable
■■
Flash plating eliminated for improved
heat transfer
■■
Tested to over 1000 horsepower!
14
Nissan VG35DE
20002725
Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal
Size 0
20002724
Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal
Size 0
PR7911
Size 1
PR7910
Size 1
PR7853
Size 2
PR7854
Size 2
PR7859
Nissan VQ35 (3.5L) Thrust Bearing Set
High Performance Engine Bearings
Part No.
Application
Cosworth High performance engine
Specification
bearings are now available in three
sizes. It is imperative that bearing
Nissan SR20DET (except RNN14 Pulsar Gti-R)
20002727
Nissan SR20 (2.0L) Main Bearing Set - Tri Metal
Size 0
clearances
20002726
Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal
Size 0
selecting the appropriate bearing size.
PR7896
Size 1
PR7895
Size 1
PR7851
Size 2
PR7852
Size 2
PR7937
Nissan SR20 (2.0L) Thrust Bearing Set
Nissan RB25/26
20002729
Nissan RB25/26 Main Bearing Set - Tri Metal
Size 0
20002728
Nissan RB25/26 Rod Bearing Set - Tri Metal
Size 0
PR7892
Size 1
PR7891
Size 1
PR7655
Size 2
PR7656
Size 2
are
measured
before
■■
Size 0 generally provides close to
factory oil clearances
■■
Size 1 usually provides slightly
larger than factory oil clearances
■■
Size 2 provides large oil clearances
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
Size 1
PR7912
Size 1
PR7915
Size 2
PR7913
Size 2
PR7916
Honda K20 (2.0L) Thrust Bearing Set
15
Forged Pistons
With 50 years of world class engine design
Features & Benefits:
and manufacturing experience, Cosworth’s
■■
Skirt profile & ovality 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
■■
components gives the us the distinct
Oil and combustion gas control features - reduced blow-by and oil consumption
■■
Offset pin bores - for reduced engine noise
advantage in piston design resulting in the
finest piston available.
Polished Crown
The piston is one of the most important
components within the engine. It can be
subjected to directional change up to 285
times every second and must withstand
acceleration forces of 8500 G’s. Cosworth
high performance forged pistons are
Anti-detonation bands
designed and engineered to withstand
this type of punishment and still perform.
All Cosworth pistons are manufactured
Optimised Forging
using the same methods as our Formula
One pistons and include features such as
anti-scuff skirt coating, ultra-strong pins,
polished top and patented anti-detonation
bands. Additionally, each application uses
a unique forging to minimize weight and
Xylan Skirt Coating
ensure the strongest possible piston.
Subaru EJ25, 9.2:1
16
Mitsubishi 4G63
Subaru EJ25
Forged Piston Sets (Includes pistons, pins and circlips - rings not included)
Part No.
Application
Subaru
20003674
Subaru WRX STI EJ25 (2.5L) 99.5mm 8.2:1cr
20003675
20003676
Subaru WRX STI EJ25 (2.5L) 100.mm 8.2:1cr
20003677
Subaru WRX EJ20 (2.0L) 92.mm 8.0:1cr
20003678
Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr
20003682
Subaru WRX STI EJ25 (2.6L) 99.5mm 8.2:1cr (For use with 81mm crankshaft)
20003683
20003684
Subaru WRX STI EJ25 (2.6L) 100.mm 8.2:1cr (For use with 81mm crankshaft)
20004531
20004532
20004533
20004534
20004535
20004536
20003685
Subaru WRX EJ20 (2.2L) 92.mm 8.5:1cr (For use with 79mm crankshaft)
20003687
Subaru WRX EJ20 (2.2L) 92.5mm 8.5:1cr (For use with 79mm crankshaft)
20003223
Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr
20003225
Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr
20003679
Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application)
20003681
Nissan VQ35 (3.5L) Low CR 96.mm 8.8:1cr (Turbo application)
20005861
Nissan RB26DETT 86.5mm 8.5:1cr-Stroker
20005862
Nissan RB26DETT 87 mm 8.5:1cr-Stroker
20005863
20003688
Mitsubishi Evo IV-IX 4G63 (2.0L) 85mm 8.8:1cr
20003690
20003693
Mitsubishi Evo IV-IX 4G63 (2.2L) 86mm 8.8:1cr (For use with 94mm crank)
20005129
Mitsubishi 4B11 (2.0L) 86mm 9.0:1cr
20005130
Mitsubishi 4B11 (2.0L) 86.5mm 9.0:1cr
20005131
20005856
Mitsubishi 4B11 (2.2L) 86mm 9.0:1cr (For use with 94mm crank)
20005859
20005860
20005865
Honda K20A 86mm 12:1cr
20005866
Honda K20A 86.25mm 12:1cr
20005867
Features Include:
■■
Unique forgings for each application
■■
‘Xylan’ anti scuff skirt coating
■■
Polished tops (reduces carbon build
up and relieves stress)
■■
Manufactured from proprietary alloy
(CosAl 010)
■■
Ultra strong pin
■■
Patented anti-detonation bands
Nissan
Mitsubishi
Honda
Nissan VQ35 High Compression
17
Single Forged Pistons
Single Forged Pistons (Includes pins and circlips)
Part No.
