PERFORMANCE

PA R T S

A History Of Excellence
Cosworth has a legendary reputation for high performance racing engines and vehicle
electronics systems in Formula One, the IndyCar Series, NASCAR, WRC and many more.
In 40 years of F1 competition (through the 2006 season), Cosworth engines delivered 176
F1 wins, 13 Constructors Championships and 10 Drivers Championships. Its results
in American open-wheel racing, United States Auto Club (USAC), Championship Auto
Racing Teams (CART) and the Indy Racing League (IRL), are equally impressive. From
1976 through 2002, Cosworth, sometimes in association with Ford, powered drivers to 305
race wins including 12 Indy 500 victories and 14 Series Championships. As the exclusive
engine supplier to the Champ Car World Series (CCWS) from 2003 through 2007, it was
the winning engine in 73 more races and claimed five more series championships.
Cosworth has supplied the power to a significant cohort of respected F1 teams (Lotus,
Tyrrell, Williams, McLaren), and drivers (Jim Clark, Graham Hill, Jackie Steward, Mario
Andretti and Michael Schumacher), as well as providing engines for champions and Indy
500 winners in the United States (Andretti, Sebastien Bourdais, Nigel Mansell, Rick Mears,
Bobby Rahal, Danny Sullivan, Paul Tracy, Al and Bobby Unser, and Jacques Villeneuve).
Now Cosworths unique combination of advanced powertrain experience and state of the
art electronics technologies has been employed to create a race-proven range of high
performance components for some of the most popular performance production vehicles.
The Cosworth range of high performance aftermarket components includes everything the
serious enthusiast needs, designed to Cosworths superlative standards and manufactured
to precise tolerances using high quality materials.

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

Big Valve Cylinder Heads

For over 40 years, Cosworth has been
the leader in innovative multi-valve
cylinder head design for both racing
and high performance production
cars. The Cosworth CNC Ported Big
Valve Cylinder head range is the latest
advancement. Modified from new OE
cylinder head castings, substantial gas flow
improvements and upgraded valve train
components offer superior performance for
your high performance engine.
Each original cylinder head design is
carefully evaluated and tested to establish
the improvements required to meet
the target performance level. Hours of
testing and flow bench validation are
used to determine the best advanced
port design yielding maximum usable
power and response. However, there
is more to cylinder head design than
just maximum flow. It is critical that port
velocity is maintained to ensure drivability
and valve train components are matched
to guarantee reliable performance. Once
all of these factors have been tested
and validated, the final port contour is
digitized. Using the digitized program, we
then reshape both intake and exhaust
ports using a 5 axis CNC mill producing
an accurate and consistent port shape
every time. In addition to re-shaping and
enlarging the intake and exhaust ports,
most Big Valve Cylinder heads feature
a re-shaped combustion chamber to

CNC Ported Big Valve Cylinder Heads

Part No.

Description
Subaru

KK3670

Subaru WRX STI EJ25 (2.5L) Pr. 2004-2006

20001699

Subaru WRX STI EJ25 (2.5L) Pr. 2007 (with air injection ports)

20004544

Subaru WRX STI EJ25 (2.5L) Pr. 2008-2009 (with dual AVCS)
Nissan

KK3918

Nissan VQ35 (3.5L) Pr. 2002-2006 (includes rev up version)

KK3672

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

KK3852

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

Mitsubishi

20005685

Mitsubishi Evo X 4B11T (2.0L) 2008+

Others

20000691

Ford Duratec, 2.0L/2.3L

20000704

Mazda MZR, 2.0L/2.3L

CNC Ported Big Valve Cylinder Heads with Camshafts

Part No.

Description
Subaru

SB8010

Subaru WRX STI EJ25 (2.5L) Pr 2004-2006 w KK3766 Camshafts (USA & MY06 Japan/Euro) Electronic Throttle

SB8012

Subaru WRX STI EJ25 (2.5L) Pr 2004-2006 w KK3920 Camshafts (Japan/Euro) Cable Throttle

20002024

Subaru WRX STI EJ25 (2.5L) Pr 2007 w KK3766 Camshafts (USA/Japan/Euro)

20002026

Subaru WRX STI EJ25 (2.5L) Pr 2007 w KK3920 Camshafts (Special Applications Only)

20010140

Subaru WRX STI EJ25 (2.5L) Pr 2008 w Dual AVCS Camshafts

un-shroud the valves increasing air flow

and performance. After machining, each
cylinder head receives a multi-angle high
performance valve job on our precision
Newen CNC valve seat cutter. Then
each cylinder head is ultrasonically

cleaned, serialized and finally hand

assembled with select high performance
valve train components, ready to install on
your engine.

Nissan VQ35DE

Subaru EJ25

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

High Performance Short Block Assemblies

Cosworth high performance engine
assemblies are the perfect basis for
your high performance application. Each
version has gone through countless
hours of engineering and evaluation to
determine the best combination of parts
and build specification, ensuring maximum
reliable performance. Each Cosworth
high performance engine assembly starts
with all new select components as the
foundation of the performance build. Every
block is thoroughly inspected before the
cylinders are honed to perfection. We then
balance the rotating assembly that includes
either a new factory forged crankshaft or
Cosworth billet crank along with Cosworth
forged connecting rods, Cosworth tri-metal
bearings and Cosworth forged pistons.
The motorsport grade parts are then
professionally assembled by expert engine
builders in the Cosworth engine assembly
facility. Each high performance engine
assembly includes a complete specification
sheet listing all critical dimensions along
with a serialized plaque. For maximum
performance, combine with a Cosworth
CNC ported Big Valve Cylinder Head and
camshaft set.

High Performance Short Blocks

Part No.

Description
Subaru

SB8005

Subaru STI EJ25 Short Block (2.5L)-Forged Pistons, Rods 8:2:1 cr

SB8007

Subaru STI EJ25 Short Block(2.5L)-Forged Pistons, Rods W 79mm Billet Crank 8:2:1 cr

20003486

Subaru STI EJ25 Short Block(2.5L)-Forged Pistons, Rods W 81mm Billet Crank 8:2:1 cr

20007702

Subaru STI EJ25 Short Block OE Crank 9.2:1 cr (High compression ratio)

20007697

Subaru STI EJ25 Short Block 81mm Crank 9.2:1 cr (High compression ratio)

20007703

Subaru STI EJ25 Short Block 79mm BLT Crank 9.2:1 cr (High compression ratio)

20000067

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

CI8019

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

CI8015

Mitsubishi Evo VIII/IX 4G63 Short Block (2.0L)-Forged Pistons, Rods

CI8018

Mitsubishi Evo VII/IX 4G63 Short Block (2.2L)-Forged Pistons, Rods, Billet Crank

Nissan

Mitsubishi

20014144

Mitsubishi Evo X 4B11T Short Block (2.2L)-Forged Pistons, Rods, Billet Crank

Subaru EJ25 High Performance Short Block 2.5/2.6L

The Cosworth EJ25 is an excellent starting
point for high performance and track day
applications.

New Subaru EJ25 STI EJ257 Block

New Subaru EJ25 STI Forged
Crankshaft or Cosworth Billet Crank (79
or 81mm)
Cosworth 79mm or 81mm Forged
H-beam connecting rods
Cosworth Forged Pistons (99.5mm) and
rings
Cosworth Tri-metal bearings
Balanced to within 0.5 gram
Complete blue-printed assembly
Ring gap set
Bearing clearance checked
Deck height checked
Connecting rod side clearance checked
Crankshaft end float checked

Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L

The Cosworth 2.0L 4G63 is an excellent
starting point for high performance and
track day applications.

New Mitsubishi 4G63 Evolution Block

New Mitsubishi forged crankshaft
(88mm)
Cosworth Forged H-beam connecting
rods
Cosworth Forged Pistons (85mm) and
rings
Cosworth Tri-metal bearings
Cosworth Heavy Duty main studs
Piston squirt jets
Balanced to within 0.5 gram
Complete blue-printed assembly
Ring gap set
Bearing clearance checked
Deck height checked
Connecting Rod side clearance checked
Crankshaft end float checked

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

The Cosworth 4G63 2.2L stroker engine
combines the perfect bore to stroke ratio,
yielding potentially big gains in torque
while still allowing the engine to rotate and
produce power at higher RPMs.

New Mitsubishi 4G63 Evolution Block

New Cosworth Billet Crank (94mm)
Cosworth Forged H-beam connecting
rods
Cosworth Forged Pistons (86mm) and
rings
Cosworth Tri-metal bearings
Cosworth Heavy Duty main studs
Piston squirt jets
Balanced to within 0.5 gram
Complete blue-printed assembly
Ring gap set
Bearing clearance checked
Deck height checked
Connecting Rod side clearance checked
Crankshaft end float checked

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

The Cosworth VQ35DE high performance
short block is the perfect foundation
for your high performance application.
Available in either high compression 11:1
or low compression 8.8:1 for turbo or
supercharged applications.

New Nissan forged crankshaft (81.4mm)

Cosworth Forged H-beam connecting
rods
Cosworth Forged Pistons (95.5mm) and
rings
Cosworth Tri-metal bearings
Cosworth Heavy Duty main studs
Piston squirt jets

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

High Performance Long Block Assemblies

The Cosworth Subaru EJ25 CS600 series
is designed for extreme track day use and
the demanding performance enthusiast.
Each assembly is precision built by one
of Cosworths skilled craftsmen using
the finest components from our parts
catalogue to ensure maximum reliable
power and performance. Starting with
a new Subaru EJ257 semi closed deck
block, we meticulously diamond hone
each bore to guarantee perfect piston
to cylinder wall clearance. The block is
then assembled with our Forged Pistons,
motorsport grade Forged H-Beam
connecting rods along with our high
performance rod and main bearings and a
new STI forged crankshaft. For maximum
performance, an optional steel billet crank
is available (CS600X). Once the cylinder
block assembly is completed, we install a
pair of our CNC machine port-bored Big
Valve Cylinder heads with our proven S2
camshafts complete with valve lash set to
our specifications. The cylinder heads are
secured with our high performance 11mm
steel studs and sealed with a Cosworth
high performance stopper layer steel
head gasket. Finally, we install one of our
blue-printed, high pressure oil pumps for

High Performance Long Block Assemblies

Part No.

