CorkSport Mazdaspeed 6 Front Mount Intercooler

The MS6 FMIC installation gives you a stealth install with minor trimming and allows you to keep the windshield washer bottle.

It’s been a long time coming but it has finally returned: the CorkSport Front Mount Intercooler Kit for Mazdaspeed 6! We’ve had many challenges on this project but we’re happy to report that it’s finally here and better than ever. We originally released this way back in 2012 (check out the release blog HERE for a throwback) but the only thing we kept from that kit was the intercooler core itself. All of the piping, silicone, and mounting has been redesigned for best fitment and minimizing trimming needed for install. Check out the images and full info below!

Superior to the factory Mazdaspeed 6 TMIC, the CorkSport FMIC gives you consistent cooling all the time without heat soak

To start things off, let’s look into the intercooler itself. It is a unique design where both the inlet and outlet point toward the driver’s side of the vehicle. This means our pipe routing is a little more complicated than most, but it makes it much easier to fit as you do not need to relocate your windshield washer bottle or deal with any of the fitment issues that come with squeezing a pipe through the passenger side of the car.

The bolt in Mazdaspeed 6 FMIC kit which makes it the best intercooler kit available.

The intercooler core is a high flowing, bar and plate design that measures 21”x10”x3”. This is good for efficient flow up to 500-550WHP yet adds minimal boost lag, even at lower power/boost levels. This big core fits snugly behind the crashbar to eliminate trimming the crashbar or your underbody shields. There is still some trimming required to fit the core and piping, however almost all of it is trimming on plastic components, with one metal cut on a thin sheet metal bracket.

Mazdaspeed 6 FMIC fits up to a 4 inch SRI

Moving onto the piping, the CS intercooler kit uses varied piping sizes for the hot and cold side intercooler pipes. The 2.25” hot side pipe ensures the charge air reaches the intercooler as fast as possible, helping reduce boost lag. The cold side uses 2.5” piping in the first half and 3” piping in the second half. Having this large volume of cool charge air directly in front of the throttle body helps with throttle response and the large diameter further helps with peak flow capacity. This piping setup has proven itself to work great on our GEN2 MS3 FMIC kit, and has been pushed to 684WHP on Barett’s GEN1 (he modified the GEN2 piping to fit his GEN1).

Wire reinforces silicone hoses make the Speed 6 FMIC a quality product

There was painstaking care taken to ensure the kit is as easy as possible to fit on your MS6. The hot pipe has a lot more freedom for intake fitments than our previous kit and we made sure all the CS intakes fit like a glove. Other aftermarket intakes have not been test fit but check out the images, they will give you a good idea if your SRI will fit or not. All the piping is mandrel bent and comes in a polished finish, so it is ready to install right out of the box and look and perform great!

Keeping everything together is the custom designed silicone couplers. You may notice that some of the silicone sections are longer than a typical silicone coupler. This is to ensure the best fitment as some shapes can simply not be made easily in a piece of pipe.

As with most CS silicone components, each coupler uses 4-plys of nylon reinforcement braiding and 5 layers of silicone. This is typically very good at resisting expansion under high levels of boost; however, we wanted to really make sure the long couplers of the MS6 kit do not expand. Any coupler longer than about 6” uses an extra layer reinforcement made of metal wire. This further resists expansion under boost, and even helps keep all the piping stable between mounting locations. While the outside of the coupler may look bumpy, the insides are still very smooth like a typical piece of silicone.

A complete FMIC for the speed6, everything you need to install is included except the tools

Each Mazdaspeed 6 intercooler kit comes with everything you need for install. Stainless steel T-bolt clamps are included for each connection to ensure secure, leak free joints. The intercooler mounting bracket, hardware, and full color install instructions are also included so you know you can get the job done right.

The MS6 FMIC installation gives you a stealth install with minor trimming and allows you to keep the windshield washer bottle.

We’re happy to finally have this out and are excited to see you all get your hands on them. Be sure to drop any questions you may have below and check out the product listing for more images!

The CorkSport CST4 – The Best Turbo for the Mazdaspeed

How to get 400whp from your Mazdaspeed 3

Back in 2015, CorkSport announced the launch of the “CorkSport Turbo” or “CorkSport 18G” a high performance drop-in turbo upgrade for the MazdaSpeed 3, Mazdaspeed 6, and CX-7. Fast forward to 2020 this potent turbo is now called the CST4 with the introduction of the CorkSport CST5 and CST6 Turbochargers.