Application
Subaru
20000897
20000898
20000899
20002111
Subaru WRX EJ20 (2.0L) 92.mm 8.0:1cr
20002112
Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr
20002431
20002432
20002433
20002489
Subaru WRX EJ20 (2.2L) 92.mm 8.5:1cr (For use with 79mm crankshaft)
20002491
Subaru WRX EJ20 (2.2L) 92.5mm 8.5:1cr (For use with 79mm crankshaft)
20004522
20004523
20004524
20004528
20004529
20004530
20002036
Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr (Left hand bank)
20002038
Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr (Left hand bank)
20002039
Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr (Right hand bank)
20002041
Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr (Right hand bank)
20002132
Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application)
20002134
Nissan VQ35 (3.5L) Low CR 96.mm 8.8:1cr (Turbo application)
20005791
20005792
Nissan RB26DETT 87 mm 8.5:1cr-Stroker
20005793
Nissan
18
Single Forged Pistons (Includes pins and circlips)
Part No.
Application
Mitsubishi
20000832
20000834
20000971
Mitsubishi Evo IV-IX 4G63 (2.2L) 86mm 8.8:1cr For use with 94mm crank
20004488
20004675
20004676
20005783
20005784
20005785
20005799
Honda K20A 86mm 12:1cr
20005800
20005801
Honda
Cosworth Tech: Green Pistons
Xylan is a fluorpolymer coating designed for use on various engine components and
fasteners. Cosworth pistons use Xylan coating to provide lubrication and control friction,
wear resistance, heat resistance, nonstick and release properties and, at the same
time, can also protect from corrosion. This is the same coating we use on many of our
ultra-high performance race engines.
Spare Piston Pins and Circlips
Cosworth Pistons feature heavy duty, ultra
utrong piston pins designed for the higher
stress and elevated load levels found in
high performance engines. Spare parts
are available for routine engine rebuilds.
Spare Piston Pins and Circlips
Part No.
Application
PA2674
23mm Pin, Subaru EJ20 / EJ25 Piston
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
PP2371
Circlip, 22mm Nissan / Mitsubishi Piston. 2 req per piston
SB8004
Circlip install tool, Subaru
tool engineered to simplify the task. This
high quality tool is machined from steel to
ensure years of trouble free use.
19
Performance Ring Sets
Developed using the latest technologies,
and highest quality materials, Cosworth
Performance Ring Sets are designed
to meet the demands of modern high
performance engines for higher power
output, improved sealing, lower friction,
and longer life.
Performance Ring Sets for Cosworth Pistons
Part No.
Application
Specification
Subaru
20001515
99.5mm
20001516
99.75mm
20001517
100.mm
20005160
Subaru WRX EJ20 (2.0L)
92.mm
20005161
92.5mm
20003605
92.mm (Use with Stroker pistons 20002489/ 20003685)
20003607
92.5mm (Use with Stroker pistons 20002491/ 20003687)
Nissan
20001512
Nissan VQ35 (3.5L)
20001514
Nissan VQ35 (3.5L)
95.5mm
96.mm
Mitsubishi
PR7317
Mitsubishi Evo 4G63 (2.0L)
20002246
Mitsubishi Evo 4G63/4B11
20005705
Mitsubishi Evo 4B11 86.5mm
20005706
Mitsubishi Evo 4B11
85mm
86mm
86.5mm
87mm
Cosworth Tech: Ring Sets
Cosworth Performance Ring Sets are comprised of a chrome top ring, an iron second
ring, and three-piece oil ring. Some Cosworth Performance Ring Sets offer upper rings
that are Gas Nitride treated for quicker break-in, lower wear, and improved sealing.
Manufacturing tolerances exceed OEM standards. Axial tolerance is +/- 0.0002” and
radial tolerance is +/- 0.0005”.
20
Kevlar High Performance Timing Belts
Cosworth Kevlar High Performance Timing
belts are 300% stronger than original
equipment timing belts and are the perfect
compliment
when
installing
Cosworth
camshafts or cylinder heads.