Description
Subaru - North American spec EJ25 CS600 & CS600X

20000162

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

20000161

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

20002503

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

20002504

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

20007705

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

20007706

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

20007709

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

20007710

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

20003488

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

20003489

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

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

20007711

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

20007712

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

20000160

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

SB8008

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

Subaru - European/Asia spec EJ25 CS600 & CS600X

20002503

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

20002504

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

20007708

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

20007707

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

maximum lubrication. This proven engine

combination has been used by top teams

to win race and rally events in both North

America, Asia and Europe.

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

Features

New Subaru EJ25 STI Engine case

New Subaru EJ25 STI Forged
Crankshaft
Optional Cosworth Billet Crankshaft
(79/81mm stroke available)
Cosworth forged H-beam Connecting
rods
Cosworth Forged Pistons and rings
Cosworth motorsport Tri-metal bearings
Balanced to within 0.5 gram
Complete blue-printed assembly
Enlarged intake and exhaust ports
Large diameter stainless steel intake
valves
Large diameter inconel exhaust valves
Hi-rev, dual valve springs
Titanium retainers
Hardened steel spring platforms
Multi angle valve job
CNC machined port finish
Knife edge port divider
Cosworth S2 High lift camshafts
Valve lash set
Cosworth high pressure oil pump
Cam covers
Cosworth serial number

High Performance Long Block Assemblies

Part No.

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

20003490

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

20003489

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

20007713

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

20007712

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

20007211

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

20007212

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

20007213

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

20007714

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

20007715

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

20007716

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

20010271

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

20010272

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

20010273

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

20010274

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

20010275

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

20010276

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

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

Subaru 2008~2011 CS600 & CS600X

Subaru Engine Testing

Billet Crankshafts
Increased engine performance often
means increased engine speed and load.
Original factory crankshafts may not
be able to withstand the added stress,
resulting in catastrophic engine failure.
Additionally, many OE crankshafts rod
journals are lubricated from only one
main oil feed. Cosworth billet crankshafts
feature full-flow oiling whereby each
rod journal is lubricated from two main
sources. This provides superior lubrication
during sustained high rpm use preventing
rod bearing failure. Cosworth Subaru
crankshafts are manufactured entirely from
high grade steel in a light-weight, high
strength design with a unique Isotropic
Superfinish.

Billet Crankshafts
Part No.

Description
Mitsubishi

20020632

Mitsubishi EVO 4G63 (2.2L conversion) 94mm stroke - Fully counter-weighted Billet Steel, F1 Rod Bearing type
(must use with Cosworth connecting rod 20020201)

20006577

Mitsubishi EVO 4B11T (2.2L conversion) 94mm stroke - Fully counter-weighted Billet Steel

20002315

Subaru WRX STI EJ25 (2.5L) 79mm stroke - Light weight version Billet Steel

20002316

Subaru WRX STI EJ25 (2.5L) 81mm stroke - Light weight version Billet Steel

Features Include:

Superior lubrication
Profiled counterweights
High strength
Light weight

Cosworth Tech: Isotropic

Superfinish
The ISF Process is a chemically
accelerated vibratory mass finishing
process. Any time two metal parts come
into contact with each other, the resulting
friction causes heat build up. These high
temperatures cause wear and over time
reduce efficiency and eventually create

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

the need for replacement. By creating a

smooth and shiny finish, the ISF Process
improves the life and efficiency of moving
metal parts. Increased life translates into
lower operating costs as well as better
performance. In extreme environments,
such as automobile or motorcycle racing,
every component must work in harmony
at 100% capacity. Races are won and

lost by fractions of a second, so it all

comes down to getting the most power
output possible. With the ISF Process,
the energy normally lost to friction is now
available in the form of increased power
output. Once friction is reduced, the
engine will run cooler allowing for longer
durability of parts and fewer failures.

Stroker Engine Kits

Cosworth stroker kits are the perfect way
to add displacement, torque and power
to your engine. Each kit includes select
matched components from our parts list
ensuring reliable performance.

Stroker Kits
Part No.

Description
Mitsubishi

KK3831

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

20007783

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

20002500

Subaru EJ25 (2.6L) w 81mm Billet Crankshaft

20002501

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

20004359

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

20002502

Subaru EJ20 (2.2L) w 79mm Billet Crankshaft

Subaru

Subaru EJ25 2.6L

Cosworth Forged Pistons (99.5mm)

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

Mitsubishi 4G63 (Evolution VII-IX) 2.2L

Cosworth Forged Pistons (86mm)

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

Mitsubishi 4B11T (Evolution X) 2.2L

Cosworth Forged Pistons (86mm)

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

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:

Rods include genuine Cosworth H11

tool steel rod bolts (260,000psi).
Proprietary forging made in the USA.
Detailed machined work to maintain
optimum weight and strength.
Solid beam design for high power
applications
Radial Truss small end for superior
strength and reduced reciprocating
mass
Manufactured from 4340 (EN24) steel

12

Forged Connecting Rods

Part No.

Description

Ctr. to Ctr.
(mm)

P.E. Bore
(mm)

B.E. Bore
(mm)

Total
Nominal
Weight (g)

Subaru

20002587

Subaru WRX STI EJ25 (2.5L) set of four

130.48

23.03

55.01

530

20002587

Subaru WRX EJ20 (2.0L) set of four

130.48

23.03

55.01

530

Mitsubishi

20002632

Mitsubishi Evo 4G63 (2.0L) set of four

150.01

22.03

48.00

568

20020201

Mitsubishi Evo 4G63 (2.2L) set of four for

use with Cosworth crankshaft 20020632

150.01

22.03

52.89

565

20002596

Mitsubishi 4B11T (2.0L) set of four

143.74

23.03

55.01

565

20007184

Mitsubishi 4B11T (2.2L) 94mm Stroker Rod

set of four

142.72

21.03

55.01

556

Nissan

20002585

Nissan VQ35 (3.5L) set of six

144.17

22.03

55.01

547

20007115

Nissan VQ35 (3.8L) Stroker Rod set of six

141.71

22.03

55.01

538

20002588

Nissan RB26 (2.6L) set of six

121.51

21.02

51.02

507

20002589

Nissan SR20 (2.0L) set of four

136.30

22.03

51.02

564

20011563

Nissan VR38 (3.8L) set of six

164.99

23.03

59.00

629

22.03

51.02

430

Honda

20002590

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

139.03

Ultra High Performance Head Studs

Essential for high performance engine
builds, heavy duty head studs reduce
cylinder head movement in high boost
or high compression engines optimising
cylinder head to block sealing. Cosworth
Ultra High Performance Head Studs
are manufactured from H11 tool steel
with 260,000psi tensile strength and
come complete with nuts and washers.
Manufactured with hex broach end for
ease of installation.

Ultra High Performance Head Stud Kits

Part No.

Description

20002440

Subaru WRX STI EJ25/EJ20 (2.5L) 11mm

20002442

Mitsubishi Evo 4G63 (2.0L) 11mm

20006025

Mitsubishi Evo X 4B11T Head Stud Kit

20002444

Nissan SR20DET (2.0L) 11mm

Additionally, genuine Cosworth head studs

utilize a base seating feature to evenly
distribute maximum load on the stud and
not the threads. This feature is typically
found only in high level race engines.
Features:

Essential for high power applications

Superior strength compared to other
brands
High clamping force helps to seal block
to cylinder head joint
Hex broach ends ease installation
Roll die formed threads
260,000psi+ tensile strength
Special heat treat process includes
heating in vacuum sealed furnace and
quenched in a nitrogen chamber for
precision control

13

Ultra High Performance Engine Bearings

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

upgrades.

Performance

High Performance Engine Bearings

Part No.

Description

Specification

Subaru EJ25 / EJ20

20002720

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

Size 0

20002721

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

Size 0

PR7940

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

Size 1

friction. Cosworth race bearing sets feature

PR7889

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

Size 1

unique combinations of design, metallurgy

SB0006

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

Size 2

and engineering to deliver performance

SB0007

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

Size 2

engineered, multi-layer bearings generate

less heat than normal bearings by reducing

in extreme conditions. Cosworth race

bearings sets are available in three sizes
to accommodate most applications.
Engineered with the following features:

High strength overlay plate with

reduced thickness for better oil control
and less friction

Hardened steel backing on all

connecting rod bearings

Increased crush for better retention

3/4 grooving on main bearings

providing optimum oil supply

Mitsubishi Evo 4G63 Evo 1992-2006

20002723

Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal

Size 0

20002722

Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal

Size 0

PR7894

Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal

Size 1

PR7893

Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal

Size 1

PR7427

Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal

Size 2

PR7428

Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal

Size 2

PR7429

Mitsubishi Evo 4G63 (2.0L) Thrust Bearing set

Mitsubishi 4B11T Evo X

20007172

Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal

Size 0

20007175

Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal

Size 0

20007173

Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal

Size 1

20007176

Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal

Size 1

20007174

Mitsubishi Evo X 4B11T Main Bearing Set - Tri Metal

Size 2
Size 2

Tight consistent wall tolerances

20007177

Mitsubishi Evo X 4B11T Rod Bearing Set - Tri Metal

Oversize chamfers where applicable

20007178

Mitsubishi Evo X 4B11T Thrust Bearing Set

Flash plating eliminated for improved

heat transfer

20002725

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

Size 0

20002724

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

Size 0

Tested to over 1000 horsepower!

14

Nissan VG35DE

PR7911

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

Size 1

PR7910

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

Size 1

PR7853

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

Size 2

PR7854

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

Size 2

PR7859

Nissan VQ35 (3.5L) Thrust Bearing Set

Cosworth High Performance Engine

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

All three sizes are within the nominal

standard range. We do not offer
undersized bearings for ground
crankshafts.
Size 1 is in the middle of the range
Size 0 provides .025mm or .001 less oil
clearance than our size 1 bearing
Size 2 provides .025mm or .001 more
oil clearance than our size 1 bearing
Bearing half shells can be mixed and
match to provide the incremental
changes in oil clearance

High Performance Engine Bearings

Part No.

