Tag: engine

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MZR DISI Injector Seals – The Correct Seal for YOUR Mazdaspeed

Many years ago we helped bring a revolutionary design to the Mazdaspeed community.  Fast forward 4+ years and you’ll find that the CorkSport Mazdaspeed Injector Seals are still the best option for your Mazdaspeed.  

Recently, we had a customer ship their stock block engine core to us for a fresh Dankai 2 Built Block.  During the engine core tear-down and inspection, we found a set of CorkSport Injector Seals installed.  We realized this was a great opportunity to share what we found with the community.

When the CorkSport Injector Seals arrive at your door they look like this:

Mazaspeed 3/6 Injector Seals

Brand new and fresh of the lathe with all of their beryllium copper brilliance.  After many thousands of miles of use and abuse, they look like this:

Durable Long Lasting Madaspeed Injector seals

Now to the untrained eye you may think they look bad, but the truth is they look fantastic!  The visible top of the seal has a small amount of carbon deposits present. This is to be expected because this surface is exposed to the combustion chamber.  Moving to the side of the seal you can see a distinct clean edge and no carbon deposits on the sides of the seal. This distinct clean edge is where the exterior of the seal is designed to seal in the cylinder head.  This is awesome!

Now let’s look at the inside of the used seals:

How the Injector seals look after use on Madaspeed

Again we see carbon deposits, but they are in and only in the expected locations.  Moving up the side of the seal you can see a “shelf” or “step” that is clean. This is the edge that the fuel injector seals against. Beyond that the inside of the seal is clean.

From this inspection, we can see that the injector seal was functioning as designed and doing its job effectively.  

So you might be asking…”What is so special about this design?” Well, we wrote a two-part design blog answering that exactly.  We highly suggest spending the 10 minutes to read these.

Injector Seals Design Part 1

Injector Seals Design Part 2

This is exactly why every single CorkSport Dankai Built Long Block includes a set of CS Mazdaspeed Injector Seals, but if you’re not looking for a built block but still want the assurance of the CS Seals you can check them out right here.  The install of the seal can be a bit tricky sometimes, especially getting dirty injectors out of the cylinder head.  Because of that we’ve developed an injector puller tool that makes the job MUCH easier.  

We hope you enjoyed this quick tech inspection of the injector seals!  Thanks for tuning in with CorkSport Mazda Performance.

Stay up-to-date on the latest news and product updates from CorkSport.

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600hp Mazdaspeed 3 Build Path – CorkSport Barett’s 2009 Mazdaspeed

If you haven’t heard already, the CorkSport Dyno Day and Summer Event was a blast with food, friends, raffles, a Show-N-Shine, and the continuous string of dyno runs.  The highlight of the dyno runs came when one of the CorkSport Engineers, Barett, put his car on the rollers.  With a few minutes of warm up and anticipation building, it was finally time to see what the “CorkSport Speed” could do. 

600+ WHP Mazdaspeed 3 on Dyno

Getting past the ecstatic crowd to see the dyno screen showed an impressive 620whp/530wtq.  Now, whether you were at the show or not, you may be wondering what Barett’s setup is to support these numbers.  It’s not a short list but is simpler than you would expect. 

In this blog, we are going to layout the WHOLE build to show you how your Mazdaspeed can make 600+whp.  

Dynograph data of Maszdaspeed 3 625 WHP

The engine was built by CorkSport in preparation for setting up the Dankai Engine Program.  It features Manley Connecting Rods and Platinum Pistons, head work very similar to the Dankai 2 Built Longblock, along with the CS BSD (balance shaft delete) and CorkSport Camshafts.  Holding the block together are L19 head studs and ARP 2000 main studs.  

