Warning: It has come to our attention that the use of a non-oem crankshaft and/or crankshaft pulley (damper) may interfere with the installation of the Cosworth Dry Sump Set-Up Kit for Subaru EJ25 engines (p/n 20004463). It is important to ensure that there is clearance between the face of the crankshaft snout and the small diameter rear face of the Cosworth pump drive hub. If the crankshaft snout is longer than that of an OEM crankshaft, it will prevent the crank pulley bolt from properly securing the OEM damper to the crankshaft. Serious engine damage may occur. Prior to permanent installation, mock up the crankshaft drive pulley assembly and check clearance. The crankshaft damper should be securely clamped between the large diameter rear face of the Cosworth pump drive hub and the face of the timing belt drive pulley. Some aftermarket crankshafts have been found to have a longer than OEM snout, preventing the Cosworth drive pulley from properly clamping the damper. If this is the case, do not continue with the installation. The crankshaft will need to be modified to ensure proper fitment of the Cosworth Dry Sump Set-Up Kit.
Part Number: 20004463 Applications: Subaru STI EJ25 (2.5L) Disclaimer To properly install this part, you MUST have access to a genuine Subaru factory service manual. The installation of these parts on a vehicle intended for use on public streets or highways may violate laws and regulations relating to motor vehicle safety standards or emission regulations. Additionally, these parts are sold as is, without warranty of any kind whatsoever, expressed or implied, (including all warranties of merchantability or fitness for a particular purpose). The installation of these parts could also void vehicle warranty coverage. For your own safety DO NOT use this product unless suitable high speed rated tires, suspension and brake modifications have been fitted. 1. Disclaimer 2. Parts List 3. Parts Diagram 4. Installation 5. Recommendations Index
Parts List ITEM # QTY. DESCRIPTION COSWORTH PART # 1 1 Bolt M8x1.25 x 80 SCH PP5650 2 1 Washer M8 PR6577 3 1 Idler 20003920 4 1 Idler Spacer 20003939 5 1 Washer M8 Thick 20003921 6 1 Nut M8 Hex PP1484 7 1 Crankshaft bolt 20004079 8 5 Bolt 4-40 UNC x 0.375 FHCS 20015228 9 1 Crank Drive Gear Plate 20006931 10 1 Crank Drive Gear 20006905 11 1 Key 5mm Square 6mm length 20016105 12 1 Pump Bracket 20006933 13 3 AN Fitting -12 Male Flare to -12 Male O-ring 20004493 14 4 Bolt ¼-20 UNC x1 SCH PP0213 15 1 Scavenge Pump 20003591 16 1 Scavenge Pump Gear 36 Tooth (comes with set screw) 20003914 17 3 Bolt M10x1.5x40 SCH 20004596 18 1 Belt 8mm Pitch 720mm 20008317 19 1 Vacuum Regulator 20015229 20 1 Vacuum Regulator to Oil Fill Flange Adaptor 20008296 21 2 Bolt M6x1.0x12 SCH 20001132 22 1 O-ring 25.1mm ID x 1.6 sec PP2355 23 1 Dry Sump Pan 20003952 24 14 Bolt M6x1.0x16 SCH PP1395 25 1 Dry Sump Pan Windage Tray 20004337 26 6 Bolt M5x0.8x10 BHCS PP3307 27 6 Washer M5 PP4256 28 2 AN Fitting -12 Male Flare to -12 Male Screen 20004479 29 1 O-ring 22mm ID x 2.0 sec PR1440 30 1 O-ring Large 20008350
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Installation Notes Congratulations on your purchase of Cosworth s Subaru STI Dry Sump Set-Up Kit. This kit is designed to ensure your engine receives sufficient oiling during high G load situations. This kit features a custom dual stage rotor-style scavenge pump, -AN fittings, and an array of bespoke billet parts that have been designed and manufactured in-house in Torrance, CA. It is recommended that this dry sump set-up kit be installed by a professional engine builder. Cosworth dry sump oiling set-up kits are intended for racing applications only and are not intended for use on street operated or emissions controlled vehicles. Be sure to use Loctite 242 (Blue) or equivalent on all hardware. The components of this dry sump oiling kit are designed to bolt on to factory mounting locations. Therefore, the assembly procedures and torque specifications depicted in your Subaru factory service manual must be followed. Pre-installation Due to the fact that you will need to remove your air conditioning pump, it is necessary to have your air conditioning system evacuated by a professional. After the air conditioning system has been evacuated, remove the air conditioning pump following the steps outlined in the factory service manual. For 2008 and newer vehicles, the A/C compressor bracket and A/C belt tensioner assembly must be replaced with equivalent parts from a 2007 model year STI. For 2006 and newer vehicles, the air injection pump must be removed following the Subaru factory service manual. The air pump inlet ports at the rear of the cylinder heads must be blocked off. We recommend Cosworth Air Pump Delete Kit (P/N 20004539). It is also recommended that the OEM oil pump be replaced. While the OEM pump will work with this kit, it will not provide optimal oil delivery. We recommend either the Cosworth High Volume/Pressure Blueprinted Oil Pump (P/N 20001185) or Cosworth 08+ STI High Pressure Blueprinted Oil Pump (P/N 20009093), depending on application.