Description

Specification

Nissan SR20DET (except RNN14 Pulsar Gti-R)

20002727

Nissan SR20 (2.0L) Main Bearing Set - Tri Metal

Size 0

20002726

Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal

Size 0

PR7896

Nissan SR20 (2.0L) Main Bearing Set - Tri Metal

Size 1

PR7895

Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal

Size 1

PR7851

Nissan SR20 (2.0L) Main Bearing Set - Tri Metal

Size 2

PR7852

Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal

Size 2

PR7937

Nissan SR20 (2.0L) Thrust Bearing Set

Nissan RB25/26

20002729

Nissan RB25/26 Main Bearing Set - Tri Metal

Size 0

20002728

Nissan RB25/26 Rod Bearing Set - Tri Metal

Size 0

PR7892

Nissan RB25/26 Main Bearing Set - Tri Metal

Size 1

PR7891

Nissan RB25/26 Rod Bearing Set - Tri Metal

Size 1

PR7655

Nissan RB25/26 Main Bearing Set - Tri Metal

Size 2

PR7656

Nissan RB25/26 Rod Bearing Set - Tri Metal

Size 2

Honda K20/K23/K24 (except A3)

20002731

Honda K20 (2.0L) Main Bearing Set - Tri Metal

Size 0

20002730

Honda K20 (2.0L) Rod Bearing Set - Tri Metal

Size 0

PR7914

Honda K20 (2.0L) Main Bearing Set - Tri Metal

Size 1

PR7912

Honda K20 (2.0L) Rod Bearing Set - Tri Metal

Size 1

PR7915

Honda K20 (2.0L) Main Bearing Set - Tri Metal

Size 2

PR7913

Honda K20 (2.0L) Rod Bearing Set - Tri Metal

Size 2

PR7916

Honda K20 (2.0L) Thrust Bearing Set

15

Forged Pistons
With 50 years of world class engine design
and manufacturing experience, Cosworths
intimate knowledge of the interaction
between the piston and other engine
components gives the us the distinct
advantage in piston design resulting in the
finest piston available.
The piston is one of the most important
components within the engine. It can be
subjected to directional change up to 285
times every second and must withstand
acceleration forces of 8,500 Gs. Cosworth
high performance forged pistons are
designed and engineered to withstand
this type of punishment and still perform.
All Cosworth pistons are manufactured
using the same methods as our Formula
One pistons and include features such as
anti-scuff skirt coating, ultra-strong pins,
polished top and patented anti-detonation
bands. Additionally, each application uses
a unique forging to minimize weight and
ensure the strongest possible piston.

Features & Benefits:

Skirt profile & oval technology - reduces engine noise, increases life & performance
F1 quality forgings - proprietary CosAl 010 for high stress applications
Oil and combustion gas control features - reduced blow-by and oil consumption
Offset pin bores - for reduced engine noise

Polished crown

Anti-detonation bands

Optimised forging

Xylan skirt coating

Subaru EJ25, 9.2:1

16

Mitsubishi 4G63

Subaru EJ25

Features Include:

Unique forgings for each application

Xylan anti scuff skirt coating
Polished tops (reduces carbon build up
and relieves stress)
Manufactured from proprietary alloy
(CosAl 010)
Ultra strong pin
Patented anti-detonation bands

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

Description
Subaru

20003674

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

20003675

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

20003676

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

20003677

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

20003678

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

20003682

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

20003683

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

20003684

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

20004531

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

20004532

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

20004533

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

20004534

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

20004535

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

20004536

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

20003685

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

20003687

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

20003223

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

20003225

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

20003679

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

20003681

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

20003688

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

20003690

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

20003693

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

20005129

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

20005130

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

20005131

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

20005856

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

20005859

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

20005860

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

20009276

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

20009277

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

20009278

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

20005865

Honda K20A 86mm 12:1cr

20005866

Honda K20A 86.25mm 12:1cr

20005867

Honda K20A 86.5mm 12:1cr

Nissan

Mitsubishi

Honda

Nissan VQ35 High Compression

17

Single Forged Pistons

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

Description
Subaru

20000897

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

20000898

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

20000899

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

20002111

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

20002112

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

20002431

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

20002432

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

20002433

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

20002489

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

20002491

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

20004522

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

20004523

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

20004524

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

20004528

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

20004529

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

20004530

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

20002036

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

20002038

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

20002039

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

20002041

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

20002132

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

20002134

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

Nissan

18

Single Forged Pistons (Includes pins and circlips)

Part No.

Description
Mitsubishi

20000832

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

20000834

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

20000971

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

20004488

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

20004675

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

20004676

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

20005783

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

20005784

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

20005785

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

20009273

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

20009274

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

20009275

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

20005799

Honda K20A 86mm 12:1cr

20005800

Honda K20A 86.25mm 12:1cr

20005801

Honda K20A 86.5mm 12:1cr

Honda

Cosworth Tech: Green Pistons

Xylan is a fluoropolymer coating designed for use on various engine components
and fasteners. Cosworth pistons use xylan coating to provide lubrication and control
friction, wear resistance, heat resistance, nonstick and release properties and, at the
same time, can also protect from corrosion. This is the same coating we use on many
of our ultra-high performance race engines.

Spare Piston Pins and Circlips

Cosworth Pistons feature heavy duty, ultra
strong piston pins designed for the higher
stress and elevated load levels found in
high performance engines. Spare parts are
available for routine engine rebuilds.
For ease of circlip installation on Subaru
engines, we offer an exclusive installation
tool engineered to simplify the task. This
high quality tool is machined from steel to
ensure years of trouble free use.

Spare Piston Pins and Circlips

Part No.

Description

PA2674

23mm Pin, Subaru EJ20 / EJ25 Piston

PA1846

22mm Pin, Mitsubishi 4G63 Piston

PA1251

22mm Pin, Nissan VQ Piston

PP5433

Circlip, 23mm Subaru EJ20 / EJ25 Piston. 2 req per piston

PP2371

Circlip, 22mm Nissan / Mitsubishi Piston. 2 req per piston

SB8004

Circlip install tool, Subaru

19

Performance Ring Sets

Developed using the latest technologies,
and highest quality materials, Cosworth
Performance Ring Sets are designed
to meet the demands of modern high
performance engines for higher power
output, improved sealing, lower friction,
and longer life.

Performance Ring Sets for Cosworth Pistons

Part No.

Description
Subaru

20001515

Subaru WRX STI EJ25 (2.5L) 99.5mm

20001516

Subaru WRX STI EJ25 (2.5L) 99.75mm

20001517

Subaru WRX STI EJ25 (2.5L) 100.mm

20005160

Subaru WRX EJ20 (2.0L) 92.mm

20005161

Subaru WRX EJ20 (2.0L) 92.5mm

20003605

Subaru WRX EJ20 (2.0L) 92.mm

20003607

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

20001512

Nissan VQ35 (3.5L) 95.5mm

20001514

Nissan VQ35 (3.5L) 96.mm

(Use with Stroker pistons 20002489/ 20003685)

Nissan

Mitsubishi

PR7317

Mitsubishi Evo 4G63 (2.0L) 85mm

20002246

Mitsubishi Evo 4G63/4B11 86mm

20005705

Mitsubishi Evo 4B11 86.5mm

20005706

Mitsubishi Evo 4B11 87mm

20008832

Tool -85.00Mm Ring Compressor

20007717

Tool -86.00Mm Ring Compressor

20007751

Tool -86.25Mm Ring Compressor

20007761

Tool -86.50Mm Ring Compressor

20007782

Tool -87.00Mm Ring Compressor

20007784

Tool -87.50Mm Ring Compressor

20007785

Tool -92.00Mm Ring Compressor

20007786

Tool -92.50Mm Ring Compressor

20007787

Tool -95.50Mm Ring Compressor

20007788

Tool -96.00Mm Ring Compressor

20007793

Tool -99.50Mm Ring Compressor

20007794

Tool -99.75Mm Ring Compressor

20007795

Tool -100.0Mm Ring Compressor

Tool

Piston Ring Compressor

Cosworth Cylindrical Ring Compressors
are precision machined to exact tolerance
to ensure easy piston installation on most
engines. They feature a smooth, tapered
bore along with a knurled top ring to
securely hold it in place while installing
the piston. Each tool is machined form
high grade aluminum and features a hard
anodized finish.

Cosworth Tech: Ring Sets

Cosworth Performance Ring Sets are comprised of a chrome top ring, an iron second
ring, and three-piece oil ring. Some Cosworth Performance Ring Sets offer upper
rings that are gas nitride treated for quicker break-in, lower wear, and improved
sealing. Manufacturing tolerances exceed OEM standards. Axial tolerance is +/0.0002 and radial tolerance is +/- 0.0005.

20

Kevlar High Performance Timing Belts

Cosworth Kevlar High Performance Timing
belts are 300% stronger than original
equipment timing belts and are the perfect
compliment when installing Cosworth
camshafts or cylinder heads.

High saturation HNBR elastomeric

composites ensure durability and heat
resistance
Durable nylon fiber provides extra wear
resistance and increased tooth strength
Kevlar backing improves strength

Cosworth Kevlar High Performance Timing Belts

Part No.

Description

20004950

Timing Belt Mitsubishi 4G63 Heavy Duty, All

20004952

Balance Belt - Mitsubishi 4G63 Heavy Duty, All

20004953

Timing Belt Subaru EJ20/25 Heavy Duty, All

20019487

Timing Belt - Nissan RB25/26

21

High Performance Camshafts

Cosworth has been engineering camshafts
for nearly 50 years. That coupled with
years of innovative multi valve cylinder head
design ensures our camshaft designs are
the most efficient in providing maximum
usable power across the widest power
band.
Each cam is ground from a new blank
and finished using the same procedures
we use in our extreme level race engines.
Cosworth camshafts are the perfect
compliment to our CNC Ported Big Valve
Cylinder Heads. Our cams are profiled to
increase boost response thereby increasing
engine torque and power and are fully
compatible with our CNC Ported Big Valve
Cylinder Heads.

Performance Camshafts
Part No.