To get the air in and out of the engine efficiently we have an assortment of bolt-on parts and some prototype parts because what kind of CorkSport R&D car wouldn’t have some prototype performance parts on it?  To break this down in the simplest way possible we have laid out a full build list:

600hp Mazdaspeed 3 Build List:

  • CorkSport Built Engine:
    • Manley Pistons – 0.5mm overbore @ 88mm
    • Manley H-Beam Connecting Rods
    • CS Balance Shaft Delete
    • “Dankai 2” Ported Headed: Single Runner Intake, Bowl Work, Combustion Chamber Touch Up, Exhaust Porting
    • CS Camshafts
    • Stock Valve Springs (We would recommend upgrading these and plan to do so ourselves)

Now, this isn’t the complete list, but it does lay out most of the essential parts to get your Mazdaspeed 3 over 600whp.  You might have picked out a couple “prototype” mentions in that list above…well we can share a bit on the new CorkSport Mazdaspeed Turbo.  You’ve seen the power it can make…and it still has some more left in it up top, now check it out some sexy billet and massive turbine.

Mazdaspeed 3 Turbo for making 600 WHP
Mazdaspeed 3 Turbo Turbine Closeup for 600+ WHP

Lastly, none of this power would be possible without the fuel to support it.  As you may know already, the OE direct injection fuel system taps out around 380whp on an efficient build so how do we make another 240whp?  Auxiliary fueling is the key my friends, and we recently posted a blog to help you explore Methanol Auxiliary Fueling that I invite you to read.  To stay focused on Barett’s 600+whp build we have made an auxiliary fueling build list below:

Upgrade Your Turbo with the CST4

Methanol Auxiliary Fueling 600hp Mazdaspeed Build List:

  • AEM Boost Based Pump Controller
  • Snow Performance 5 Gallon Cell Trunk Mounted w/CS Prototype Mounting Bracket
  • AEM 80 micron in-line filter pre-pump
  • ProMeth 220psi Pump (Essential for flowing this volume of methanol)
  • Snow Performance Solenoid
  • Devil’s Own 1in/4out distribution block
  • 4x Devil’s Own 90degree nozzle holders
  • 4x ProMeth Compact Check Valves (Essential for proper AFR control between shifts)
  • 4x Devil’s Own D07 Nozzles (One per intake manifold runner; each flowing ~10gph)

Despite that this auxiliary fuel setup is providing the fuel required to support just over 600whp; it is at the ragged edge of what can be supported.  Looking at the dyno graph further up you can see torque decline after 6000rpm and horsepower go flat. This is due to the auxiliary fuel system reaching its maximum fueling capacity and thus forcing us to reduce boost pressure as engine RPM goes past 6000rpm.  

At this power level, true port injection auxiliary fueling is the correct step to take.  Lucky for you guys and gals, we are currently exploring this path with our product R&D. We plan to give you guys and gals a full breakdown of our experience and how we built a full port injection auxiliary fuel system that can support over 600whp.  

AND…I forgot to mention one very critical aspect of this entire build.  Professional Tuning! This specific build was E-Tuned on the CorkSport in-house dyno by Dale Owen of Gem Tuning.  E-Tuning is a great way to set up your car with the tuner that is the best suited for your platform and vehicle build because it doesn’t require the tuner and the vehicle to be in the same place at the same time.  

Hang tight for more on the PI Auxiliary Fueling and thanks for tuning in with CorkSport Performance.

-Barett @ CS

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CorkSport Built Engine

CorkSport Built Long Blocks for the 2006-2013 DISI MZR

You’ve probably seen the stellar videos posted on our news feed or heard the rumors about CorkSport building stout long blocks for our employee’s Mazdaspeeds and the company R&D Mazdapeed.  Today, we are ready to let the “cat out of the bag.”

CorkSport is building long blocks for your Mazdaspeed and here’s why it will interest you:

We have complete long-blocks ready for installation with blueprint certificates. These long-blocks are in-stock and are ready to ship. If you’d rather send us your motor, we guarantee one month or less turnaround.  

Let’s check it out:

Every engine is meticulously inspected and measured to extremely precise tolerances per our ASE certified master technicians.  Critical surfaces are measured to the 0.0005” for the pistons, bearings, and camshafts to create a tight, powerful, and reliable engine setup that you can depend on. To support this, every engine comes with a blueprint certificate to confirm all critical tolerances in your engine.