■■
High saturation HNBR elastomeric
composites ensure durability and heat
resistance
■■
Durable nylon fiber provides extra wear
resistance and increased tooth strength
■■
Kevlar backing improves strength
Cosworth Kevlar High Performance Timing Belts
Part No.
Application
20004950
Timing Belt – Mitsubishi 4G63 Heavy Duty, All 20004952
Balance Belt - Mitsubishi 4G63 Heavy Duty, All
20004953
Timing Belt – Subaru EJ20/25 Heavy Duty, All 21
High Performance Camshafts
Cosworth has been engineering camshafts
for nearly 50 years. That coupled with years
of innovative multi valve cylinder head
design ensures our camshaft designs are
the most efficient in providing maximum
usable power across the widest power
band.
Each cam is ground from a new billet and
finished using the same procedures we
Performance Camshafts
Part No.
camshafts
are
the
perfect
compliment to our CNC Ported Big Valve
Cylinder Heads. Our cams are profiled
to
increase
boost
response
thereby
increasing engine torque and power and
are fully compatible with our CNC Ported
Big Valve Cylinder Heads.
Specification
Subaru
KK3814
Subaru WRX STI EJ25 (2.5L) Set of four
(AVCS Type) North American spec
Int.”260” deg. 9.6mm lift / Exh. “260” deg.
9.6mm lift
KK3766
Subaru WRX STI EJ25 (2.5L) Set of four
(AVCS Type) North American spec S2 Grind
10.mm lift
KK3765
Subaru WRX EJ20 (2.0L) Set of four
KK3920
Subaru WRX STI EJ25/EJ20 Set of four
(AVCS Type) Japan / European spec S2 Grind
KK3805
Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1
exhaust cam) M1 Grind
“264” deg. 10.2 mm lift
KK3806
Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1
exhaust cam) M2 Grind
“272” deg. 11 mm lift
KK3921
Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake
and 1 exhaust cam) M2 Grind
MIVEC Intake/Exhaust “272” deg. 11 mm lift
20002517
Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake
and 1 exhaust cam) M3 Grind
MIVEC Intake “280” deg. 11.6mm lift /
Exhaust “272” deg. 11 mm lift
“272” deg. 10mm lift
10.mm lift
Mitsubishi
use in our extreme level race engines.
Cosworth
Application
PR7832
Mitsubishi Evo 4G63 (2.0L) Intake cam only
M1 Grind
“264” deg. 10.2 mm lift
PR7833
Mitsubishi Evo 4G63 (2.0L) Exhaust cam only
M1 Grind
“264” deg. 10.2 mm lift
PR7834
Mitsubishi Evo 4G63 (2.0L) Intake cam only
M2 Grind
PR7835
Mitsubishi Evo 4G63 (2.0L) Exhaust cam only
M2 Grind
Nissan
20002507
Nissan VQ35 “287hp” Set (2 intake and 2
Exhaust cams) “ZK1” Grind
Intake “268” deg. 10.4mm lift / Exhaust
“268” deg. 9.5mm lift
20002508
Nissan VQ35 “287hp” Set (2 intake and 2
“270” deg. 10.65mm lift
20002510
Nissan VQ35 “Rev up” Set (2 intake and 2
“268” deg. 9.5mm lift
20002511
Nissan VQ35 “Rev up” Set (2 intake and 2
“270” deg. 10.65mm lift
Cosworth Tech - Subaru Cams
Our Subaru AVCS cams are available for both North American and Japanese/European
applications. While cam profiles are the same, cam angle triggers are significantly different.
AVCS camshafts for North American applications use a series of three slots to activate the
cam angle sensor. Japanese/European applications rely on four raised triggers to activate
the sensor. If in doubt, check your original cams before ordering.
22
North American
Japanese/European
Features Include:
■■
Ground from new billets
■■
Engineered and tested profiles
■■
Broad power band
■■
Compatible with Cosworth CNC ported
Big Valve Cylinder Heads
Subaru AVCS
Mitsubishi Evo 4G63
Mitsubishi EVO 4G63 Mivec
Nissan VQ35
23
High Performance Valve Train
High Performance Valves
Large
diameter
valves
(2400° F) reliability. Each valve features
are
essential
for improved air flow. Cosworth high
performance intake valves are produced
from high quality stainless steel for
maximum durability. Exhaust valves are
swirl polished back for improved air flow
and dished face for additional weight
reduction. Cosworth high performance
valves are compatible with Cosworth Ultra
Race Valve Spring Kits.
machined from Inconel for high temperature
Performance Valves
Part No.
