How to make 400 WHP…

How to make 400WHP… a tried and true Method

The MZR DISI engine has been around for just over 10 years now, and CorkSport along with the community, racers, shops, and enthusiasts alike have learned quite a bit about these engines. We have learned what they like and what they don’t. How they react to certain mods, how to maintain them, and also some of their weak points.

Among the many things we have learned, we have developed a great understanding of what is needed to get these engines to make power. More specifically, with the right set of bolt-on parts and tuning one can easily and safely make 400WHP on a stock bottom end of your MS3 or MS6. The torque will just need to be kept under control of course.

It’s not a secret or rocket science on how to achieve this power level in a Mazdaspeed3 or Mazdaspeed6, and it is very much doable.

Today I want to share with you a simple blog on just one way of doing just that. If you would like more in-depth information on some of these parts after checking out this blog, I suggest picking up a copy of our Ultimate Mazda Performance Guide. This simple read is packed full of information for 2004+ NA and Mazdaspeed models and is a great place to start for guys that are new to aftermarket performance and modification game.

Disclaimer up front.

There are certainly many variables that can come into play when trying to achieve 400WHP safely such as health of your engine, quality of engine tune, octane rating of fuel, engine management software and more. This is by no means an all-inclusive guide and the only way of making this level of power. What this, however, is a tried and tested method of making good power safely and reliably coming from years of experience doing it ourselves and helping the community. We have spent years and years developing this platform and continue to do so on a daily basis. What I aim to do is educate you guys on how you can make the most out of your MZR Engine.

Now before we get too ahead of ourselves, there are two modifications that are a must before going down the 400whp quest. Those are high-pressure fuel pump internals and a tuning solution such as those provided by COBB or Versatuner.

Now while inherently in themselves these parts do not increase hp and tq levels they are 100% necessary to achieve not only safe and reliable power with your Mazdaspeed, but give you the ability to make the most out of your hard part modifications. A high-quality tune is worth every penny, and when paired with things such as the intake and exhaust mentioned above you will not only have a reliable and smooth running car, but you can capitalize even more so your parts and net more horsepower.

The DISI MZR 2.3 T is not much different than any other gasoline direct injected engine that you would find on any modern automobile.

Air goes into your Mazdaspeed, it combines with the correct ratio of fuel, and the mixture gets compressed. From there, a spark event occurs that ignites a controlled burn, forcing the piston downwards. Exhaust gases then leave the Mazda, and the cycle repeats with new fresh air. So in an oversimplified matter that is all an internal combustion engine is just a glorified air pump with more bells and whistles. And one of the best ways to make a really effective air pump is to make it as efficient as possible in moving air in and out of the cylinders.

For that reason, it’s best to start at the front and back of our car to help give it a little breathing room.

It’s no secret that intake and exhaust systems are among the most popular first upgrades for any automobile and it’s for a good reason. Letting air in and out as easy as we can is a great first step to make power and free up restrictions, especially on a factory turbocharged vehicle. The OEM pieces are more concerned with emissions and pricing rather than performance.

So, stepping up to 3” or 3.5” intake for your Mazdaspeed, paired with a turbo-back exhaust will help to help free up some headroom in the exhaust system. Achieved by doing things such as: increasing our overall pipe diameter and either eliminating our catalytic converter or replacing it with a high flow race cat we reduce a lot of restriction, so the engine doesn’t do as much work. Since we are effectively making its job easier; we are now able to take more of that power stroke and translate it into much more power at the wheel, rather than having it consumed by products such as waste heat, noise, and vibration.

Those two mods alone can net you an easy 50+Whp (With the proper tuning) which is huge looking at your dollar per horsepower figures. Note the exhaust systems are different between the 1st and 2nd gen Mazdaspeed models.  (Mazdaspeed3 has 2 generations that have slight differences, meaning not all parts are compatible across the two models)

Now another great way to make more power with your Mazdaspeed, and to get us closer to 400whp, is to increase the level of boost pressure that we start running through our engine. OEM boost levels are around the 14-15 PSI. But once we have our intake and exhaust installed on our Mazdaspeed, our tuning solution can allow us to start increasing that level into the 19-21 range.

