The Dangers of Direct Injection

Caring for your Mazda DISI engine

Direct injection engines are nothing new… for diesel lovers. The application of direct injection in gasoline engines in large volume is a much newer feat however. As far back as 1902, manufacturers have tried to inject gasoline directly into the cylinder, companies such as: Mercedes, Ford, AMC and many others all tried to perfect the technology. Ironically, the first company to roll out gasoline direct injection cars en mass was Mitsubishi. The long story short version is now most manufacturers offer a direct injection engine or many. The technology is extremely versatile in adding power, improving gas mileage, fine tuning and in many other areas.
Mazda DISI engine
Who Cares?
So with all the hoopla surrounding direct injection technology why isn’t it in every car? Well, there are a few reasons.
1. Technology is expensive, DI engines require new heads, cams, and many more additional pieces of equipment.
2. The process is proven but un-proven.
3. Change, many auto companies can be slow to adopt newer technology.

With DI engines being the future, why are we talking about them? Well, there are certain problems that many are seeing as a direct result of this technology. The main issue revolves around the intake and the intake valves. In traditional engines, fuel is sprayed outside the combustion chamber into the intake manifold and passes the valves on the way to the chamber. The detergents in modern gasoline help clean the intake tract and the valves and can help prevent deposits left from debris or from the EGR system. With direct injection technology, the injector is directly in the combustion chamber and the gas does nothing but get instantly atomized and ignited. As such, we are seeing common failures in DI engines, there are two key steps you can take to prevent these build ups and increase the power and longevity of your engine.
The first is quality oil. With any modern engine, we recommend a synthetic oil. The benefits far outweigh the costs and in many cases you can actually save money in the long run with longer oil change intervals and fewer mechanical issues as a result of the better protection.
CorkSport Mazda DISI engine oilWhy Oil Matters

All synthetic oils are not created equal. Here in America we are at a disadvantage as to knowing what oils are synthetic and which are not. Due to a loophole in regulations and advertising, companies in America can advertise their group 3 oils (which start life as gasoline and are turned to liquid via hydrocracking) as fully synthetic. Many of these oils such as Royal Purple, Castrol Syntec, Mobil 1 cannot be called synthetic in other parts of the world where these things are taken much more seriously. As such, we recommend group 4 and group 5 oils exclusively. Many oils like Redline, ELF (Total), Amsoil, Torco, and Castrol formulations from Europe are all good examples of this. These oils are so important that every Volkswagen company (VW, Audi, Porsche, Bentley, Lamborghini, etc.) REQUIRE their dealerships to use them exclusively. So when in doubt, you can always have your oil changed at one of those dealerships to make sure you are getting the best quality oil.

What You Can Do
The second way you can care for your direct injected engine is to use an oil catch can. Modern engines have to use EGR systems. EGR stands for exhaust gas recirculation. The basic purpose of EGR is to reduce nitrogen oxide emissions and it works by recirculating a portion of the engines exhaust gas back into the intake to be “burned” again. The unfortunate byproduct of this set up is that many of the things in your exhaust you do not want going in your engine. Unburned gas vapor, burned oil vapor, water contaminated with other different chemical compounds are just a few of the terrible things EGR can introduce back into your engine.
CorkSport Mazdaspeed 6 oil catch can
With the installation of an oil catch can, you can capture many of those contaminates and dispose of them before they ever get to the engine you’ve spent so much money on. The gains are easy to see every time you empty it.

So there you have it; to keep your DISI Mazda running strong and trouble free, follow those simple tips and you’ll have a long and happy life together.

Product Release! CorkSport Mazdaspeed 3 and Mazdaspeed 6 High Performance Brake Pads

After many months of testing and development, CorkSport is happy to announce the release of our all-new CorkSport Front and Rear Brake Pads for the Mazdaspeed 3 and Front Brake Pads for the Mazdaspeed 6!

Designed using a proprietary semi-metallic and ceramic formula, CorkSport brake pads offer superior stopping capability without compromising wear and unlike other metallic brake pads on the market, do not require a “warm-up” period to perform to their full potential.

The CorkSport brake pads are a low dust solution that will help to keep your wheels nice and clean and this highly durable compound provides less fade on your brake pads. Made for superior performance in all weather conditions, the CorkSport brake pads have been thoroughly tested for endurance and braking power both on and off the track.

“Upgrading your brake pads will provide performance improvements for your Mazdaspeed and added safety for your vehicle.” Said CorkSport owner and race car driver, Derrick Ambrose “Having driven on these pads extensively on the track, I can say without a doubt that you will notice improved stopping performance and braking responsiveness with CorkSport brake pads on your vehicle”

The CorkSport Brake Pads come in sets for fronts and for rears and are priced competitively.

CorkSport brake pads are warrantied against all defects from workmanship and materials and come with full-color installation instructions, all of the needed installation hardware, and knowledgeable telephone installation support.