Application
PR7559
Valve, Inlet +1.0mm Subaru EJ25 - Stainless Steel (37.0mm)
PR7558
Valve, EX +1.0mm Subaru EJ25 - Inconel (33.0mm)
PR7500
Valve, Inlet +1.0mm Mitsubishi 4G63 - Stainless Steel (35.0mm)
PR7501
Valve, Ex +1.0mm Mitsubishi 4G63 - Inconel (31.5mm)
PR7602
Valve, Inlet +1.0mm Nissan VQ35 - Stainless Steel (38.15mm)
PR7603
Valve, Ex +1.0mm Nissan VQ35 - Inconel (32.35mm)
Ultra Race Valve Spring Kits
Cosworth Ultra Race Valve Springs are
Cosworth Ultra Race Valve Spring Kits
wound from the highest quality chrome
are engineered for use in situations that
require valve control in extreme conditions.
Each kit consists of dual valve springs with
matched lightweight titanium retainers,
keepers, and hardened steel spring seats.
silicone steel with chamfered ends and are
heat treated and stress relieved for long
term reliability. Ultra Race Valve Spring
kits are compatible with Cosworth high
performance valves.
Ultra-High RPM Valve Spring Sets
Part No.
Application
KK3813
Mitsubishi Evo 4G63 (2.0L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set
KK3839
Subaru EJ25 STI (2.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set
20002550 24
Nissan VQ35 (3.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set
High RPM Valve Springs
performance potential and improved valve
Cosworth High RPM Valve Springs are the
control. Single spring design allows easy
result of countless hours of engineering,
testing and validation ensuring the best
installation with no machining required
and is perfect for typical high performance
possible spring for high performance
use.
applications. Cosworth High RPM Valve
■■
Manufactured from the finest Japanese
Kobe steel
■■
Single spring design for easy
installation
and retainers. Each spring has been
■■
Dual chamfered ends
engineered with increased seat pressure
■■
Increased performance
Springs are wound from the world’s finest
Japanese Kobe steel and feature dual
chamfered ends to reduce wear on seats
*Seal clearance
Install Height
“F1”
along with higher lift capability for optimum
High RPM Valve Spring Sets
Part No.
Application
Mitsubishi
20000164
High RPM Single Valve Spring set (16) Mitsubishi Evo VII-IX 4G63
20000166
High RPM Single Valve Spring set (16) Subaru WRX STI EJ25 (2.5L) EJ20 (2.0L)
Subaru
Nissan
20000163
High RPM Single Valve Spring set (24) Nissan VQ35 (3.5L)
20000168
High RPM Single Valve Spring set (16) Nissan SR20DET (2.0L)
20000169
High RPM Single Valve Spring set (24) Nissan RB26 (2.6L)
BMW
20000167
High RPM Single Valve Spring set (16) BMW MINI Cooper/Cooper S (1.6L)
Mitsubishi 4G63
Subaru EJ20/EJ25
Nissan VQ35DE
Valve Train Specification (L1=Install Height, F1=Force @ L1, L2=Max Lift, F2=Force @ Max Lift)
Free Height
L1 mm
F1 N
F1 lbs
L2 mm
F2 N
F2 lbs
Max Lift
Coil Bind
20000167
Part No.
Mini 1.6 Tritec
48.85
43.0
348
80
33.0
944
212
11.0
30.7
20000164
Mitsubishi EVO 7-9
47.00
38.1
381
85
26.1
900
202
12.0
24.3
20000169
Nissan RB26
49.30
41.9
359
81
29.9
941
212
12.0
28.4
20000168
Nissan SR20
46.00
39.0
365
82
27.5
964
217
11.5
25.4
20000163
Nissan VQ35DE
46.00
38.0
289
65
24.5
775
175
13.5
22.9
20000166
Subaru EJ 2.0/2.5
42.00
36.0
275
62
25.0
780
175
11.0
23.2
KK3813
Mitsubishi EVO 7-9
50.00
38.1
512
115
26.9
1268
285
12.0
25.7
Nissan VQ35DE
47.00
38.0
378
85
23.9
1183
266
14.1
22.6
Subaru EJ 2.0/2.5
46.10
36.0
356
80
22.1
1019
229
13.9
20.8
20002550
KK3829
Application
All dimensions are in millimetres unless otherwise specified
25
High Performance Head Gaskets
Cosworth High Performance Head Gaskets
are engineered to seal in power under the
most demanding conditions. Constructed
from stainless steel with a folded stopper
layer, each application features superior
sealing compared to conventional multilayer steel gaskets. Additionally, Cosworth
High Performance Head Gaskets are
manufactured from pre-coated die cut
stainless steel resulting in uniform coating
distribution and consistent shape.