But, of course, a natural byproduct of increasing the pressure within our system is a rise in intake air temperature. To be able to make the most of our increased boost levels, we must keep our temperatures in check. A great way of doing that is upgrading to a larger TMIC or go a step further and upgrade to a large FMIC core. By doing this, we create a way to get rid of excess heat which allows us to make more stable and efficient power. Not to mention that the stock TMIC is also a terrible bottleneck so this will free up the extra flow as well.

The intercoolers primary function is to act as a heat exchanger, and we know that heat is the #1 roadblock to any engine to make more power. The more efficiently we can remove heat from the system the better. Having less overall heat in the system allows us to make more power safely and reliably as ‘knock’ is also reduced.

Now that we have a good way of getting air into our MS3 or MS6, out, and keeping cool, we want to be able to make more of it. A nice and easy way to be able to do that is by dropping in a turbocharger upgrade into your Mazdaspeed. Doing this easily replaces your factory undersized unit and allows us the potential to make some serious power. We can generally do one of three things once this happens.

#1) we make the same power on less boost
#2) we make more power on the same boost
#3) we make way more power on WAY more boost!!!

If we are shooting for 400whp, then we generally like to choose door #3.

A quick note on a pair of other items that we highly suggest/need at this point. Those items being a 3.5 bar MAP sensor and an electronic boost control solenoid (or EBCS). Once we start to increase our boost pressures north of 21psi, the OEM electronics begin to lose resolution and can negatively affect our tuning if not addressed.

By upgrading our MAP sensor we are now allowing the PCM to be able to recognize and look up higher boost targets than those equipped from the OEM, the computer can basically now record and accurately look up these values. We also upgrade our EBCS to allow more fine tuning of our maps and boost targets. An OEM EBCS just won’t allow us as fine of control of our boost pressure and that can cause some headache as we start to approach these higher levels.

With the above combination of mods and proper tuning on a healthy engine, a medium frame turbo on pump gas can get you into the 330-340whp range.

If we go another step further and open up to some more breathing mods such as an intake manifold, taller lift camshafts, or a larger throttle body we can stretch into the 350-360hp range.

That being said without the help of e85 or aux fueling we can’t go any closer to our 400whp mark. We simply hit the limits of the Mazdaspeed factory fuel system and need to look into upgrading that system as well.

Making the switch over to e85 allows us to get in the 380 range, but we soon run out of fuel injector headroom in the Mazdaspeed at this point and max out our injector duty cycle. We then have to look at aux fueling (Meth or Port Injection) as a solution to get us to our 400whp mark safely. What’s unfortunate is that at this point we are also looking at upgrading our hard parts such as our in-tank fuel pump to keep up with demand if you plan to run PI. There are quite a few options for AUX fueling which are beyond the scope of this blog.

Now, as mentioned this is not the only way of making these power levels, but it could be said that it is one of the easiest and most popular. It’s important to remember that along way we supplement the engine with other supporting mods to ensure we are safe and can make full use of our power. Things like lower heat range spark plugs and a stage 2 rear engine mount can go a long way.

Thanks for following along and feel free to leave us a comment if you have any questions or want some more specific information on a product.

Dear Mazda, I have a Wish List

Dear Mazda,

I want to let you know what’s on my wish-list so that if you ever happen to stumble upon our wonderful little world of CorkSport, you’ll see everything I’ve been dreaming of.

1.      New Mazdaspeed

While I personally prefer the Mazdaspeed3 hatchback look, I’d even be ok with a Mazdaspeed6 iteration. I like to have fun; I like to be pushed back in my seat by power and performance, and realistically I LIKE TO GO FAST. The newest generations of Mazda are missing some of these aspects, and I’ve been dreaming of their return!!

Now, don’t get me wrong, I like the Gen3 Mazda3. It’s a smooth ride, and we’re pretty stoked about what it can offer. However, our customers like to make power, N/A leaves us begging for more despite what HP we can squeeze out of the Mazda3.

So, Dear Mazda, Please bring back the Mazdaspeed!

2.      Mazda CX-3 with a turbo

Genuinely, I like the look of the CX3, I enjoy the size of the CX-3 and even find that it suits my ever changing lifestyle being a little higher off the ground. (For those who don’t, check out CorkSport’s lowering springs for the CX-3). It’s just flat out missing the power that comes with a turbo. It’s “get up and go” is … well… slow. This could, with the right improvements, be a great replacement for the Mazdaspeed3 for those of us waiting for the newest generation. Just please, please, can we get some more POWER?!