Description

Specification
Subaru

KK3766

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

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

deg. 10.mm lift

KK3765

Subaru WRX EJ20 (2.0L) Set of four 9/99 - 8/05 non AVCS JDM
EJ205 ~ 9/01 - 8/05 non AVCS USDM WRX EJ205 engines

"272" deg. 10mm lift

KK3920

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

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

deg. 10.mm lift

20007395

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

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

deg. 10.mm lift

20005187

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

"270" deg. 10.4mm lift

Mitsubishi

KK3805

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

KK3806

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

"272" deg. 11 mm lift

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

Intake"280" deg. 11.6mm / Exhaust

"272" deg. 11mm lift

20002513

"264" deg. 10.2 mm lift

KK3921

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

Grind

MIVEC Intake/Exhaust "272" deg. 11

mm lift

20002517

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

Grind

MIVEC Intake "280" deg. 11.6mm lift /

Exhaust "272" deg. 11 mm lift

20004124

Mitsubishi Evo X 4B11 (2.0L) Pr (1 intake and 1 exhaust cam) MX1

Grind

MIVEC Intake "266" deg. 10.8mm /

Exhaust "266" deg. 10.4mm lift

20002698

Mitsubishi Evo 4G63 (2.0L) "280" Intake cam

280 deg. / 11.6 mm

20016008

Mitsubishi Evo 4G63 (2.0L) "290" Intake cam

290 deg. / 11.6 mm

20004722

Mitsubishi Evo IX 4G63 MIVEC (2.0L) "280" Intake cam

280 deg. / 11.6 mm

20016009

Mitsubishi Evo IX 4G63 MIVEC (2.0L) "290" Intake cam

290 deg. / 11.6 mm

20016006

Mitsubishi Evo 4-9 4G63 (2.0L) "280" Exhaust cam

280 deg. / 11.6 mm

20016007

Mitsubishi Evo 4-9 4G63 (2.0L) "290" Exhaust cam

290 deg. / 11.6 mm

Mitsubishi SWB Race Camshafts

Nissan

20002507

Nissan VQ35 "287hp" Set (2 intake and 2 Exhaust cams) "ZK1" Grind

Intake "268" deg. 10.4mm lift /

Exhaust "268" deg. 9.5mm lift

20002508

Nissan VQ35 287hp Set (2 intake and 2 Exhaust cams) ZK2 Grind

Intake 270 deg. 10.65mm lift /

Exhaust 270 deg. 10.65mm lift

20002510

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

Intake 268 deg. 10.4mm lift /

Exhaust 268 deg. 9.5mm lift

20002511

Nissan VQ35 Rev up Set (2 intake and 2 Exhaust cams) ZK2 Grind

Intake 270 deg. 10.65mm lift /

Exhaust 270 deg. 10.65mm lift

Mazda MZR

20002515

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

Intake 264 deg. 9.8mm lift / Exhaust

244 deg. 8.5mm lift

Cosworth Tech - Subaru Cams

Our Subaru AVCS cams are available for both North American and Japanese/European
applications. While cam profiles are the same, cam angle triggers are significantly
different. AVCS camshafts for North American applications use a series of three slots
to activate the cam angle sensor. Japanese/European applications rely on four raised
triggers to activate the sensor. If in doubt, check your original cams before ordering.
North American

22

Japanese/European

Features Include:

Ground from new blanks

Engineered and tested profiles
Broad power band
Compatible with Cosworth CNC ported
Big Valve Cylinder Heads

Subaru AVCS

Mitsubishi EVO 4G63 Mivec

Mitsubishi 4B11T

Subaru WRX STi EJ257B

Nissan VQ35

23

High Performance Valve Train

High Performance Valves

High Performance Valve Train

Large diameter valves are essential

for improved air flow. Cosworth high
performance intake valves are produced
from high quality stainless steel for
maximum durability. Exhaust valves
are machined from Inconel for high
temperature (2400 F) reliability. Each valve
features a swirl polished back for improved
air flow and dished face for additional
weight reduction. Some Cosworth High
Performance Valves are only compatible
with Cosworth Ultra Race Valve Spring
Kits. Please confirm application before
ordering.

Part No.

Description
Subaru

SB0034

Valve, Inlet +1.0mm Subaru EJ25-Stainless Steel (37.0mm)

SB0033

Valve, EX +1.0mm Subaru EJ25-Inconel (33.0mm)

PR7710

Subaru EJ25 (2.5L) Graded Cam bucket 4.50

PR7711

Subaru EJ25 (2.5L) Graded Cam bucket 4.52

PR7712

Subaru EJ25 (2.5L) Graded Cam bucket 4.54

PR7713

Subaru EJ25 (2.5L) Graded Cam bucket 4.56

PR7714

Subaru EJ25 (2.5L) Graded Cam bucket 4.58

PR7715

Subaru EJ25 (2.5L) Graded Cam bucket 4.60

PR7716

Subaru EJ25 (2.5L) Graded Cam bucket 4.62

PR7717

Subaru EJ25 (2.5L) Graded Cam bucket 4.64

PR7718

Subaru EJ25 (2.5L) Graded Cam bucket 4.66

PR7719

Subaru EJ25 (2.5L) Graded Cam bucket 4.68

PR7720

Subaru EJ25 (2.5L) Graded Cam bucket 4.70

PR7721

Subaru EJ25 (2.5L) Graded Cam bucket 4.72

PR7722

Subaru EJ25 (2.5L) Graded Cam bucket 4.74

PR7723

Subaru EJ25 (2.5L) Graded Cam bucket 4.76

PR7724

Subaru EJ25 (2.5L) Graded Cam bucket 4.78

PR7725

Subaru EJ25 (2.5L) Graded Cam bucket 4.80

PR7726

Subaru EJ25 (2.5L) Graded Cam bucket 4.82

PR7727

Subaru EJ25 (2.5L) Graded Cam bucket 4.84

PR7728

Subaru EJ25 (2.5L) Graded Cam bucket 4.86

PR7729

Subaru EJ25 (2.5L) Graded Cam bucket 4.88

PR7730

Subaru EJ25 (2.5L) Graded Cam bucket 4.90

PR7731

Subaru EJ25 (2.5L) Graded Cam bucket 4.91

PR7602

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

PR7603

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

CI0113

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

CI0112

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

Nissan

Mitsubishi

20007107

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

20007082

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

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

L1 mm

F1 N

F1 lbs

L2 mm

F2 N

F2 lbs

Max Lift

Coil Bind

20000164

Part No.

Mitsubishi EVO 7-9

47.00

38.1

381

85

26.1

900

202

12.0

24.3

20000169

Nissan RB26

49.30

41.9

359

81

29.9

941

212

12.0

28.4

20000168

Nissan SR20

46.00

39.0

365

82

27.5

964

217

11.5

25.4

20000163

Nissan VQ35DE

46.00

38.0

289

65

24.5

775

175

13.5

22.9

20000166

Subaru EJ 2.0/2.5

42.00

36.0

275

62

25.0

780

175

11.0

23.2

KK3813

Mitsubishi EVO 7-9

50.00

38.1

512

115

26.9

1268

285

12.0

25.7

Nissan VQ35DE

47.00

38.0

378

85

23.9

1183

266

14.1

22.6

Subaru EJ 2.0/2.5

46.10

36.0

356

80

22.1

1019

229

13.9

20.8

20002550
KK3839

Application

All dimensions are in millimetres unless otherwise specified

24

High RPM Valve Springs

Cosworth High RPM Valve Springs are the
result of countless hours of engineering,
testing and validation ensuring the best
possible spring for high performance
applications. Cosworth High RPM Valve
Springs are wound from the worlds finest
Japanese Kobe steel and feature dual
chamfered ends to reduce wear on seats
and retainers. Each spring has been
engineered with increased seat pressure
along with higher lift capability for optimum
performance potential and improved valve
control. Single spring design allows easy
installation with no machining required and
is perfect for typical high performance use.

High RPM Valve Spring Sets

Part No.

Application
Mitsubishi

20000164

High RPM Single Valve Spring set (16) Mitsubishi Evo VII-IX 4G63

20004844

High RPM Single Valve Spring set (16) Mitsubishi Evo X 4B11T

20000166

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

20000163

High RPM Single Valve Spring set (24) Nissan VQ35 (3.5L)

20000168

High RPM Single Valve Spring set (16) Nissan SR20DET (2.0L)

20000169

High RPM Single Valve Spring set (24) Nissan RB26 (2.6L)

Subaru

Nissan

Manufactured from the finest Japanese

Kobe steel
Single spring design for easy installation
Dual chamfered ends
Increased performance

Ultra Race Valve Spring Kits

Cosworth Ultra Race Valve Spring Kits
are engineered for use in situations that
require valve control in extreme conditions.
Each kit consists of dual valve springs with
matched lightweight titanium retainers,
keepers, and hardened steel spring seats.
Cosworth Ultra Race Valve Springs are
wound from the highest quality chrome
silicone steel with chamfered ends and are
heat treated and stress relieved for long
term reliability. Ultra Race Valve Spring
kits are compatible with Cosworth high
performance valves.

Ultra-High RPM Valve Spring Sets

Part No.

Application

KK3813

Mitsubishi Evo 4G63 (2.0L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

KK3839

Subaru EJ25 STI (2.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

20002550

Nissan VQ35 (3.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

20007182

Mitsubishi Evo 4B11T Ultra-High RPM Dual Valve Spring / Titanium Retainer set

*Seal clearance
Install Height
F1

Nissan VQ35DE

Mitsubishi 4B11

Mitsubishi 4G63

Subaru EJ20/EJ25

25

High Performance Head Gaskets

Cosworth High Performance Head Gaskets
are engineered to seal in power under the
most demanding conditions. Constructed
from stainless steel with a folded stopper
layer, each application features superior
sealing compared to conventional multilayer steel gaskets. Additionally, Cosworth
High Performance Head Gaskets are
manufactured from pre-coated die cut
stainless steel resulting in uniform coating
distribution and consistent shape.
Each gasket is carefully engineered with
the following features:

Individual die cut layers of stainless steel

with superior consistency compared to
laser cut gaskets
Pre-coated stainless steel with a 0.25
micron layer of nitrile rubber ensures
consistent distribution of coating with no
high or low areas
Manufacturing dimensional tolerance of
+/- 0.001
Die cut manufacturing process ensures
smooth edges, unlike laser cut gaskets
Cosworth gaskets feature a folded
stopper layer for additional clamping
force around each cylinder. The width
of sealing area is specific for each
application thereby providing ultimate
sealing properties
Available in a range of thicknesses for
specific applications

Folded
Stopper Layer

Gasket Layer

High Performance Head Gaskets

Part No.