Folded stopper layer provides complete sealing
around entire combustion chamber
Without folded stopper layer, clamping force is
limited resulting in incomplete sealing around
combustion chamber
High Performance Head Gaskets
Part No.
Application
Specification
Nissan
20000900
Nissan VQ35DE (3.5L)
Bore = 96mm T ~ 0.6mm (Pair)
20000903
Nissan VQ35DE (3.5L)
Bore = 98mm T ~ 0.6mm (Pair)
20000924
Nissan SR20DET (2.0L)
Bore = 87mm T ~ 1.1mm
20000925
20000926
20000927
Nissan RB26DETT (2.6L)
20000928
20000929
20000930
Nissan RB25DET (2.5L)
20000931
Nissan RB25DET (2.5L)
Mitsubishi
20001689
20001690
20000909
Mitsubishi Evo IV-VIII 4G63 (2.0L)
20000910
Mitsubishi Evo IV-VIII 4G63 (2.0L)
20004122
20004123
Subaru
20000913
Bore = 101mm T ~ 0.78mm each
20000916
20002145
20000919
20000922
20003127
Honda K20/24
Bore = 87mm T ~ 0.8mm for use with RAA, RAC, RBB, and RBC cylinder heads
20003128
Honda K20/24
20003129
Honda K20/24
20005454
Honda K20/24
Bore = 87mm T ~ 0.8mm for use with PRB, PNC, and PPA cylinder heads
20005455 Honda K20/24
20005456
Honda K20/24
Honda
26
Each gasket is carefully engineered with
■■
Die cut manufacturing process ensures
smooth edges, unlike laser cut gaskets
■■
Cosworth gaskets feature a “folded
stopper” layer for additional clamping
force around each cylinder. The width
of sealing area is specific for each
application thereby providing ultimate
sealing properties
■■
Available in a range of thicknesses for
specific applications
the following features:
■■
Individual die cut layers of stainless
steel with superior consistency
compared to laser cut gaskets
■■
Pre-coated stainless steel with a 0.25
micron layer of nitrile rubber ensures
consistent distribution of coating with
no high or low areas
■■
Manufacturing dimensional tolerance of
+/- 0.001”
Folded
Stopper Layer
Stopper Sealing Layer
Gasket Layer
Gasket Layer
Nissan VQ35DE
Uniform Nitrile Rubber Coating
Mitsubishi 4G63
Mitsubishi 4b11t
Die Cut Edges
Subaru EJ25
27
Oil Control
High
performance
engines
reject
a
substantial amount of heat through the
oil system. Maintaining oil pressure and
control along with an increase in actual
volume will help dissipate heat and stabilize
oil temperatures. Cosworth oil control
components are engineered to combat
several problem areas experienced in high
Oil Control
Part No.
Application
Subaru
KK3928
Subaru (EJ20/EJ25) Blueprinted Oil Pump with high pressure mod & install kit
20001185
Subaru (EJ20/EJ25) High Volume/Pressure Blueprinted Oil Pump & install kit
20001238
Subaru (EJ20/EJ25) High Volume Oil Pan
20002499
Subaru (EJ20/EJ25) Oil Control Baffle
20004463
Dry Sump Kit, Subaru EJ
20001382
Mitsubishi Evo VII-IX 4G63 (2.0L) Crankshaft Oil Scraper
performance engines.
Mitsubishi
Mitsubishi 4G63 Crankscraper
The Cosworth 4G63 Crankscraper is
engineered to reduce parasitic drag on the
crankshaft caused by oil accumulation that
surrounds the crankshaft during rotation.
This oil buildup causes additional drag
and can reduce power output. Additionally,
overall oil control is improved by keeping
oil in the sump. Especially useful in high
rpm and race applications. Mounts to
main bearing girdle. Designed from 2.6
mm (12gauge) steel plate and includes
required mounting hardware.
Subaru Oil Pan Baffle
Oil control can be a problem with high
performance and high revving Subaru
engines. High crankcase pressure along
with the horizontal engine platform restricts
rapid oil return from the cylinder heads to
the oil pan. Pressure builds in the heads
and crankcase causing massive blow by
and power loss.
The Cosworth Subaru
Oil Pan Baffle has been engineered with
diverters to control oil returning from the
cylinder heads to the pan directing it away
from the crankshaft. Additionally, one-way
valves prevent oil from re-entering the
upper crankcase chamber thereby limiting
blow by and preventing oil starvation
during hard driving. Manufactured from
stainless steel and installs easily between
the block and oil pan on both EJ20/EJ25
series engines. Use with our High Volume
Oil Pan for maximum oil control.
