Oil Catch Can Kit for 2016+ SkyActiv Turbo 2.5L

Skyactiv Turbo OCC Kit

When you think of a performance aftermarket component you typically think of a part that increases the vehicle’s power, but some performance parts don’t. Instead they have a more critical purpose, increasing the reliability of your performance engine and components.  The CorkSport Oil Catch Can Kit (OCC Kit) is just that type of component(s). 

CNC machined Mazda Oil Catch Can

Why is an Oil Catch Can Kit critical for your Mazda?  Despite the huge advancement Gasoline Direct Injection (GDI) technology there are still some downfalls.  Compared to the more conventional port injection fuel systems, GDI is much more prone to engine oil fuel dilution.  This is primarily due GDI injecting directly into the cylinder; in low speed operation and cold starts the fuel simply does not have enough time to fully atomize into a gas before ignition.  This results in some excess fuel seeping past the piston rings into the oil along with any combustion chamber blow by the pistons.  This is fuel dilution. 

OCC catch all the nasty build up from entering your Mazda Skyactiv engine

Here you can see the results of a CorkSport OCC installed for ~3000 miles on a 2018 Mazda 6 2.5T.  This engine only has 500 miles and has an average commute of 15 miles & 20 minutes of mixed traffic and speeds. 

Mazda’s OE design attempts to resolve some of this with a valve cover breather that vents directly into the turbocharger compressor inlet and a PCV (Positive Crankcase Ventilation) valve in the engine block that vents to the intake manifold. 

How the Mazda OCC works

Mazda’s setup depends on the fuel and water vapor inside the crankcase being drawn into the intake manifold and intake system to then be re-ingested by the engine.  This has two major flaws:

  1. The direct crankcase ventilation via the PCV valve only works while cruising (no boost).  Combustion gas blow by will occur most often while in boost under high throttle application when the PCV valve is closed.
  2. This forces the engine to re-ingest dirty air that carries contaminants in the form of fuel and water vapor along with carbon debris.  These containments then build up on the inside of the intake manifold, cylinder head runners, and the intake valves slowly degrading performance over time. 
Carbon build up on a Mazda engine without the catch can

The CorkSport OCC Kit provides you with two major features:

  1. Both the valve cover vent and the PCV valve are drawn from the turbo inlet directly ahead of the turbocharger compressor. Thus both the valve cover and PCV valve have constant vacuum in all driving conditions, both cruising and high throttle application.
  2. The oil catch can itself acts as a “filter” for the vapor and debris that would normally be directly ingested by the engine. The drawn crankcase vapor and debris is separates and collects in the catch can for easy removal during normal oil changes. 

As you saw above, there is a significant amount of vapor and fine debris that is being filtered out of the crankcase air that would have normally been ingested.  As you continue down the path of modifying and demanding more form your Mazda, the need for a OCC System only becomes more and more critical. 

Bolt on Mazda Cx5, Cx9, and Mazda 6 turbo

Why Lowering Springs?

Whether you want the better handling that comes with the lowered center of gravity, or you want to rid yourself of the wheel gap eyesore.  Lowering springs will give you want you’re looking for.

For running the track, or a spirited drive through the countryside, CorkSport lowering springs are the upgrade you’ve been looking for. By adding lowering springs and lowering the center of gravity of your Mazda allows the car to stay more planted to the road.

One of the biggest things to note on stock suspension is how far upward the suspension travels when hitting a bump. It can make the car feel like it wants to lift off of the road; depending on how fast you’re taking corners. Lowering springs help to correct the car’s suspension travel when you hit a bump in a turn.

Corksport Mazda 3 racer

Lowering springs also have about 25% increased stiffness. For the Mazdaspeed platform, increased stiffness in the rear is a must. Mazdaspeeds like to squat pretty hard when hitting full boost, so any way you can manage to stiffen up the rear is a great modification for your car.

Adding lowering springs also gives your baby amazing eye appeal and a much more aggressive look. Whether you drive a Mazdaspeed3Mazdaspeed6Mazda 3, Mazda 6, CX-5, CX-3 or MX-5, lowering springs will get rid of that ugly wheel well gap. The result is a Mazda that carries a much cleaner and more aggressive look and gives you the ability to take it to the track if you want to.

Drop your Mazda for an aggressive look and better handling with the CorkSport lowering springs.

Some people want to drop their Mazda as much as possible, and some don’t. CorkSport lowering springs don’t deliver a super aggressive drop. If you’re not interested in scraping your front bumper on every road bump, the CorkSport lowering springs have the right drop for you, and provide the increased handling capabilities you’re looking for.

If you’re curious about other suspension pieces for your Mazdaspeed, check out our Struts and Shocks combo kits, that give you just what you need for suspension.