Better yet, this precision doesn’t come with at the cost of a  3-6 month wait. We intend to have these motors in stock. Even if you send us yours for a rebuild, we guarantee we will have your engine ready to ship faster than the industry standard! 

No bull pricing means you get exactly what we list out here.  

At no point will you get a call from CorkSport stating extra work or cost is needed to get your engine complete and ready for you.  We’ve all been through this; starting a build with one budget and ending with a different, much larger, budget. We hate it and we won’t let it happen to you.  

Other than the block and cylinder head themselves; all the parts going into your build are brand new, not reconditioned or re-used.  This includes genuine OEM Mazda components; Manley connecting rods and Mahle pistons, ARP fasteners (specifications depend on Dankai Build), along with CorkSport Camshafts, Injector Seals, and other supporting parts.  

Finally, what good is all this if your engine can’t get back to you safe and secure?  

We want your new built block to arrive for delivery without issue, that’s why we use heavy duty sealed plastic crates that are designed to ship engines.  This provides ample mounting and restraining of the engine block in the upright position for easy access for you. Along with that your engine ships free of charge within the lower 48 states.  Just return your good engine core in the provided crate and get the core charges refunded.  

This sounds pretty great, right?  If you’re thinking about a built engine for your Mazdaspeed, then I invite you to check on the CorkSport Dankai Engine Builds to see which version fits your goals and desires.  

-Barett @ CS

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CorkSport Coolant Temperature Gauge

Another Gauge added to the CorkSport Lineup!

We are proud to announce the new CorkSport Coolant Temperature Gauge. It uses the same components and materials as all our other gauges so you can be sure that it will look good. Matching your existing CorkSport Mazda gauges, and most importantly, clearly and accurately provide you with the engine monitoring you want.

As with our other gauges, the CS Coolant Temp Gauge is designed to be good looking and easy to read. By using a simple and clear design, a quick glance at the gauge is all you need to know exactly what temperature your engine’s coolant is at. The gauge face is backlit with two color options to match your OE gauges, interior, and any other aftermarket gauges you may have. You can even wire the gauge to have a “night mode” where the backlighting changes to a different color once you turn your headlights on.

Don’t let the good looks fool you, it is still a very accurate gauge. A 270° stepper motor is used within the gauge to provide rapid response and precise readings. The stepper motor also allows for more of the gauge to be an actual dial for even more added clarity. Finally, the appropriate sensor and wiring you need to install the gauge are included to ensure the gauge is displaying the correct value.

Since the stepper motor needs a small logic board to control it, we are able to pack a few extra features in with the gauge. There is a programmable maximum limit that when reached, that has audio and visual warnings. This means no more risk of overheating while out on the track as your CorkSport Coolant Temp Gauge will be blinking and beeping up a storm. You can also keep track of the maximum temperature reached while out on the track or after a spirited drive using the gauge’s peak recall feature.

The CorkSport Coolant Temperature Gauge is a great mod to help you monitor your engine. Whether you are lacking a coolant gauge from the factory or simply want a number to go with your existing reading, the CS Temp Gauge has the accuracy, reliability, and looks you want.

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New Products for the 2007 – 2009 Mazdaspeed 3

We have been listening and they are finally here. The CorkSport Hood Strut Kits for the 2007 – 2009 Mazdaspeed 3.

While working on your Mazdaspeed 3 on those weekends when you are adding that performance upgrade you keep on running into the same problem, the hood prop is always in the way. It does its job of keeping the hood from falling on your head, but it is always difficult when working in the engine compartment. CorkSports hood strut kit cleans up your engine bay and makes it easier and safer to work on your Mazda.

Axe_8_700 Mazda3 hoodstrrut installed3

With an easy installation and no drilling necessary, this direct bolt-on, is the perfect next addition to your first generation Mazdaspeed 3.

Axe_8_700_Mazda3_hoodstru_installed3a

2007 – 2009 Mazdaspeed 3 Hood Strut Kit –