Visit our online catalog for more information or to purchase today.

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Adjustable Mazda 2 Struts and Shocks at Last! Pre-Sale Now On!!

CorkSport is happy to announce the pre-sale of our highly anticipated CorkSport Adjustable Struts and Shocks for the Mazda 2! For those of you that have been following development of our strut and shock kit for the Mazda 2 on Mazdas247, the time has finally arrived for our pre-sale!

The CorkSport Mazda 2 Struts and Shocks are 15 way adjustable with the #1 setting similar to the OEM ride. This will allow you to customize your ride to your driving style and limit body roll to make your car more predictable and stable even without the addition of lowering springs.

CorkSport Shocks and Struts are made with gas charged twin tube shock absorbers to allow the shock to react faster and more predictably, for a quicker response time and will help to keep the tire firmly planted on the road. You will have the ability to change both rebound and compression damping simultaneously for greatly improved ride quality. This variable tuning range makes it possible to use for daily driving, B-Spec, and auto-crossing.

As an added bonus, the CorkSport Mazda 2 Struts and Shocks can be paired with the Mazda 2 H&R Lowering Springs for an additional 10% savings on the springs!

All pre-purchases will be charged at time of purchase and will ship the week of January 7th, 2013. If you plan to order other parts when you make this purchase, they will be shipped at the time the struts and shocks do, so if you want other parts sooner, place it as a separate order.

For more information or to purchase today, please visit this product listing in the CorkSport catalog at https://www.corksport.com/mazda-2-shocks-and-struts-by-corksport-performance.html

Gwynne-

Tuning Q&A by Rob Finkle

Mazdaspeed 3 CorkSport

The Mazdaspeed platform includes a large demographic. From drivers who just got their license to career engineers who personally help to understand the ecu coding.

Today, I will be answering some basic questions about ECU tuning. This will help to explain the benefits of tuning and sort out some jargon and acronyms used for some of the newer people to modding who may be interested in custom maps and tuning.

What is custom tuning/what does ECU remapping do?

Ecu remapping, a.k.a. tuning are terms used to describe the process of making changes to the instructions that a car’s brain (Engine Control Unit) follows.

Remapping / tuning alters the variables that control the way the car behaves under a variety of conditions, including startup, idle, part throttle and WOT (wide open throttle).

To “remap” a car, different platforms use different software to communicate and alter the directions the ecu follows in order to meet the tuner’s goals. The most dominant and reliable software for the Mazdaspeed platform is made by either COBB or Versatune.

Why would you want to tune your vehicle?

When Mazda engineers tuned the factory variables, they were concerned with many more goals than enthusiasts. The engineers at Mazda know that each of the Mazdaspeeds that leave their manufacturing plant will be used in a variety of weather conditions, under a variety of user demands, and must be repaired under warranty if parts prematurely fail. Mazda is also heavily concerned with emissions, gas mileage and tries to balance the stock map they create with performance and reliability.

The enthusiast usually sees performance as the most important goal, while weighting reliability, gas mileage and emissions much lower in terms of importance. If you want to maximize the performance of a car, especially a factory turbocharged vehicle, many “nannies” or electronic performance limitations need to be removed and overly conservative measures taken in a stock map can usually be maximized to make substantial gains in horsepower and torque.

Who should tune their vehicle?

This is an interesting question, because I think I share an opinion with many people familiar with Mazda’s stock mapping that both reliability and performance can be increased with a well thought out tune. In my opinion, if budget allows, anyone who owns a Mazdaspeed can benefit from a custom tune.

What gains can be expected?

While every car is different across the Mazdaspeed platform, in general, if the 93 octane gasoline in your area is of decent quality, a stock Mazdaspeed usually has about 240 hp / 260-280 tq at the wheels.  On an OTS (off the shelf map), cars with an upgraded fuel pump and common modifications usually make roughly 270 hp / 300 tq at the wheels.

  • Custom tuned cars usually dyno in the area of 300 whp, 330-350 tq.
  • Custom tuned cars running e85 usually make 320-330 whp and 350-375 wtq.

What is the benefit to a custom tune vs. a chip or power programmer?

Much like Mazda engineers, creators of maps included on custom programmers such as hypertech etc. are responsible for making maps that will run well in all weather conditions, at all altitudes and with many different combinations of hard part modifications. A custom tune on the other hand can take full advantage of every condition and every modification that the car will be subject to, as well as allow the owner of the tune to communicate with the tuner his wants.

Custom tuners on the Mazdaspeed platform can tune the car to perform and feel just about any way the owner wants. Boost onset, boost level, boost level per gear, engine idle speed and pedal feel all can be customized per the owner’s preference.

What are the adjustable parameters?

When utilizing the COBB Accessport or Versatune, just about every aspect of the driving experience can be customized.