The CST4 has found home in thousands of community members Mazdaspeeds since launch and continues to be a highly sot after upgrade today…a testament to the CST4’s performance and durability. Starting from scratch, the CST4 is a 100% brand new performance unit.  No core, no revised K04 parts…this is a performance turbocharger from the ground up.  

A bolt on 400whp Mazdaspeed 3 bolt in turbo

Let’s recap on what makes the CST4 such a great fit for the MazdaSpeed.  A proven MHI journal bearing center section, these offer great cooling capabilities and fantastic reliability, especially when combined with our high performance journal bearings and 360° high performance thrust bearing. The CST4 can seriously take a beating, and does it in a package that fits perfect in the OEM location.

Mazdaspeed 3 Mitsubishi 18G CHRA

Attached to this center section is a compressor and turbine wheel combo that is a little unconventional. Creating boost is a custom MHI 18Gbillet compressor wheel that is rated at 50lb/min while the turbine that drives the CST4 is a MHI TD05H 9 blade design. Compared to a traditional 12 blade turbine wheel, the CorkSport design is lighter weight for faster spool times and less blades for higher maximum flow capacity.

Speed3 turbocharger high flow exhaust wheel

The wheels are wrapped in new housings. On the compressor side there is an OEM diameter inlet to simplify the installing with any intake system you had setup with your K04. The turbine housing maintains the stock flange design for easy fitment with any exhaust manifold and downpipe that bolted to the K04. 

The best mazdaspeed 3 turbo upgrade internal or external wastegate, better than the BNR S3.

So what’s the hype now?  Great question!  The community has pushed this turbo to the limits and has asked for more…with the development of the 500whp CST5 and 600whp CST6 we found that an EWG turbine housing can be very beneficial to boost control.  That development bleed over to the CST4 in the form of a EWG turbine housing for increase boost control and an increase in A/R size. 

Mazdaspeed 3 turbo upgrade dyno sheet

Like the CST5, you can now choose your boost control.  Internal wastegate for a stealth and simple install or go for the EWG turbine housing for extra noise and a little more top end power potential.  The choice is now yours. 

Mazdaspeed 3 EWG bolt on turbo kit

Now what does all of this tech mean for you and your car? If you have a stock block you can easily max out power (~380WHP depending on fuel and bolt-ons) and keep some of the K04 spool you love.  With professional tuning you can keep a safe tune that hits hard and carries power.

The wheel and housing options delivers great response as well as great power. When pushed to its limits on a built block, 20psi was hit at 3300-3400RPM with peak boost around 27-28psi carried to 7000rpm. Obviously this isn’t stable for a stock block but is possible on fully built cars with full bolt-ons and a high flowing head.

Mazdaspeed 3 Turbocharger installation hardware

Both the IWG and EWG options come with a full hardware kit that includes everything you need for install. This means all coolant/oil lines, new gaskets, new crush washers, and even new studs and crimp nuts for both the turbine and downpipe flanges. The EWG setup includes a custom designed elbow for great EWG actuator fitment on MS3 and MS6, and the correct clamp to attach it to the housing. More info to come later on an add-on screamer pipe option.

Bolt on Mazdaspeed 3 EWG dump tube kit

Each CST4 also comes with full CorkSport support, including full color install instructions, a 1-year warranty, and assistance with any questions you may have. We are extremely excited for you all to get your hands on the CST4 and start taking your FBO Mazdaspeed to the next level.  Check out the product listing for full details and to place to order.

Need More information? Check out our video below

2018+ Mazda6 Performance Exhaust for the 2018-up 2.5T

Mazda did a great job bringing a turbocharged engine back to the Mazda 6 (Mazda 3 next please?), but may have done too good of a job of keeping it quiet. Say hello to the CorkSport 80mm Cat Back Exhaust and Axle Back Exhaust for 2018+ Mazda6 equipped with the turbocharged 2.5L engine. If you’re interested in waking up your SkyActiv-T in both excitement and power, read on as we breakdown the newest CS exhaust.

As with all CorkSport exhausts, the goal of the MZ6 2.5T exhaust is to improve power and sound by improving the flow of the OEM exhaust. We started by increasing the size of the piping from 60mm to 80mm. That is an increase of over three-quarters of an inch to really help your turbocharger breathe better. In addition, the CS exhaust system eliminates the crushed areas present in the OEM exhaust and replaces the restrictive muffler sections with pass-through resonators. These resonators control volume and drone without affecting power output.