28
Subaru Dry Sump - Part number
Complete
scavenging
The Cosworth Dry Sump System for the
20004463
reduces excessive and residual oil that can
Subaru EJ20/EJ25 replaces the original
A must for racing and high performance
cause blow-by and power loss. A Dry Sump
oil sump with a machined from solid, low
also offers more consistent oil pressure
profile alloy pan with twin scavenge ports,
to the engine, improved scavenging, and
internal baffling and o-ring sealing. A two
increased ring seal due to greater pan
stage scavenge pump driven by a HTD
vacuum.
belt, mounted to a heavy duty bracket
use, dry Sump oiling systems offer an
unparalleled level of safety and reliability
compared to factory Wet Sump systems.
crankcase
oil
evacuates the oil from the engine.
Includes:
Internal baffling
■■
Machined From Solid Sump
■■
2-Stage Scavenge Pump
■■
Pump Mounting Bracket/Manifold
■■
34T Pump Drive Pulley
■■
Crankshaft Drive Adapter Assembly
■■
HTD Drive Belt
■■
Crankcase Breather Filter and Fitting
■■
Fittings and Hardware
Required to complete the installation:
Twin Scavenge Ports
■■
Oil Tank
■■
Hoses/Hose Ends
■■
2004-2007 Subaru STI Alternator
bracket
■■
Cosworth High Volume/Pressure Oil
Pump 20001185
Heavy duty mounting bracket / pump manifold
Low profile design
29
Subaru EJ20/25 High Volume Oil Pan -
fabricated from both custom and original
Part number 20001238
components resulting in an additional 2qts
Sustained high RPM or prolonged high
oil capacity when compared to standard
speed driving will result in elevated oil
temperatures. Additional oil volume along
with improved oil control will reduce
damaging oil temperatures. The Cosworth
oil pan. Each kit includes powder coated
oil pan, mounting hardware, oil pickup and
spacer.
Will not work with some equal
length exhaust manifolds.
EJ20/EJ25 High Volume Oil Pan is
Subaru EJ20/25 Oil pump - High
Additionally, sustained High RPM use may
12mm rotor to increase volume by 20%.
Volume - Part number 20001185
cause oil starvation at the rod and main
Suggested applications include drag, track
Increasing oil volume will help to prevent
bearings. The Cosworth High Volume
day and race use. Each kit includes all
Subaru
required mounting hardware and seals.
bearing
damage
and
engine
failure.
EJ20/EJ25
series
oil
pump
utilizes a completely new inner and outer
Pump Gear: 10mm vs 12mm
Subaru EJ20/25 Oil pump - High
increase oil pressure helping to ensure
Pressure - Part number KK3928
superior lubrication. Each pump is carefully
High
performance
engines
require
additional oil pressure because of the
increased demand placed upon various
components
within
the
engine.
The
Cosworth High Pressure Subaru EJ20/
EJ25 series oil pump is modified to
30
inspected and de-burred for unobstructed
oil flow. Perfect for high performance daily
use Each kit includes all required mounting
hardware and seals.
High Flow Synthetic Air Filters
Cosworth Performance 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 molded from High Impact Polystyrene or Polypropylene. Each
Cosworth air filter has been engineered to fit the vehicles original air box providing a true
cold air supply to the engine. Cosworth Performance Air Filters also provide increased air
flow when compared to original equipment air filters.
High Flow Synthetic Air Filters
Part No.
Honda Fit
Application
20002270
Nissan 350Z -06
20005381
Nissan 350Z Nismo / Infiniti G37 07+(Twin Air Box Applications)
20002271
Honda S2000
20002272
Honda Fit
20005380
Acura RSX 02-07
20002274
Mazda 3 2.0, 2.3L petrol, Mazdaspeed 3
20002273
Mazda RX8 03+
20002275
Mazda MX-5 Miata/Roadster 2.0L all 2005+
20002277
Mitsubishi Lancer Evolution 7/8/9
20004232
Mitsubishi Lancer Evolution X 2008+
20002270
Subaru Impreza GC, GD, GG
20002278
Subaru Legacy GT N/A and Turbo, 08+ Sti
20002281
Lexus IS250/350
20002286
Toyota Tundra 3.4L and 4.7L all
20002282
Scion tC
20002282
Lotus Elise & Exige
■■
Improved performance
■■
Superior filtration
■■
Exceptional dust holding capacity
■■
Reduced restriction (10%+ compared to OE filters)
■■
Over 98% efficiency (ISO5011:200 Fine Dust Test)
Honda S2000
Mitsubishi Evo 8/9
Nissan 350Z / Subaru Impreza
Subaru Legacy 2008+ STI
Mazda 3
Lexus IS250/350
Toyota Tundra
31
Mazda MX5 Supercharger system 2006-2008
The Cosworth bolt on Supercharger system
The all inclusive, bolt-on system features an
■■
Eaton MP62 Supercharger unit
for the 2006+ Mazda MX-5 features a
efficient air to water intercooler, upgraded
■■
Intercooler (Air to water)
state of the art 4th generation Eaton MP62
fuel system and complete installation
■■
High flow injectors
rotating group housed in an integral inlet
hardware. A high flow air box cover and
■■
manifold. It was designed as a compact,
a revised accessory drive arrangement
High flow air box lid
■■
flexible supercharger system for increased
complete the major components list. An
Compact installation
power with original equipment quietness
included re-flashing device takes care of
and reliability without adversely affecting
fuel and ignition calibration.