Description
Nissan

20013292

Nissan GTR VR38DETT (3.8L) Bore = 96mm T ~ 0.8mm (Pr)

20004667

Nissan VQ35HR / VQ37VHR Bore = 96mm T ~ 0.6mm (Pr)

20000900

Nissan VQ35DE (3.5L) Bore = 96mm T ~ 0.6mm (Pr)

20000903

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

20000906

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

20000924

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

20000925

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

20000926

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

20003395

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

20003396

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

20000927

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

20000928

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

20000929

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

20000930

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

20000931

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

20001689

Mitsubishi Evo IX 4G63 (2.0L) Bore = 86mm T ~ 1.3mm

20001690

Mitsubishi Evo IX 4G63 (2.0L) Bore = 86mm T ~ 1.5mm

20000909

Mitsubishi Evo IV-VIII 4G63 (2.0L) Bore = 86mm T ~ 1.3mm

20000910

Mitsubishi Evo IV-VIII 4G63 (2.0L) Bore = 86mm T ~ 1.5mm

20004122

Mitsubishi Evo X 4B11T (2.0L) Bore = 87mm T ~ 1.1mm

20004123

Mitsubishi Evo X 4B11T (2.0L) Bore = 87mm T ~ 1.3mm

20000913

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

20000916

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

20002145

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

20010706

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

20010707

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

20010708

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

20000919

Subaru WRX EJ20 (2.0L) Bore = 93mm T ~ 0.78mm each

20000922

Subaru WRX EJ20 (2.0L) Bore = 93mm T ~ 1.1mm each

Mitsubishi

Subaru

Honda

Gasket Layer

26

20010904

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

20010905

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

20010906

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

20010907

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

20003127

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

20003128

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

20003129

Honda K20/24 Bore = 89mm T ~ 1.1mm for use with RAA, RAC, RBB, and RBC cylinder heads.

20010903

Honda K20/24 Bore = 87mm T ~ 0.38mm for use with PRB, PNC, and PPA cylinder heads.

20005454

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

20005455

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

20005456

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

Folded stopper layer provides complete sealing

around entire combustion chamber

Without folded stopper layer, clamping force is

limited resulting in incomplete sealing around
combustion chamber

Honda F20C

Nissan VQ35DE

Stopper sealing layer

Uniform nitrile rubber coating

Mitsubishi 4G63

Mitsubishi 4b11t

Die cut edges

Subaru EJ25

27

Thermal Composite Gaskets

The Cosworth Thermal Guard Composite
Intake Gasket is designed to aid in the
reduction of inlet air temperature by
isolating the intake manifold from the heat
generated by the engines cylinder head.
By reducing the temperature of the inlet
manifold the temperature of the intake air
charge is also reduced. The density of
cooler air is greater than that of warm air.
A denser intake air charge contains more
oxygen which results in the potential for
increased power and torque.
Each Cosworth Thermal Guard Composite
Intake Gasket is precision manufactured
from an engineering grade composite
phenolic material that resists deformation
common with plastic gaskets. As an
added feature Cosworth Thermal Guard
Composite Intake Gaskets are reusable
and include a tube of Hylomar Universal
Blue Racing Formula sealant. The use of
OE inlet manifold gaskets is not required
with the Cosworth Thermal Guard
Composite Intake Gasket.

Thermal Composite Gaskets

Part No.

Description

20013283

Thermal Intake Manifold Gasket - EJ25 2004+ all (Pair)

20013286

Thermal Intake Manifold Gasket - 4G63 EVO 4-9

20013287

Thermal Intake Manifold Gasket - 4B11T EVO X

20013288

Thermal Intake Manifold Gasket - 2ZZ-GE

20013289

Thermal Plenum Gasket - VQ35DE

20013290

Thermal Plenum Gasket - VR38DETT

Isolates inlet manifold from engine and

cylinder head
Reduces inlet air temperature
Reusable with no deformation
Higher temperature resistance than
plastic gaskets (+500 F)
Precision CNC manufactured
Includes Hylomar Universal Blue Racing
Formula sealant
Race proven
Safe with all fuel types

Nissan VQ35

Mitsubishi 4B11

Mitsubishi 4G63

Subaru EJ25

28

High Flow Intake Systems

Cosworths High Flow Intake Systems
feature increased diameter, large smooth
radius bent aluminum inlet tubes for
superior air flow management coupled with
a high flow air filter for maximum air flow
and performance.
Each kit includes an integrated heat shield
designed to isolate the air intake from
engine heat - delivering cold air into the
engine for superior power conversion. The
filter element is large, conical in shape and
engineered to dramatically reduce intake
restriction resulting in additional power and
torque.

High Flow Intake Systems

Part No.

Description

20019421

2001-2007 Subaru Impreza WRX, 2004-2007 Subaru Impreza WRX STI

20019422

2008-2010 Subaru Impreza WRX

20019423

2008-2010 Subaru Impreza WRX STI

20019424

2008-2010 Mitsubishi Lancer EVO X

Up to 15% More Performance

Lightweight aluminum mandrel shaped

inlet tube for maximum airflow
Conical Cosworth blue cotton gauze
cleanable air filter with Cosworth
embossed dry carbon composite end
cap
Integrated heat shield for cold air
isolation
Hardware kit included for easy, perfect fit
Made in USA

29

Oil Control
High performance engines reject a
substantial amount of heat through the
oil system. Maintaining oil pressure and
control along with an increase in actual
volume will help dissipate heat and stabilize
oil temperatures. Cosworth oil control
components are engineered to combat
several problem areas experienced in high
performance engines.
Mitsubishi 4G63 Crankscraper
The Cosworth 4G63 Crankscraper is
engineered to reduce parasitic drag on the
crankshaft caused by oil accumulation that
surrounds the crankshaft during rotation.
This oil buildup causes additional drag and
can reduce power output. Additionally,
overall oil control is improved by keeping
oil in the sump. Especially useful in high
rpm and race applications. Mounts to main
bearing girdle. Designed from 2.6 mm
(12gauge) steel plate and includes required
mounting hardware.

Oil Control
Part No.

Application
Subaru

20001238

Subaru (EJ20/EJ25) High Volume Oil Pan

20002499

Subaru (EJ20/EJ25) Oil Control Baffle

KK3928

Subaru (EJ20/EJ25) Blueprinted Oil Pump with high pressure mod & install kit

20001185

Subaru (EJ20/EJ25) High Volume/Pressure Blueprinted Oil Pump & install kit

20009093

Subaru 2008+ STI (EJ25) Blueprinted Oil Pump with high pressure mod .& install kit

20004463

Dry Sump Kit, Subaru EJ (Includes pan, 2 stage scav pump, brackets and pump drive-fluid lines / tank are not
included)

20009175

Nissan (VQ35) High Pressure Oil Pump Kit

20008841

Nissan (VQ35) Oil Control Baffle

20008632

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

20001382

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

20007845

Mazda Miata NC Oil Cooler Kit

Nissan

Mitsubishi

Mazda

Nissan Oil Control Baffle

The Cosworth Oil Control Baffle for the
Nissan VQ35 has been engineered to stop
oil from surging away from the oil pick
up during hard driving conditions. The
unique Cosworth one-way control valves
allow oil to flow towards the pickup but
restrict oil from migrating to the back of
the sump during aggressive maneuvers
to help maintain constant oil pressure.
Manufactured from stainless steel.
Model Year 2003-2004 require fit kit PN
20008632 for proper installation.

Subaru Oil Pan Baffle

Oil control can be a problem with high
performance and high revving Subaru
engines. High crankcase pressure along
with the horizontal engine platform restricts
rapid oil return from the cylinder heads to
the oil pan. Pressure builds in the heads
and crankcase causing massive blow by
and power loss. The Cosworth Subaru
Oil Pan Baffle has been engineered with
diverters to control oil returning from the
cylinder heads to the pan directing it away
from the crankshaft. Additionally, oneway valves prevent oil from re-entering the
upper crankcase chamber thereby limiting
blow by and preventing oil starvation during
hard driving. Manufactured from stainless
steel and installs easily between the block
and oil pan on both EJ20/EJ25 series
engines. Use with our High Volume Oil Pan
for maximum oil control.

30

Nissan Baffle Install Kit

Subaru Oil Control Baffle

Nissan Oil Control Baffle

Subaru Dry Sump - 20004463

The Cosworth Dry Sump Setup Kit for the
Subaru EJ series engine is a must for race
and performance applications. Dry sump
oiling systems offer an unparalleled level of
safety and reliability compared to factory
wet sump systems. Complete crankcase
oil scavenging reduces excessive and
residual oil that can cause blow-by and
power loss. A dry sump also offers more
consistent oil pressure to the engine,

improved scavenging, and increased

ring seal due to greater pan vacuum.
The Cosworth Dry Sump System for the
Subaru EJ20/EJ25 replaces the original
oil sump with a machined from solid, low
profile alloy pan with twin scavenge ports,
internal baffling and o-ring sealing. A two
stage scavenge pump driven by a HTD
belt, mounted to a heavy duty bracket
evacuates the oil from the engine.

Heavy duty mounting bracket / pump manifold

Includes:

Machined from Solid Sump

2-Stage Scavenge Pump
Pump Mounting Bracket/Manifold
34T Pump Drive Pulley
Crankshaft Drive Adapter Assembly
HTD Drive Belt
Crankcase Breather Filter and Fitting
Fittings and Hardware

Internal baffling

Required to complete the installation:

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

Low profile design

Twin Scavenge Ports

31

Subaru EJ20/25 High Volume Oil Pan 20001238

Sustained high RPM or prolonged high
speed driving will result in elevated oil
temperatures. Additional oil volume along
with improved oil control will reduce
damaging oil temperatures. The Cosworth

Subaru EJ20/25 Oil pump - High

Volume - 20001185
Increasing oil volume will help to prevent
bearing damage and engine failure.

EJ20/EJ25 High Volume Oil Pan is

fabricated from both custom and original
components resulting in an additional 2qts
oil capacity when compared to standard
oil pan. Each kit includes powder coated
oil pan, mounting hardware, oil pickup and
spacer. Will not work with some equal
length exhaust manifolds.