All that extra flow does mean a power increase. In our in-house dyno testing, we saw an increase in 5-6WHP just by bolting on the CorkSport  Cat Back Exhaust. Check out the dyno sheet down below to see. This increase came with no tuning changes, no check engine lights, and the only other mod being the CorkSport Short Ram Intake, which was installed for both tests. With the 80mm piping size, this exhaust is ready to support future modifications and would likely show more power gains with proper tuning.

The CorkSport MZ6T exhaust is more than just function. We went through multiple iterations and designs to ensure the best sounding exhaust for your 6. The finished product ups the volume without being annoying to daily drive yet still sounds great when in hard acceleration. We strongly recommend you watch the video below to hear what to expect from this exhaust.

If you feel the video below gives you too much volume for the daily, then check out the Axle Back Only Exhaust.  Recently added to the CorkSport line-up, the Axle Back alone adds a mellower, but still noticeable tone to the exhaust.  This is a great middle ground between the CorkSport Cat Back and the stock exhaust.

To give a great looking, long-lasting finish to each exhaust, they are manufactured from fully polished 304 stainless steel. To ensure a high quality fitment, all components are precision TIG welded together on jigs made from OEM exhaust components. Lastly as a finishing touch, we use 100mm dual wall exhaust tips. They fill out the bumper cutouts and are extended slightly to give a classy look and enhance the new Mazda 6’s styling.

The CS Mazda 6 Turbo Exhaust comes with all the hardware and gaskets you need for installation, high quality instructions, and CorkSport support for any questions you may have. Pick up a CorkSport MZ6 2.5T Exhaust today and liven up that daily commute.

Easy and Accurate Boost Readings: The CorkSport 4.5Bar MAP Sensor

Mazdaspeed 3 4.5 bar MAP sensor

We are proud to introduce the release of a new product: the CorkSport 4.5Bar MAP Sensor for Mazdaspeed 3, Mazdaspeed 6, and Mazda CX-7 Turbo. We’ve had the CS 3.5 Bar MAP Sensor for a while now as it’s a necessity when targeting over 21psi, however, while maxing out the CST6, we found the 35psi ceiling of the 3.5Bar sensor just wasn’t enough. Enter the CS 4.5Bar MAP Sensor!

Mazdaspeed 3 4.5 bar MAP sensor

Before I get into explaining what makes this sensor tick, lets quickly go over what exactly a MAP sensor does on your Mazdaspeed. Manifold absolute pressure (MAP) sensors in a nutshell just read the pressure present in the intake manifold of your car. During normal driving conditions, the sensor is typically reading vacuum (or negative pressure) as the engine sucks in air. While in boost, the sensor reads the positive pressure (boost pressure) produced by your turbocharger. In both situations, this pressure reading is being sent to the ECU so the ECU understands exactly what the engine is doing.

The OEM sensor is a 2.5Bar unit, meaning it can do 1Bar of vacuum (negative pressure) leaving you only 1.5Bar (~21psi) before the sensor runs out of accuracy. Both the CS MAP Sensors allow you to accurately read boost levels higher than the stock sensor, so your tuner can target a higher boost pressure for more power, provided you have the right supporting mods. The sensors themselves do not increase your boost pressure, they simply enable your tuner to safely do so.

Mazdaspeed 6 plug in 4.5 bar MAP sensor

Enough learning, let’s get into the 4.5Bar Sensor! The CorkSport 4.5Bar MAP Sensor can read a maximum boost pressure of ~48psi before it starts running out of accuracy. Having a huge potential boost pressure means nothing without a fast responding sensor, so we designed the CS 4.5Bar MAP Sensor to have near instantaneous response of only 2 milliseconds. This means if you have the build and turbocharger to do so, this sensor is ready for just about anything you want to throw at it.

A true plug in MAP sensor for your Mazdaspeed no adapter required

The CorkSport 4.5Bar MAP sensor uses a custom injection molded body that mimics the OEM sensor. This makes it a direct install into the OEM location and a direct plug into the OEM wiring harness. No wiring or adapter harness needed. This results in a clean install that takes as little as 15-30 minutes! 

Everything needed for installation is included with the CS 4.5Bar MAP sensor. A new mounting bolt is supplied to ensure everything stays put, while a fresh O-ring is attached to the sensor to provide a good seal in your intake manifold. To top it off, calibrating for the sensor is easy as the calibration for use with Cobb Accessport is laser etched right on the body of the sensor.

Speed3 3 bar MAP sensor

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