fuel economy. The MP62 has proven itself
in a number of OE applications.
Mazda MX5 Supercharger 2006+
HP/Torque
245
235
225
215
205
195
185
175
165
155
145
135
125
115
HP
Torque
105
95
2000
2500
3000
3500
4000
4500
RPM
32
5000
5500
6000
6500
Mazda MX5 Supercharger
Part No.
20001310
Application
Mazda MX5 / Miata 2006+ Manual transmission
Flashing Kit
33
Induction / Fuel
VQ35 Twin Plenum Intake Manifold
enhancing velocity stacks improve mid-
lightweight aluminium alloy with carbon
The Cosworth Twin Plenum Inlet Manifold
range power. With performance derived
fibre end caps and includes all required
from countless hours of development
mounting hardware. Will fit with original
including computational fluid dynamics,
strut tower brace. Can be used with the
the Cosworth Twin Plenum Inlet Manifold
factory fuel rail system or the Cosworth
is perfect for both normally aspirated and
High Volume Fuel Rail kit.
for the Nissan VQ35DE has been designed
to enhance mid-range and high RPM power.
It features increased plenum volume for
improved high RPM power while torque
Mitsubishi EVO High Volume Fuel Rail
System
The Cosworth High Volume Fuel Kit
features a machined from solid, hard
anodized aluminium fuel rail with o-ringed
fittings and a pre-shaped inlet pipe. The
Cosworth High Volume Fuel Rail Kit can
be used with original or various aftermarket
injectors and PRV’s.
■■
Direct fit replacement- includes all
necessary components for a complete
bolt-on installation
■■
Designed with expansion in mind,
facilitating installation of custom
fuel systems including AN fuel lines
and remote mounted fuel pressure
regulators
■■
Full-flow ½” bore will support upwards
of 600hp worth of fuelling
■■
Hard anodized finish is methanol
compatible.
forced induction applications. Cast from
Nissan VQ35 High Volume Fuel Rail
Each system includes sleeved high
System
pressure fuel lines along with a CNC
The original factory VQ35DE fuel rail
machined distribution block that includes
arrangement is limited in performance.
The Cosworth VQ35 High Volume Fuel
System features high volume anodized
fuel rails, with o-ringed fittings and is fully
an additional port for various sensors.
The Cosworth High Volume Fuel Rail
System can be used with original or
various aftermarket injectors.
configurable for various applications.
VQ35 Fuel Rail System
(upgraded fittings and seals required)
Mitsubishi Evo Fuel Rail System
34
Induction / Fuel
Part No.
Application
Nissan
20000063
Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold W Carbon plenum covers
20005779
Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold W Carbon plenum covers "Bright Polish
Finish"
KK3905
Nissan VQ35DE (3.5L) High Volume Fuel rail kit
Mitsubishi
20005241
Mitsubishi EVO X High Volume Fuel rail kit
20005378
Subaru Intercooler Kit, 2008 STI
20006438
Subaru High Volume Inlet Manifold
Subaru
Subaru Air Intake - Part number
for power. Engineered for easy installation
20006438
and is the key to making big power.
The Cosworth Subaru High Volume Inlet
■■
Substantially increased plenum volume
Manifold is cast from aluminium featuring
■■
Large, tapered runners with radiused
inlets
■■
Tuned plenum volume and runner
length/taper
■■
Over 10% increase in flow
■■
Integral vacuum manifold for
connection of brake booster, boost
gauge, MAP sensor, boost controller,
etc.