Additionally, sustained high RPM use may

cause oil starvation at the rod and main
bearings. The Cosworth High Volume
Subaru EJ20/EJ25 series oil pump
utilizes a completely new inner and outer

Pump Gear: 10mm vs 12mm

Subaru EJ20/25 Oil pump - High

Pressure - KK3928
High performance engines require
additional oil pressure because of the
increased demand placed upon various
components within the engine. The
Cosworth High Pressure Subaru EJ20/
EJ25 series oil pump is modified to
increase oil pressure helping to ensure

32

superior lubrication. Each pump is carefully

inspected and de-burred for unobstructed
oil flow. Perfect for high performance
daily use. Each kit includes all required
mounting hardware and seals.

12mm rotor to increase volume by 20%.

Suggested applications include drag, track
day and race use. Each kit includes all
required mounting hardware and seals.

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

Professional motorsport design

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

ECPro
Part No.

Description

30C-550004

Cosworth ECPro Kit - Mitsubishi Evo 9 USDM

30C-550020

Cosworth ECPro Kit - Mitsubishi Evo X USDM

30C-550000

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

20009237

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

20009236

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

60C-550019

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

01C-099500

ECPro Software CD

30C-550018

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

30C-550017

ECPro Advanced User Dongle (with 1 year subscription)

30C-550035

ECPro Dash

ECPro - Subaru STi

ECPro

ECPro - Evo X

ECPro Dash Display

(Alternate between red
and blue backlight)

Pi CalTool

33

High Flow Synthetic Air Filters

Cosworth High Flow Synthetic Air Filters
are constructed from a proprietary
synthetic, non-woven single layer, pleated
polyester filter media that requires no
oiling. For an OE-like fit, the filter housing
is injection moulded from high impact
polystyrene or polypropylene. Each
Cosworth air filter has been engineered
to fit the vehicles original air box providing
a true cold air supply to the engine.
Cosworth Performance Air Filters also
provide increased air flow when compared
to original equipment air filters.

Nissan 350Z / Subaru Impreza

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

Mazda 3

Mitsubishi Evo 8/9

Honda Fit

Subaru Legacy 2008+ STI

Honda S2000

34

Lexus IS250/350

Toyota Tundra

Performance Air Filters

Part No.

Description

Performance Air Filters

Performance Air Filters

Year

Part No.

Description

ACURA (Honda)

Year

Part No.

Description

Year

OPEL / VAUXHALL

MITSUBISHI

20005380

Acura Rsx

2002-2007

20006783

Lancer Evo X

2008-2010

20002270

Corsa (1.5L Diesel)

1988-1993

20005380

Acura Rsx Type S

2002-2006

20002277

Lancer Evo IX - IX

1996-2007

20002270

Vectra (1.7L) Turbo Diesel

1992-1995

20006783

Lancer (1.5/1.8/2.0L)

2008-2010

20002270

1991-1992

20002277

Lancer (1.3/1.6/2.0L)

1999-2008

Astra (1.7L) with Isuzu Diesel

Engine

20006783

Outlander (2.0/2.4L) Diesel

2007-2009

20002270

Cavalier with Isuzu Diesel

Engine

1992-1995

20002277

Outlander (2.0/2.4L)

2003-2007

20002270

Colt (1.3/1.6L)

1996-2005

Nova (1.5L) Incl. Diesel &

Novavan

1989-1992

20002277
20002277

Mirage (1.5/1.8L)

1997-2004

20002270

Kadett (1.5L)

20002270

350Z

2003-2006

CITROEN

20006783

C-Crosser

2008-2009
FORD

20002270

Maverick (2.4L)

1993-1998

HONDA

20002271

S2000 (2.0/2.2L)

1999-2009

20005380

Integra Type R (2.0L) JDM

2001-2006

20005380

Civic Type R (2.0L)

2000-2006

NISSAN

20005380

Civic Type R (2.0L) JDM

2001-2005

20005381

350Z (Twin Air Box)

2007-2010

20005380

Civic (2.0L)

2001-2006

20002270

R34 Skyline Gtr (2.6L)

1999-2002

20005380

Fr-V

2005-2008

20002270

R33 Skyline Gtr (2.6L)

1995-1998

20005380

Cr-V

2002-2006

20002270

R32 Skyline Gtr (2.6L)

1989-1994

20002272

Jazz (1.4L)

2007-2008

20002273

Fit (1.5L)

2007-2009

20002270

Skyline Coupe V35

(2.5/3.0/3.5L)

2001-2006

20002273

Fit JDM (1.3/1.5L)

2001-2006

20002270

R34 Skyline (2.0/2.5L)

1998-2001

20005380

Stream (2.0L)

2001-2005

20002270

R33 Skyline (2.0/2.5L)

20005380

Stepwagon (2.0L)

2001-2005

20002270

R32 Skyline (2.0/2.5L)

1989-1993

20002273

Mobilio JDM (1.5L)

2001-2007

20002270

R31 Skyline (2.0L)

1985-1989

20002273

Mobilio Spike JDM (1.5L)

2002-2007

20002270

R30 Skyline (2.0/2.8L)

20002270

Stagea (2.0/2.5/3.0/3.5L)

2002

20002270

300Zx (3.0L)

1987-1990

1988-1996

20002270

200Sx (1.8/2.0L)

20002270

HOLDEN

2002270

Calais (3.8L)

2002270

Commodore (3.8/5.0L)
INIFINITI

2008-2009

Impreza 2.0L

2008-2009

20002270

Impreza WRX STi

1997-2007

20002270

Impreza WRX

1993-2007

20002270

Impreza

1993-2007

20002278

Legacy (2.5L/3.0L/GT)

2005-2009

1988-1999

20002278

Legacy B4 (2.0/2.5/3.0L)
JDM

2003-2008

Silvia JDM (1.8./2.0L)

S12/13/14/15

1980-2002

20002270

Legacy B4 (2.0/2.5/3.0L)
JDM

1998-2005

20002270

Primera (1.6/1.8/2.0L)

1990-2007

20002270

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

1989-2003

20002270

Xtrail (2.0/2.2/2.5L)

2001-2006

20002278

Forester (2.0L/2.5L)

2008-2009

20002270

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

1982-2009

20002278

Outback (2.0/2.5/3.0L)

2005-2009

20002270

Altima (2.4/2.5/3.5L)

1993-2008

20002278

Tribeca (3.0/3.6L)

2006-2008

20002270

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

1995-2007

20002279

Tribeca (3.0/3.6L)

2006-2009

2004-2008

20002270

Alcione Svx (3.3L) JDM

1991-1996

20002278

Exiga (2.0L) JDM

2006-2008

1981-1990
1996-2006

20002270

G20 (2.0L)

1991-2002

20005381

Ex35 (3.5L)

2008-2009

20002270

Fx35 (3.5L)

2003-2008

20002270

I35 (3.5L)

2002-2004

20002270

Quest (3.5L)

20002270

I30 (3.0L)

1996-2001

20002270

Sentra (1.6/1.8/2.0/2.5L)

20002270

J30 (3.0L)

1993-1997

20002270

Terrano (2.4L)

1992-2005

20002270

Q45 (4.5L)

2001

20002270

Navarra (3.0L)

2004-2005

20002270

Qx4(3.3/3.5L)

1997-2003

20002270

Xterra (3.3L)

2000-2004

20002270

M30 (3.0L)

1990-1992

20002270

Pathfinder (2.7/3.0/3.3/3.5L)

1990-2004

20002270

Frontier (3.3L)

1999-2004

20002270

Patrol (4.2L)

1988-1997

20002270

Serena (1.6/2.0/2.3L)

1992-2001

1991-2006

20002281

IS250

2005-2009

20002270

Prairie (2.0/2.4L)

1989-1996

20002281

IS350

2006-2009

20002270

Pickup (3.0L)

1990-1996
1995

20002281

IS220

2005-2009

20002270

QX (2.0/3.0L)

20002281

GS350

2005-2009

20002270

Sunny (1.5/1.6/1.7/1.8/2.0L)

1985-1993

20002270

NX (1.6/1.8/2.0L)

1987-1993

20002270

Stanza (2.4L)

1990-1992

20002270

Axxess (2.4L)

1990-1991

20002270

Bluebird (1.9/2.0L)

1982-1990

20002270

Laurel (2.0/2.4/2.8/3.0L)

1980-1989

20002270

Cedric (2.8L)

1983

20002270

810 (2.4/2.8L)

1981

20002282

Elise 1.8L (Toyota Engine)

2004-2007

MAZDA

20002273

RX-8

2003-2009

20002275

MX-5 (1.8/2.0L)

2005-2008

20002274

Mazda 3 (2.0/2.3L)

2003-2008

20002274

Mazda 3 Mazdaspeed

2007-2008

2007-2009
SUBARU

20002278

1993-1998

2003-2007

LOTUS

Tc (2.4L)

2008-2010

G35 (3.5L)

2006

20002282

Impreza 2.5L

20002270

GS430

2003-2009
SCION

Impreza WRX

2007-2008

20002281

Vibe

20002278

G35 (3.5L)

LEXUS

20002282

20002278

20005381

1985

2007-2009
PONTIAC

2008-2010

2008-2010

Gemini (1.5/1.7L)

4007

Impreza WRX STi

G37 (3.7L) (Twin Air Box)

20002270

20006783

20002278

20005381

ISUZU

1989

PEUGEOT

TOYOTA

20002281

Rav4 (2.2L) Diesel

20002282

Corolla T Sport

20002282

Corolla (1.4/1.6/1.8L)

2002-2009

20002282

Matrix Xrs/Xr (1.8L)

2003-2009

20002282

Avensis (1.6/1.8/2.0/2.4L)

2003-2007

20002282

Altis (1.6/1.8/2.0L)

20002270

Lexcen (3.8L)

1989-1997

20002282

Premio JDM

2001-2007

20002282

Noah JDM

2001-2008

20002282

Opa JDM

2000-2008

20002282

Isis JDM

2004-2008

20002282

Allion JDM

2001-2007

20002282

Ipsum JDM

2001-2008

20002282

Wish JDM

2003-2008

20002282

Voxy JDM

2001-2007

20002282

Volt JDM

2008-2009

20002282

Caldina (Non-Turbo) JDM

2002-2008

2006-2010
2002

2001

35

Induction/Fuel
Subaru High Volume Air Intake
Manifold - PN 20006438
The Cosworth Subaru High Volume Inlet
Manifold is cast from aluminum featuring
large tapered runners with radiused inlets
for improved air flow. Plenum volume has
been substantially increased and tuned for
power. Engineered for easy installation and
is the key to making big power.