3.     Turbo Diesel Mazda 6

You gave it to everyone else!!! Why in the world would you leave us out?! You have to do ZERO redesigns; just getting it to the states is all I’m asking. The clean look of the Gen3 Mazda6 is something we like, but the power and improvements that come with the Turbo Diesel, I mean COME ON?! Just let us have a chance at it!

Heck, make that an AWD Mazda 6.

If you’re feeling generous, you could make it an AWD Turbo Diesel Mazda 6.

If we’re going THAT far, make it an AWD Turbo Diesel Mazda 6 wagon, because “I love me some hatchback!” that big booty look, and being able to fit all of the things… What’s not to love?!

It’s not a long list, and I realize that it’s selfish of me to ask, but I’m pretty sure I’m not the only one you would be making happy if you would just deliver on even ONE of these items.

Hopefully yours,

Kim@CorkSport

 

P.S Apple Carplay, and Android Auto… have been in the works for about 3 years, and you probably could have just hired a coder and completed a custom code in half the time… so we’re still waiting for that one too.

The Wait Is Over: The CorkSport Performance Intake Manifold Is Here

Can you believe we started this project back in 2012?

Yes, it’s been a long journey, and a few too many “two weeks”, only to find that more improvements were needed. We’ll be frank, this has been a challenging project to tackle, but we have prevailed. We have pushed past the challenges faced in manufacturing the complex design, and are proud to announce that we are ready to present you with the most complete solution for the Mazdaspeed 3 and Mazdaspeed 6 platform.

The CorkSport Intake Manifold is here for those of us wanting some more flow in our lives.

Our design focuses on performance without sacrificing OEM fitment or drivability. With equal flowing runners, higher flow than OE, and TMIC fitment, it truly is a complete solution to the OE intake manifold.

Fitment is huge when it comes down to large engine components like intake manifolds. While designing the CorkSport IM, we wanted to retain as many OE features and mounting locations as possible while maintaining neat and tidy packaging. By doing so, we were able to keep components such as the TMIC, OEM throttle body, MAP Sensor, and even the oil dipstick bracket in OE locations. This all means a relatively quick and easy part to install, but we made it even easier by clearing some space around hard-to-reach areas.

The CorkSport Intake Manifold may fit like OE, but that’s where the similarities end.

The CorkSport Mazdaspeed Intake Manifold is designed with performance and drive-ability in mind, with the larger plenum design and long cylinder runners. Since the intake plenum is about three times larger than OE, there is an increase in high RPM power capacity without sacrificing throttle response and drivability. By maintaining the length of the cylinder runners (vs the typical aftermarket intake manifold), we improved mid-range power while still having peak RPM capacity with the single runner design vs. an OE split runner design.

The increase in performance also comes with an increase in engine health.

By optimizing the design for equal flow between runners, the CorkSport IM eliminates the flow imbalance of the OE intake manifold. This significant imbalance causes cylinders to run excessively lean or rich, affecting engine durability and performance. Check out the graph below to see the difference. Not only does the CorkSport Intake Manifold outflow the OE design by 70CFM per runner on average, but also significantly reduces the flow imbalance to 2% or less vs the OE imbalance of 21%.

This means your engine can run stronger, longer, and have a higher potential to make power.

But enough talk about numbers and flow, let’s SEE some numbers. The dyno graph below shows the difference before and after the CS IM on a Mazdaspeed3 with a CorkSport TD05H-18G turbo equipped. Not only was there an increase in power and torque across the entire RPM range, the turbo spooled around 100RPM faster than with the OE intake manifold.

But wait there’s more! Along with the overall design improvement over OE; there are additional design features that you need to know about.

  • Firstly, we increased the size of the throttle body opening. This allows the OE throttle body to work great but also allows for a larger throttle body to be installed without modification.
  • Next there are added fueling ports for each runner. They are standard 1/8-27 NPT ports that can be used with methanol nozzles or other fueling options.
  • Finally there is an extra 1/8-27 NPT port that can be used for boost controllers, gauges, or the like.