Pump Drive Gear Installation Remove the radiator cooling fans in order to make room in front of the crankshaft pulley. Remove the crankshaft pulley bolt. Hold the crankshaft with either the factory Subaru crank pulley wrench or with an appropriate flywheel locking tool. Attach the crankshaft drive adapter guide plate to the adapter with the five 20015528 screws. Torque to 5 in-lb with blue Loctite. Ensure the 5mm square key is securely installed into the Cosworth crankshaft drive adapter. Install the crankshaft drive adapter, aligning the 5mm key with the keyway in the OEM crank pulley. Attach the crankshaft drive adapter to the crankshaft pulley using the supplied 20004079 bolt. Torque to 133 ft-lb. Scavenge Pump Installation Ensure that the O-rings are in place on the mating surface of the scavenge pump. Attach the scavenge pump to the pump bracket using the four PP0213 screws. Torque to 6 ft-lb with blue Loctite. Attach the dry sump bracket to the A/C compressor bracket using the three 20004596 screws. Torque to 29 ft-lb with blue Loctite. Lubricate o-rings with clean engine oil and install two -12AN male to 1 1/16-12 male adapters to the dry sump bracket. Ensure the pump drive key is securely installed in the slot on the scavenge pump drive shaft. Slide the pump drive gear onto the shaft until the face is flush with end of the pump shaft. Tighten the four set screws on the gear. Dry Sump Pan Installation Drain the engine oil. Remove the factory oil pan following the steps in the Subaru factory service manual. After the pan has been removed, clean off all of the excess sealant on the mounting face of the crankcase. Lubricate o-ring with clean engine oil and install -12AN male to 1 1/16-12 male adapter in the bottom of the dry sump pan. Lubricate o-rings with clean engine oil and install both -12AN male to 1 1/16-12 male screen adapters to the side of the dry sump pan. Bolt the baffle plate into the dry sump pan using the six PP4256 washers and six PP3307 bolts. Torque to 48 in-lb using blue Loctite. Fit the large 20008350 o-ring into the groove on the dry sump pan. Place the PR1440 22mm o-ring in the oil pickup o-ring groove. Bolt the pan to the crankcase using the 14 PP1395 M6 bolts. Torque these bolts to 4.7 ft-lb using blue Loctite.
Crankcase Ventilation Remove the factory positive crankcase ventilation hoses and Y-pipe. The hoses originate from the cam covers and are the front most of the two adjacent hoses on each side. Remove the hoses from the nipples and replace them with the supplied rubber caps. One rubber cap will be needed for each of the two cam covers as well as one for the turbo inlet tube PCV inlet. The rear most hoses are balance hoses and are to remain attached. Remove the oil fill neck tube. Install the PP2355 o-ring on to the oil fill neck adapter fitting and lubricate with clean engine oil. Bolt on the oil fill neck adapter to the LH cam cover using the two 20008296 screws. Torque to 4.7 ft-lb using blue Loctite. Lubricate the o-ring with clean engine oil and install the vacuum regulator into the oil fill neck adapter. Tensioner Assembly Some OEM Subaru parts will be combined with Cosworth supplied parts to complete the tensioner assembly. Again, if your vehicle is 2008 or newer, you will need to purchase parts separately from a certified Subaru parts dealer. Assemble the tensioner as shown below. Install the factory tensioner arm to the A/C compressor bracket using the two stock mounting bolts. Torque the mounting hardware to 18 ft-lb.
Stock Subaru Tensioner Bolt Stock Subaru Tensioner Bracket PP5650 PP1484 20003921 Stock Subaru Tensioner Slide 20003939 20003920 PR6577 PP5650 Install the dry sump drive belt onto the crankshaft adapter, and then on to the scavenge pump pulley. Use the Subaru factory slide to move the idler pulley into the desired position. Tighten the tensioner assembly through-bolt PP5650 to 18 ft-lb. The drive belt does not require tension like a v-belt does. The idler should be used to take up any excess slack in the belt and ensure appropriate wrap around the sprockets, but there should not be any tension on the belt.
Plumbing and Tank Recommendations The oil tank (not included) may be mounted anywhere in the vehicle. Ideally, the oil tank should be mounted as low as possible. Be sure to check the oil level in the tank with the car running at idle to verify the correct volume of oil. This will vary depending on the size and shape of your tank. Follow the routing diagram shown below. It is recommended that hard line be run under the vehicle if the tank is mounted in the rear of the car. At the top of the tank there is an outlet for crankcase vapor. This must be routed to a breather can (not included). Front of Engine -12 AN (-12) Scavenge Pump Scavenge Out Breather Out -16 AN Scavenge In -12 AN -12 AN Pressure In Note: If the engine will go for an extended period of time without running, it is possible for oil to migrate from the oil tank into the sump. It is necessary to scavenge the engine prior to start up to avoid potential engine damage. This can be done by removing the drive belt and spinning the pump by hand until the sump is dry. Verify that there is no standing oil in the sump by checking the oil tank level.
Disclaimer A vehicle modified with Cosworth competition and or racing performance products will not meet the legal requirements for operation on public roads and highways. It is the purchaser s responsibility to check and comply with all local, state and federal laws prior to operating vehicle. Installation and use of performance products may also affect and void warranty and insurance policies. In general, Cosworth Performance Parts carry no warranty. Cosworth, LLC and Cosworth Ltd. 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 labor. There are no warranties expressed or implied. Warranty In general, Cosworth competition and/or performance parts carry no warranty. Cosworth LLC and Cosworth Limited shall not be liable for direct, indirect, incidental or consequential damage or injury to persons or property that might be claimed as result from the installation or improper installation and failure of part, including claims for delay, loss of profits or labor. There are no warranties expressed or implied.