Substantially increased plenum volume

Large, tapered runners with radiused
inlets
Tuned plenum volume and runner
length/taper
Over 10% increase in flow
Integral vacuum manifold for connection
of brake booster, boost gauge, MAP
sensor, boost controller, etc.
Will work with standard or forward
mount throttle body configurations
Stock throttle body location for
compatibility with most aftermarket FMIC
kits

36

Induction / Fuel
Part No.

Description
Nissan

20000063

Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with Carbon plenum covers

20005779

Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with Carbon plenum covers "Bright Polish Finish"

KK3905

Nissan VQ35DE (3.5L) High Volume Fuel rail system

Mitsubishi

20005241

Mitsubishi EVO X High Volume Fuel rail kit

20005378

Subaru STI 2008+ Front Mount Intercooler System

20006438

Subaru High Volume Inlet Manifold

20015678

TGV Delete Kit - Subaru EJ25 Top Feed Injectors

Subaru

TGV Delete Kit - PN 20015678

The Cosworth Tumble Generating Valve
(TGV) Delete Kit is designed to maximize
airflow to your engine by eliminating the
obstructions inherent to the OEM TGV
intake ports. The TGV deletes are made
of a fiber reinforced polymer to insulate
the cylinder head from the intake tract,
providing your engine with a cooler,
denser charge of air. To further increase
performance, the Cosworth TGV deletes
are port matched to our CNC cylinder
heads and intake manifold. This product
is a direct fit for the 07+ Subaru STi due
to the top feed injector design and due
to a revision to the upper bolt pattern of
the TGV, specifically moving the center
two M6 holes. With our manifold and
top feed injectors, the TGV delete kit will
work without issue on most WRX/STi
applications

07+ Subaru STi specific, top feed

injector specific
Produced from fiber reinforced polymer
to lower intake air temperatures
Deletes factory Tumble Generating Valve
for increased airflow
Free flowing design, port matched to
Cosworth CNC Cylinder head & intake
manifold
Includes high temp o-rings, shoulder
bolts, and shims.
New OEM Subaru injector o-rings
included

37

VQ35 Twin Plenum Intake Manifold PN 20000063

The Cosworth Twin Plenum Inlet Manifold
for the Nissan VQ35DE has been designed
to enhance mid-range and high RPM
power. It features increased plenum volume

for improved high RPM power while torque

enhancing velocity stacks improve midrange power. With performance derived
from countless hours of development
including computational fluid dynamics,
the Cosworth Twin Plenum Inlet Manifold
is perfect for both normally aspirated and

forced induction applications. Cast from

lightweight aluminum alloy with carbon
fibre end caps and includes all required
mounting hardware. Will fit with original
strut tower brace. Can be used with the
factory fuel rail system or the Cosworth
High Volume Fuel Rail kit.

High-polished finish optional

Mitsubishi EVO High Volume Fuel Rail

System - 20005241

Nissan VQ35 High Volume Fuel Rail

The Cosworth High Volume Fuel Kit

features a machined from solid, hard
anodized aluminum fuel rail with o-ringed
fittings and a pre-shaped inlet pipe. The
Cosworth High Volume Fuel Rail Kit can be
used with original or various aftermarket
injectors and PRVs.

The original factory VQ35DE fuel rail

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

System - KK3905

configurable for various applications.

Each system includes sleeved high
pressure fuel lines along with a CNC
machined distribution block that includes
an additional port for various sensors.
The Cosworth High Volume Fuel Rail
System can be used with original or
various aftermarket injectors.

Direct fit replacement- includes all

necessary components for a complete
bolt-on installation
Designed with expansion in mind,
facilitating installation of custom fuel
systems including AN fuel lines and
remote mounted fuel pressure regulators
Full-flow bore will support upwards of
600hp worth of fuelling
Hard anodized finish is methanol
compatible.
(upgraded fittings and seals required)

VQ35 Fuel Rail System

Mitsubishi Evo Fuel Rail System

38

Intercooler Upgrade
Subaru front-mount Intercooler
System 2008+ STI - 20005378
Front mounted intercoolers offer improved
performance potential for Subaru
applications. The Cosworth front mount
intercooler for the 2008+ Subaru STI
replaces the restrictive, heat-soak prone
original top mounted core. The engineered
system features an efficient large aluminum
core with mandrel bent aluminum tubing
for maximum performance up to and
exceeding 600hp. The intercooler core
is rubber mounted on a secure bracket
system to help eliminate cracking and
breakage.

Intercooler Upgrade
Part No.

Description

20014525

Mitsubishi EVO X Front Mount Intercooler (Uses factory piping)

20019677

Mitsubishi EVO X Intercooler Hard Pipe Kit

20005378

Subaru STI 2008+ Front Mount Intercooler System

Installation is simplified as no cutting of

vehicle is required
Features

Large efficient core available in anodized

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

CAD Assembly

Large efficient intercooler core

Large diameter aluminum tubing

39

Mitsubishi EVO X Front Mount

Intercooler Upgrade - PN 20014525
The Cosworth front mount intercooler for
2008 and newer Mitsubishi Evolution X
features cast end tanks and an efficient
large core to ensure maximum charge
air cooling capability. Steel brackets with
rubber vibration isolators for optimal
resistance to the fatigue failure common
with hard mounted aluminum brackets.
Installation does not require any vehicle
modifications.
Features

Smooth transition cast aluminum end

tanks for optimum airflow. Purposeful
airflow management without the
compromises of fabricated sheet metal
end tanks.
Large, efficient intercooler core ensure
low restriction and high-efficiency heat
transfer.
Easy installation - under 30 minutes with
simple hand tools, no modification to car
needed
Heavy duty steel brackets with rubber
isolated mounting
4-ply heavy duty silicone couplers with
liner hose clamps
Made in USA
Core size: 20 x 12.3 x 3.5
55% increased flow over the factory OE
intercooler
Optional large-diameter hard intercooler
pipe kit - Part number 20019677

40

Robust mounting system

EVO X Intercooler Pipe Upgrade Kit PN 20019677

The Cosworth Intercooler Pipe Upgrade
for the Mitsubishi EVO X features large
diameter single piece mandrel bent
aluminum tubes with 4-ply silicone
couplers and stainless steel liner type hose
clamps and is designed to decrease turbo
lag and increase power in your Mitsubishi
Evolution X.
The mounting location of the bypass
valve has been optimized for reduced
turbocharger lag and is compatible with
both the original component and many
aftermarket versions.
Engineered to work with the factory
intercooler or Cosworth intercooler kit
(Cosworth part # 20014525) but may be
compatible with other brands.
Features

Bright Silver, durable powder coated

finish
Relocated bypass valve for reduced
turbocharger lag
2.5 / 63.5mm diameter tubing (hot side)
2.75 / 69.85mm diameter tubing (cold
side)
4-ply silicone couplers
Robust mounting system

NGK High Performance Spark Plugs

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

NGK High Performance Spark Plugs

Part No.

Description

Specification

20005759

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

Heat Range 8

20005760

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

Heat Range 9

20005761

NGK TR7IX Duratec

Heat Range 7

20005762

NGK TR8IX Duratec

Heat Range 8

41

Brake Pads
The racing performance pedigree that
is so much part of Cosworths heritage,
is clearly demonstrated in this exciting
addition of brake pads to our Aftermarket
Performance Parts range.
With two grades of friction material, the
StreetMaster and TrackMaster ranges
deliver exceptional levels of stopping power
specifically tailored for fast road and track
applications respectively.
Manufactured in the United Kingdom,
Cosworth brake pads feature a 1.5mm
granulated interlayer which not only serves
to act as a shock absorber, helping to
reduce stress on the rotor surface but
triples bonding strength so diminishing
edge lifting.
To reduce the bedding-in or seatingin time - this is the time it takes for the
pad and disc to adapt to each other - all
Cosworth brake pads are heat seared.
This process heats the friction material
to in excess of 600C toasting the
surface greatly enhancing the performance
the first time that the driver applies the
brakes. Scorching pads also significantly
reduces initial fading. Fading increases the
necessary force and pressure required to
maintain the deceleration of the vehicle.
Cosworths brake pads range offer
exceptional performance with no
compromise.
Why choose Cosworth Brake Pads?

Heat seared for reduced bedding-in

time
Superior bite from cold
Exceptional stopping performance - 0.7
braking coefficient
Silent running technology
Vee groove for fast debris clearance
Fade resistant
Premium grade friction material
Consistent & predictable braking
patterns

42

Medium-hard sports pad suitable for

heavy duty/fast road
ECE R90 approval
Superior bite - 0.5 friction coefficient virtually from first pedal
Strong brake effect up to 650C
Chamfered edge avoid lifting
Fitted with premium quality shim
hardware silent braking
Durability factor 6.5 with rotor minimal
rotor abrasion
Produces consistent, predictable braking
performance

Track day driving

Extremely high friction level 0.7 friction
coefficient
Strong brake effect through 800C
Vee line expansion groove technology superb debris clearance
Fitted with premium quality shim
hardware silent braking
Durability Factor 9.5 with minimal rotor
abrasion
Super fast bed-in typically under 2 laps
Heat stable, predictable & heat cycle
exceptionally well
This track formulation CAN be safely
used on highways except in Europe
where ECE R90 approvals are required.
This pad has too much brake effect to
be compliant with these regulations.