At present, tuners have access to the necessary tables to customize idle speed, boost levels, drive-by-wire interpretation by the ECU, air fuel ratios, ignition, and variable valve timing… you name it, it likely can be altered from stock form.

Does it have an effect on your warranty/Hidden costs and drawbacks?

This is a fuzzy question in terms of the relationship to reliability and warranty. As discussed above, I’d argue that a well-tuned Mazdaspeed will be more reliable than one that is running the “canned” Mazda map due to the ability of the tuner to customize a map for driving style, altitude, etc., as well as fuel the car with a performance bias vs. fuel economy.

As far as the Mazda warranty is concerned, the tune is not usually the point of contention with Mazda, as most warranty rejection is due to installed hard parts (which can be uninstalled before dealer visits). In short, after returning the stock ROM onto the ecu, Cobb suggests that the Mazda techs can only tell the ecu has been reset if there are a limited number of miles put on the car since the last reflash.

If you are a Mazdaspeed enthusiast in search for more horsepower for your Mazdaspeed, a custom tune will provide excellent gains for your money.  Having had many factory turbocharged cars before my Mazdaspeed3, I believe that a custom tune is one of the best bangs for your-buck modification that can be done from a performance-per-dollar standpoint.

I’m forever on msf, so if you have questions, feel free to pm me. If I don’t know the answer, I’ll do my best to help you find it.

-Rob Finkle
Username rfinkle2 on Mazdaspeedforums.org

Project Mazdaspeed 3 Update!

It has been awhile since we provided an update on the shop Mazdaspeed 3. Because we are in a constant state of development for Mazdaspeed 3 parts, our shop car always has parts moving on and off it.

We recently took the speed3 back to stock in order to baseline it on our new dyno. We have been building the car back out again with bolt ons to determine what our max power is on the stock turbo. The car is efficient enough that it can only run 18psi at redline and makes slightly more power at less boost which is interesting see on the dyno. For the final tune, we are running 26psi tapering to 17psi by redline. The peak torque is up 100ft.lbs over stock and really comes on hard. Overall we have seen a 36% increase in peak power and 50% increase in peak torque.

The next thing to do is figure out where the factory injectors die off. With only bolt-ons we are at 85% duty cycle to keep the air/fuel ratio in the 11 to 1 range. Generally a good rule of thumb is to not go over 85% so I can see a huge need for aftermarket injectors or a secondary fuel system.

As for the suspension, not only does the car run our coilovers, camber arms, prototype toe arms, front and rear swaybars, front and rear endlinks, and a few other braces but also some upcoming suspension components that include motor mounts and some others we will be announcing in the coming months.

With the power up and the handling on point, we needed to address stopping. We are currently using our prototype brake pads on the Mazdaspeed 3 and our Mazda 2. We went with a compound that is made for the daily driver. They don’t have to be heated up to work very well, will last longer, and stop better than the factory pads. They also dust less which is nice if you like keeping your wheels clean.

The interior is getting a prototype shift knob that should have come from the factory. How many times have you thought that the mazdaspeed3 or mazdaspeed6 shift knob just doesn’t match the rest of the red and black interior? After running a few aftermarket knobs, my biggest complaint was that most of them are made from machined aluminum. Aluminum is not only lighter than the factory weighted knob which makes shifting harder but the first time you grab a metal shift knob on a hot summers day and your skin is on fire you will never forget it. Proper shift knobs should be wrapped and weighted which ours will be and made to compliment the interior styling of the vehicle. Other than that the interior has not much changed.

The exterior is back to having the AutoEXE front bumper and is about ½” lower than it was last year which really shows off the 19” Advan RZ wheels.

Current mods:
Engine and Drivetrain
CorkSport Stage II Short Ram Intake
CorkSport FMIC for SRI Kit
CorkSport Cat Back Exhaust
CorkSport Catted Downpipe
CorkSport Silicone Radiator Hose Set
CorkSport Aluminum Skidplate
CorkSport Oil Catch Can

Suspension
CorkSport Adjustable Rear Swaybar
CorkSport Front Swaybar
CorkSport Coilovers
CorkSport Lower Tie Bar
CorkSport Trunk brace set
CorkSport Shifter Base Bushings
CorkSport Front Adjustable End Links
CorkSport Rear Camber Adjusters
CorkSport Braided Brake Lines
CorkSport Rear Adjustable Endlinks

Interior/Exterior Styling
CorkSport LED Light Kit
CorkSport Stub Antenna
CorkSport License Plate Frame
CorkSport Mud Flaps
J-Spec LED Tail Lights
CorkSport License Plate Relocation Kit
AutoExe Front Bumper
Advan RZ 19×8.5 wheels
Yokohama S-drive 235/35/19 tires

In Prototype
CorkSport Transmission Motor Mount
CorkSport Rear Motor Mount
CorkSport Rear Toe Adjusters
CorkSport Aluminum Coolant Expansion Tank
CorkSport Front/Rear Brake Pads

Brydon-