The Mazda 3 Rear Motor Mount 2.0: Back & Better

2014 Mazda 3 rear engine mount upgrade

We here at CorkSport are proud to announce the relaunch of the Mazda 3 Rear Motor Mount.

Yes, you read that correct, this is a re-launch. At CorkSport we push ourselves to design and develop new and interesting products every day, with that, we try new and innovative manufacturing designs and methods in an attempt to create exceptional, competitive, cost-effective products for our loyal customers.

Sometimes those new and innovative manufacturing methods end up not being as awesome as we originally expected. This is just part of the designing and learning process. Let’s get into the details.

The original, let’s call it V1, Mazda3 RMM used a new-to-us manufacturing method of applying the polyurethane to the billet aluminum body called vulcanizing. The billet aluminum body and the steel sleeves are mounted in a fixture then liquid polyurethane was poured into the assembly and cooled until the polyurethane had set to the final hardness.  This process appeared to be very promising; each part was set up identically, it was nearly impossible to have any missing parts not sent to you, and most importantly the polyurethane was adhered to the billet aluminum body and therefore could not fall out.  More on that last bit later.

We moved forward with the manufacturing method and had a few samples made with various polyurethane durometers ranging from 60A to 80A.  After various testing, we determined that 70A was the best compromise of response and NVH (Noise, Vibration, Harshness) experienced by the driver. We continued testing for a few months to verify long-term durability and found no issues.  Hooray! We moved forward with production to get this new great Mazda6 RMM out the door to you.

Unfortunately, it appears that our testing period just wasn’t quite long enough.  Eventually, the polyurethane would fail but fail in a style we had never experienced before.  Long story short, polyurethane has excellent compression strength compared to the tensile strength.  The polyurethane was being pulled/split apart due to the forces of the engine.  

Now we had a few options of how to redesign the Mazda 6 Rear Motor Mount after going through the failure analysis.  

  • We could have simply stuck with the same design and just increased the stiffness of the polyurethane.  Increasing the durometer rating of the poly increases the tensile strength, but this would have resulted in an unsatisfactory driving experience for you which was unacceptable.  
  • The other option was to start from scratch again to create a new design that did not compromise the driving experience or the durability; with challenge comes innovation.

Again we went through many different designs, with the greatest challenge coming in the form of retaining the polyurethane pucks.  Typically the polyurethane pucks are retained by whatever the mount is bolting to, but with the Mazda motor mount, the steel sleeves extend far past the outer edge of the polyurethane pucks.  This leaves the pucks free to slide out of the billet aluminum body and cause a major failure.  

Using the conventional polyurethane puck style, we developed a design that would work, but more than doubled the number of parts needed which increased the chance for something to go wrong and drives up the cost.  This design is shown below:

 

The red arrows show the direction the conventional polyurethane puck would slide out of the body.  The red circles show the puck retention system to hold the washer and pucks in the body.  This retention design required many parts to be successful.

With the cost going through the roof we had to go back to the drawing board. There had to be a better way… and there was.  

The third major iteration shown above solved the problems of the V2 design and got us away from the vulcanized polyurethane of the V1 design.  Things were looking good.  With the V3 design, the polyurethane pucks are pressed into the billet aluminum body.  The pucks have ribs, shown with the red circles that are just large enough to keep the puck in place, but small enough to let the puck be pressed into the body.  

With this, we were able to make some clever designs to the RMM to keep it centered in the engine and chassis brackets on the vehicle.  The smaller diameter puck extends out to the ends of the steel sleeves; this keeps the entire rear motor mount centered.  The large diameter puck retains itself in the body and allows the associated steel sleeve free to slide for easy installation; shown with the red arrows.

Now… does it work? YES! Pretty fantastically, we might add!  

We have had this design on a handful of vehicles, one of those being the CorkSport Mazda 3 Racecar during the SCCA Run-Offs at Indianapolis Speedway.  Other than some dirt and grime, the tested RMM looks great.  

You were probably expecting this blog to be all about the details and reasons you should buy this performance RMM for your Mazda 3, Mazda 6, or CX-5.  All those details can be found on our website, and I invite you to check them out.

What we really want to get across here is this:

First and foremost, we will always do the best we can to take care of you and your car if there is ever an issue or concern with your CorkSport part.  

Second, if you are a driving enthusiast, if you go driving for the sake of just driving, then you need this RMM in your life. It will completely change and improve your driving experience, plain and simple.  

-Barett, CS Engineering

 

Superior Stopping Power for your Mazda 3, Mazda 6 and Cx5 with our Big Brake Kit

After a long wait and a lot of testing, we’re proud to announce the launch of the CorkSport 4 Piston Big Brake Kit for the 2014+ Mazda 3 and Mazda 6, and the 2013+ Cx5.