■■
Will work with standard or forward
mount throttle body configurations
■■
Stock throttle body location for
compatibility with most aftermarket
FMIC kits
large tapered runners with radiused inlets
for improved air flow. Plenum volume has
been substantially increased and tuned
35
Subaru Intercooler System
Front mount Intercooler System 2008+
large
STI - Part Number 20005378
bent aluminium tubing for maximum
Front
mounted
improved
intercoolers
performance
potential
offer
for
Subaru applications. The Cosworth front
aluminium
core
with
mandrel
a secure bracket system to help eliminate
STI replaces the restrictive, heat-soak
Installation is simplified as no cutting of
engineered system features an efficient
Heavy duty mounting system
Large efficient core available in
anodized black finish for subtle
appearance
■■
Large diameter mandrel bent
aluminium tubing with grey powder
coated finish
■■
4-ply heavy duty silicone coupling
hoses
■■
Isolated mounting system
■■
Liner hose clamps
The intercooler core is rubber mounted on
cracking and breakage.
The
■■
performance up to and exceeding 600hp.
mount intercooler for the 2008+ Subaru
prone original top mounted core.
Features
vehicle is required
CAD Assembly
Large efficient intercooler core
Large diameter aluminium tubing
36
NGK High Performance Spark Plugs
in different heat ranges to suit a variety of
are designed to withstand the severe
applications.
mechanical and thermal shock associated
with high revving, high-compression, and
high boost engines. They feature a fine
Iridium tip, which ensures high durability,
and a consistently stable spark. Iridium
alloy also has an extremely high melting
point, perfect for today’s high-tech, high
performance engines. They also feature
Trivalent
Metal
Plating,
which
offers
superior anti-corrosion and anti-seizing
properties. Highly recommended for use
in high-powered engines with increased
compression
ratios,
and/or
higher
combustion chamber pressures. Available
Part No.
Application
Specification
20005759
NGK R7438-8 VQ, 4B11T, EJ257, and 4G EVO9
Heat Range 8
20005760
NGK R7438-9 VQ, 4B11T, EJ257, and 4G EVO9
Heat Range 9
20005761
NGK TR7IX Duratec
Heat Range 7
20005762
NGK TR8IX Duratec
Heat Range 8
37
Miscellaneous
Subaru Billet Timing Belt Guide - Part
number SB0001
The original sheet metal timing belt
guide can flex from belt deflection when
subjected to extreme RPM causing the
timing belt to skip one or more teeth on
the crankshaft sprocket. The Cosworth
Billet Timing Belt Guide was developed
to control this problem and is machined
from solid aluminium with a hard anodized
finish. Includes mounting hardware.
Miscellaneous
Part No.
Application
Subaru
SB0001
Subaru (EJ20/EJ25) Billet Timing Belt Guide
SB0002
Subaru Billet Cam Angle Sensor Bracket (for mounting cam angle sensor on front of head)
20004539
Subaru (EJ20/EJ25) Air pump delete plate set
Subaru Billet Cam Angle Sensor
Bracket - Part number SB0002
Used for mounting the cam angle sensor
to the front of non North American Spec
STI cylinder heads. Useful for adapting our
cylinder heads to Japanese and European
market engines.
Air Pump Delete - Part number
20004539
Used to eliminate the air pump and related
valves
found
on
2006-2008
Subaru
Engines. Used for high performance
applications or adapting later cylinder
heads to early engines. Seals off the air
injection ports at the cylinder heads. Saves
weight, reduces complexity, cleans up
engine compartment. Machined from solid
aluminium with a “Cosworth blue” anodized
finish. Mounting hardware included.
38
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 will not meet the legal requirements for operation on public roads
and highways. It is the purchaser’s responsibility to check and comply with all local, state
and federal laws prior to operating vehicle. Installation and use of performance products
may also affect/ void vehicle warranty and insurance policy.
Warranty: In general, Cosworth Performance Parts carry no warranty. Cosworth Ltd and
Cosworth LLC shall not be liable for direct, indirect, incidental or consequential damage
or injury to persons or property that might be claimed as a result from the installation,
improper installation and failure of part including claims for delay, loss of profits or labour.
There are no warranties expressed or implied.
SOME PRODUCTS MAY NOT BE LEGAL FOR SALE OR USE ON POLLUTION
CONTROLLED MOTOR VEHICLES OPERATING IN THE STATE OF CALIFORNIA
39
© Copyright 2008, Cosworth Ltd / Cosworth LLC - v2
UK Office
US Office
Cosworth Ltd
The Octagon
St James Mill Road
Northampton
NN5 5RA
United Kingdom
Tel:
Fax:
Email:
+44 (0)1604 598300
+44 (0)1604 598301
[email protected]
www.cosworth.com
Cosworth LLC
3031 Fujita Street
Torrance
CA 90505
USA
Tel:
Fax:
Email:
+1 310 534 1390
+1 310 534 2631
[email protected]
www.cosworthusa.com

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