Now you may be thinking, “But there aren’t any larger throttle bodies available.” To that we say, “Not just YET!”

Along with the great features of this new Performance Intake Manifold, we are also providing nearly all of the hardware you need for installation; that is, the brass fittings that come pre-installed on the intake manifold and the additional hardware and hoses needed for auxiliary components.

Now we would like to circle back to where we started with this conversation:

We here at CorkSport pride ourselves in doing everything in our power to provide you, our customers, with the best possible products out there. We also are committed to being real with you guy as well, because we too are Mazda-lovers who get a thrill out of overcoming the toughest challenges that stand between us and the ultimate car experience.

The most challenging aspect of this project has been getting the manufacturing to an acceptable quality, and consistent among each intake manifold. We have tested the intake manifold on multiple cars in-house and with various beta testers, the results speak for themselves: this is an exceptional performance product that your Mazdaspeed will love to have.

Believe us when we say that this design is tough to manufacture,  and that process results in no two parts being exactly the same visually; but it also means that each manifold has its own unique look and character, the same way our cars do.

We guarantee that the CorkSport Intake Manifold will give you the best performance out there, but if for whatever reason you’re not satisfied with the unique look of your IM, please contact us and we’ll be more than happy to take care of you like we always do. – We’ve got your back!

That being said, if you’re looking to take your Mazdaspeed to the next level in both speed and reliability, the CorkSport Intake Manifold is the best comprehensive solution on the market.

These babies are only available while supplies last, so don’t wait, they’ll be gone before you know it!

Order 2007-2013 Mazdaspeed 3 & 6 Intake Manifold

 

Is Your Chick Flappy? – Mazda 3/MS3 Mud Flaps

Merry Christmas CorkSport family!!

Oh wait, it’s not December. It sure can feel like it sometimes when you are getting more and more parts in the mail. Am I right?

So let’s get down to business here.

This will be the one and only time you hear me say that your side chick needs to be MORE FLAPPY! If you want to protect her skirts, and booty, then making her flappy is a definite must.

CorkSport is proud to announce that we are bringing back our 2010-2013 Mazda 3/MS3 Mud Flaps by popular demand. Ask and you shall receive!

Made from 80 durometer urethane, these 1/8” thick flaps will protect all of your painted surfaces, and result in a cleaner rear hatch.

How does this really affect you? Well, have you ever tried wiping without toilet paper? I can tell you that it can be a tad bit messy. Go ahead and skip the dirty booty by adding these to your Mazda 3/Mazdaspeed 3. 2010-2013 Mazda 3 & MS3 Mud Flaps (Set of 4)

A few extra tidbits about the mud flaps:
  • Durable 80A 1/8” thick polyurethane.
  • CorkSport logo laser etched into the mud flap.
  • 2-year limited warranty.
  • $119.99 for all four mud flaps.

These are a must-have if you are trying to increase style while still being functional. I can tell you that these definitely help to keep the rear hatch cleaner makes it easier to keep the entire car cleaner for longer periods of time.

Don’t forget to check out our CorkSport 7th Gear Membership while you are buying these for your “woman”.

Cheers,

Luke

The CorkSport Night Ride Sweepstakes

You’ve heard about our Night Ride Sweepstakes, right?

Upload one little photo of your Mazda at night, and you’ll be entered to win our LED light kit for the 2010-2013 Mazdaspeed 3 and Mazda 3?

LED Light Kit Mazdaspeed 3

We thought so, because we’ve seen almost 150 of your rides at night, most of them in the first 24 hours of the sweepstakes. We’re thrilled, because we love seeing Mazdas lit up on the road after dark — and we know you like taking night pics, because we’ve been seeing them tagged with #CorkSport for years.

Well, now’s the time to take advantage of all that photography, and enter your night ride to win if you haven’t yet! The winner’s chosen at random, so you’ll have as good a chance as anyone if you enter today.

Just remember to hurry up. We’re picking a winner from one of these gorgeous entries on Monday, October 19:

Night Ride Sweepstakes

And hey: Don’t worry about those votes. If you missed the rules and didn’t catch that random part, they won’t affect your chances of winning, just of being featured at the tip top of the contest page.

 

Cheers,

CorkSport