Why upgrade your brakes to something of this level?

On our own 2015 Mazda 3 SCCA race car, we’ve found that even mildly increased power levels can burn up the stock brakes on the track. We melted the OEM dust boots off the stock calipers after two race weekends, which is not a good sign for the longevity of OEM components.

corksport-mazda-3-big-brake-kit

CNC machined from extremely lightweight billet aluminum, the CorkSport calipers use an opposed piston design that is fixed to provide highly improved pad wear and caliper rigidity over the OEM design. At just over 7lbs, the aluminum CorkSport Big Brake Kit shaves almost 7lbs of unsprung weight off each corner of your Mazda 3, all while adding more stopping power and a much better pedal feel.

Available in 3 anodized colors, this brake system includes everything you need to easily upgrade your stock braking system including: high strength steel brackets, calipers, slotted brake rotors, stainless steel braided front brake lines, brake pads, and all necessary hardware.

mazda-3-big-brake-kit-calipers

The 2014+ Mazda 3 Big Brake Kit has the following features:

  • Superior Construction: Crafted from billet aluminum and made to last with durable components.
  • Longevity: With dual O-rings far away from the brake pads, these calipers are able to handle much more abuse than typical dust boot equipped calipers.
  • Lightweight: At just over 7lbs a side, this kit saves almost 7lbs of unsprung weight per corner!
  • Versatile: Designed around a popular brake pad style (Hawk #HB750), you can use almost any brake pad compound available on the market.
  • Available in Three Colors: Choose from black, red or blue in a durable anodized finish.
  • Ease of Use: With simple hand tools you can change brake pads in minutes and you are able to rebuild, so you can be back to factory fresh brakes in no time.
  • CorkSport Service and Support: Receive full-color installation instructions, all of the needed installation hardware, and knowledgeable telephone support.

Mazda-3-Big-Brake-Kit-testing-700

The CorkSport 4 Piston Big Brake Kit is available at corksport.com, and is ready to ship now! For more information, visit our product listing here.

The New CorkSport Mazda 3 Rear Motor Mount

Feel like your SkyActiv-powered Mazda is lacking a bit of throttle response and driver feedback?

We hear you, that’s why we’re introducing the all new CorkSport Race Rear Motor Mount for 2014+ Mazda 3 and Mazda 6, as well as 2013+ Mazda CX-5.

CorkSport Mazda 3 Rear Motor Mount

Manufactured from 6061-T6 aluminum and anodized, the CorkSport Race RMM is strong, durable, and lightweight. What truly sets the CorkSport Race RMM apart from the competition goes to the 70a polyurethane. This RMM does not use polyurethane inserts that can loosen up and degrade. The 70a polyurethane is poured directly into the mount for a permanent bond with the aluminum body and bushing collar.

CorkSport Mazda 6 Rear Motor Mount

More than a handful of prototypes have been tested to ensure that the product arriving at your door is the very best it can be. We tested different durometer polyurethane from 60a to 80a (as well as different bushing sizes) to find the maximum improvement of throttle response and driver feedback without excessive noise, vibration, and harshness. Check out one of the prototypes below.

CorkSport Mazda CX-5 Rear Motor Mount

Now you might be thinking: “How does a motor mount improve throttle response and driver feedback?” In FWD vehicles it is typical for the engine to be oriented in a transverse layout. This means the engine is parallel to the axle centerline, whereas in a longitudinal layout (typical of V8’s and RWD vehicles) the engine is perpendicular to the axle centerline. Anyway, the engine/transmission applies a rotational force (torque) to the drive shafts, in turn rotating the wheels/tires forward.

“For every action there is an equal and opposite reaction.” – Newton’s third law of motion.

The amount of torque applied to the wheels is equal and opposite to what is applied to the engine itself, but what keeps the engine from just rotating? Enter the engine mounts. Unfortunately, the OEM engine mounts are very soft, so the engine is able to move and rotate substantially while driving. This makes for a very plush ride inside the cab, but sacrifices throttle response, driver feedback, and really the general driving experience. Replacing the RMM drastically reduces the amount of rotation the engine is allowed which in turn forces more of the engine’s torque to the tires sooner instead of just rotating the engine in the engine bay. This holds true for any action that affects the engine: throttle inputs, up-shifting, down-shifting…etc.

CorkSport Mazda 3 Rear Motor Mount

Improve your vehicle’s performance with the CorkSport Race RMM, and pair it up with the CorkSport Short Shift Plate and Shifter Bushings for the ultimate performance package!

-Barett, CS Engineering

Barett Strecker-01