Vehicle Application List

Model

Year

StreetMaster
Front Pads

TrackMaster
Front Pads

StreetMaster
Rear Pads

TrackMaster
Rear Pads

Ford

Fiesta 2.0 ST

2004-2008

CFS3011

CFS3005

Escort/Orion 2.0 Cosworth

92-95

CFS3024

CFS3021

Focus 2.5 Turbo ST

2005-2009

CFS3010

CFS3013

Focus 2.5 Turbo RS

2009-

CFS3020

CFS3017

Sierra/Sapphire 2.0 Cosworth

85-90

CFS3022

CFS3021

Sierra/Sapphire 2.0 Cosworth 4x4

90-93

CFS3024

CFS3021
Honda

S2000 2.0

99-

CFS3006

CFT3006

CFS3002

CFT3002

Civic 2.0 Type-R (EP3)

2001-2007

CFS3006

CFT3006

CFS3002

CFT3002

Civic 2.0 Type-R (FN2)

2007-

CFS3006

CFT3006

CFS3016

CFT3016

Integra (Not UK) 2.0 Type R (DC5)

2001-

CFS3012

CFT3012

CFS3002

CFT3002

Integra (Not UK) 2.0 Type S (DC5)

2004-

CFS3006

CFT3006

CFS3002

CFT3002

Mazda

MX5 1.8

2006-

CFS3014

CFS3015

MX5 2.0

2006-

CFS3014

CFS3015

Mitsubishi

Lancer Evo 5 2.0 Turbo GSR

97-99

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 6 2.0 Turbo

98-2001

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 7 2.0 Turbo

2000-2003

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 8 2.0 Turbo

2002-2005

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 9 2.0 Turbo

2005-2008

CFS3004

CFT3004

CFS3009

CFT3009

Lancer Evo 10 2.0 Turbo

2008-

CFS3004

CFT3004

CFS3019

CFT3019

Nissan

GT-R (R35) 3.8 Twin Turbo

2008-

CFS3018

CFT3018

CFS3001

CFT3001

Skyline R32 GTR

89-95

CFS3003

CFT3003

CFS3023

CFT3023

Skyline R33 GTS 2.5 Turbo

93-98

CFS3003

CFT3003

CFS3023

CFT3023

Skyline R34 GTT

97-2002

CFS3003

CFT3003

CFS3023

CFT3023

Skyline 3.5 (V35 V36) (Brembo)

2001-2006

CFS3012

CFT3012

CFS3008

CFT3008

350Z 3.5 (Brembo)

2003-

CFS3012

CFT3012

CFS3008

CFT3008
CFT3023

Subaru

Impreza 2.0 Turbo (Not UK)

98-2002

CFS3003

CFT3003

CFS3023

Impreza 2.0 Turbo (UK)

98-2002

CFS3003

CFT3003

CFS3007

Impreza 2.0 Turbo P1

2000-2002

CFS3003

CFT3003

CFS3007

Impreza 2.0 Turbo WRX

2001-2005

CFS3003

CFT3003

CFS3023

CFT3023

Impreza 2.2 Turbo (22B)

98-2000

CFS3003

CFT3003

CFS3023

CFT3023

Impreza 2.5 Turbo WRX

2006-2007

CFS3003

CFT3003

CFS3023

CFT3023

Impreza 2.0 Turbo WRX STi

2002-2005

CFS3004

CFT3004

CFS3008

CFT3008

Impreza 2.5 Turbo WRX STi

2006-2007

CFS3004

CFT3004

CFS3008

CFT3008

Impreza 2.5 Turbo WRX STi

2007-

CFS3004

CFT3004

CFS3008

CFT3008

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

43

High Performance Brake Kits - Sport

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

High Performance Brake Kits - Sport

Part No.

Description

Caliper/Rotor

Front/Rear

AUDI

20020666

S4 (B6, B7 Chassis) 2004-2009

4Piston / 355 x 32

Front

20020667

S4 (B6, B7 Chassis) 2004-2009

6Piston / 355 x 32

Front

20020668

S5 (Fits stock wheels) 2008-2009

6Piston / 355 x 32

Front

Cosworth 2-piece rotors are designed

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

20020681

S5 (Fits stock wheels) 2008 - 2009

6Piston / 380 x 32

Front

20020682

TT 3.2L 2008-2009

4Piston / 355 x 32

Front

All parts are bench tested prior to

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

Bolt-in bridge minimizes caliper

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

44

BMW

20020684

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

4 Piston / 345 x 28

Rear

20020685

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

6 Piston / 355 x 32

Front

Volkswagen

20020710

Golf GTI 2.0T (Mk5) 2006-2009

4Piston / 328 x 28

Front

20020711

Golf GTI 2.0T (Mk5) 2006-2009

4Piston / 355 x 32

Front

20020712

Jetta 2.0T (Mk5)

4Piston / 355 x 32

Front

20020713

Jetta 2.5L & TDI (Mk5) 2006-2009

4Piston / 328 x 28

Front

Honda

20020687

Lancer EVOLUTION 7-9 2003-2006

4Piston / 328 x 28

Rear

20020688

Lancer EVOLUTION 7-9 2003-2006

4 Piston / 355 x 32

Front

20020689

Lancer EVOLUTION 7-9 2003-2006

6 Piston / 355 x 32

Front

20020690

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

4 Piston / 332 x 32

Front

20020691

Lancer EVOLUTION 10 2008-2010

4 Piston / 345 x 28

Rear

20020692

Lancer EVOLUTION 10 2008-2010

6 Piston / 355 x 32

Front

Subaru

20020693

Impreza WRX 2002-2007

4 Piston / 328 x 28

Front

20020694

Impreza WRX 2002-2007

4 Piston / 332 x 32

Front

20020695

Impreza WRX 2002-2007

4 Piston / 355 x 32

Front

20020696

Impreza WRX 2002-2007

6 Piston / 355 x 32

Front

20020697

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

2 Piston / 328 x 28

Rear

20020698

Impreza WRX 2008-2009

2 Piston / 345 x 28

Rear

20020700

Impreza WRX 2008-2009

4 Piston / 328 x 28

Front

20020701

Impreza WRX 2008-2009

4 Piston / 355 x 32

Front

20020702

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

4 Piston / 355 x 32

Front

20020703

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

6 Piston / 355 x 32

Front

20020704

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

4 Piston / 332 x 32

Front

20020705

Impreza WRX STi 2008- 2010

2 Piston / 345 x 28

Rear

20020706

Impreza WRX STi 2008- 2010

4 Piston / 355 x 32

Front

20020707

Impreza WRX STi 2008- 2010

6 Piston / 355 x 32

Front

20020708

Legacy GT 2005-2009

2 Piston / 328 x 28

Rear

20020709

Legacy GT 2005-2009

4 Piston / 332 x 32

Front

High Performance Brake Kits - MAXSport

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

High Performance Brake Kits - MAXSport

Part No.

Description

Caliper/Rotor

Front/Rear

AUDI

20020659

Lancer EVOLUTION 7-9 2003-2006

2 Piston / 328 x 28

Rear

20020660

Lancer EVOLUTION 7-9 2003-2006

4 Piston / 355 x 32

Front

20020661

Lancer EVOLUTION 10 2008-2010

4 Piston / 345 x 28

Rear

20020662

Lancer EVOLUTION 10 2008-2010

6 Piston / 355 x 32

Front

Volkswagen

20020663

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

6 Piston / 355 x 32

Front

20020664

Impreza WRX STi 2008-2010

4 Piston / 355 x 32

Rear

20020665

Impreza WRX STi 2008-2010

6 Piston / 355 x 32

Front

All parts are bench tested prior to

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

Bolt-in bridge minimizes caliper

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

Sport caliper fully forged for optimal strength

MAXSport caliper machined for lightness

45

Miscellaneous
Subaru Billet Timing Belt Guide - Part
number SB0001

Miscellaneous
Part No.

The original sheet metal timing belt

guide can flex from belt deflection when
subjected to extreme RPM causing the
timing belt to skip one or more teeth on
the crankshaft sprocket. The Cosworth
Billet Timing Belt Guide was developed to
control this problem and is machined from
solid aluminum with a hard anodized finish.
Includes mounting hardware.

Application
Subaru

SB0001

Subaru (EJ20/EJ25) Billet Timing Belt Guide

SB0002

Subaru Billet Cam Angle Sensor Bracket (for mounting cam angle sensor on front of head)

20004539

Subaru (EJ20/EJ25) Air pump delete plate set

Oil Filler Caps

Part No.

Description

20014944

Mitsubishi Evo X 4B11T Oil Filler Cap (Red)

20015827

Mitsubishi Evo X 4B11T Oil Filler Cap (Natural)

20014380

All Subaru vehicles from 1990 to current model years (Blue)

Oil Filler Caps

Subaru Billet Cam Angle Sensor

Bracket - Part number SB0002
Used for mounting the cam angle sensor
to the front of non North American Spec
STI cylinder heads. Useful for adapting our
cylinder heads to Japanese and European
market engines.

The Cosworth Oil Filler Cap is machined

from solid aluminum with the traditional
Cosworth three prong ergonomic style.
This light weight oil filler cap includes a
an oil ring sealing feature , preinstalled to
ensure leak free operation on your engine.
Each cap features a durable anodized
finish.

Air Pump Delete - Part number

20004539
Used to eliminate the air pump and related
valves found on 2006-2008 Subaru
Engines. Used for high performance
applications or adapting later cylinder
heads to early engines. Seals off the air
injection ports at the cylinder heads. Saves
weight, reduces complexity, cleans up
engine compartment. Machined from solid
aluminum with a Cosworth blue anodized
finish. Mounting hardware included.

46

Machined from solid aluminum

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

Disclaimer

The products in this catalogue require professional installation to ensure correct operation.
Cosworth will not accept responsibility for damage to vehicles as a result of improper
installation of our products.
The performance and power gained from installing products from this catalogue may place
vehicles within an off road use only category in certain counties and states around the
world. Cosworth will not accept responsibility for any restrictions placed on vehicles.
Product Disclaimer: A vehicle modified with Cosworth competition and or racing
performance products may not meet the legal requirements for operation on public roads
and highways. It is the purchasers 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

 Copyright 2010, Cosworth LLC - v3.0

UK Office

US Office

Cosworth Ltd
The Octagon
St James Mill Road
Northampton
NN5 5RA
United Kingdom

Cosworth LLC
3031 Fujita Street
Torrance
CA 90505
USA

Tel:
+44 (0)1604 598300
Fax:
+44 (0)1604 598301
Email: clsales@cosworth.com

Tel:
+1 310 534 1390
Fax:
+1 310 534 2631
Email: sales@cosworth.com

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www.cosworthperformance.com