Motortrend recently published this Article in their magazine. If you can see it, the article states that Mazda is planning a Mazdaspeed 3 in 2016, they list the details that have been floating around for months, 2.5L Skyactiv, Turbo, 300hp, AWD….. tell us something new!
We just want to point out that this is old news. In fact we even quoted Motortrend quoting their “source” back at the start of November saying the exact same thing!
Check out the post that is almost word for word the same article:
Now before you get upset that we are just pointing fingers and saying “we said it first” I hope you realize that this is actually a good thing! The more that we share a rumor, and so does other reputable sources like Jalopnik, Motortrend, AutoNews and more, the more credibility it gets! I doubt that the rumors of AWD, 300hp and it being a MS3 are that unlikely when it seems everyone is reporting on them.
So, more props to you MotorTrend! We are right there with you and look forward to 2016, 2017 and all the new cars Mazda brings us!
Zoom-Zoom
New Mazdaspeeds? You Heard it Here First! January 6th, 2015CorkSport
We’re offering free ground shipping to our U.S. customers through Cyber Monday! This amounts to a pretty huge savings when you consider the cost of shipping heavy products.
International customers, no way we’re leaving you out. Enjoy $25 off your order of $150 or more through Monday!
Restrictions do apply, but they are few & far between.
If you haven’t already, be sure to check out the new parts we’ve launched over the last several weeks. With a stellar pair of new exhausts and an incredible intake system, there has never been a better time to customize your Mazda than this weekend.
This post is part 2 of a 2-part series on the importance of injector seals. If you’re just now discovering this post, be sure to tune in to part 1 before continuing here.
Like the title says, you need injector seals for your MZR! Here’s why.
When Mazda designs a part, they design it with the “typical” customer and OEM power in mind – not the power hungry, boost craving driver. Yeah, I’m talking about you and you know it – and we have just the thing to keep you and your MZR in check. As you add more fuel and more boost, the weakest link is eventually going to give. That link is the OEM injector seals.
Three Reasons You Need Injector Seals For Your Mazdaspeed
Reliability is sacrificed using the OEM seals.
Leaking seals causes loss of power.
Inconsistent performance is caused by leaks.
So, if you are just tuning in to our blog, then shame on you, go read part one like everyone else! With that, let’s dive into the design of the seal and how it works.
We put 500 hard miles on the Speed3 and here are the results. 500 miles may not sound like a lot, but the company owned MS3 does not live the normal life. It spends most of its time on the dyno testing new products pull after pull, may have hit 35psi, and when it does hit the streets, it’s driven by an employee searching for the governor speed. I think we can all agree that the 500 miles was a fair amount of abuse to put the injector seals. Plus, other sets of seals have been running in alpha testers vehicles for thousands of miles without issue.
Now that we have that covered, let’s talk a bit more about the design of the seal and how it works.
It’s no longer just a washer with one sealing surface – it’s a cup. So it seals in the OEM location AND along the side of the cup. The secret is in the design (which is all thanks to @Tokay444 from MazdaSpeedForums). The lip at the bottom of the cup is flared just a bit so that it crushes down tight against the cylinder head, and as it crushes down it also crushes outward, pushing against the wall of the port much like an O-ring. If you are having trouble visualizing the flared lip crushing outward then check out the image below. Time to get technical!
Looking at this side view of the seal, you can clearly see that the flared lip is extended further outward than the side of the seal. (Please note that in this FEA, or Finite Element Analysis, the deformation scale factor is 6.5:1, i.e. highly exaggerated). This design is what separates the CorkSport seal from any other seals on the market today. In the FEA the seal is subjected to 3300lbf in the direction of the arrows; 3300lbf is the approximate clamping force of an M8x1.25 torqued to 18ft-lb. The areas in red indicate a displacement of 0.0057 inches, which is just enough to begin yielding (permanently bending) the beryllium copper material. After the 500 miles of use, we had the four seals precision measured using a CMM (Coordinate Measuring Machine). On average, the seals yielded 0.0015 inches confirming our FEA.
Still following?
So what does this mean to you? When you torque down the fuel injector bolt and clamp you are applying approximately 3300lbf to the injector seal. This crushes the seal downward pushing the flared lip outward into the wall for ultimate sealing strength; and we have all the data to prove it! The CorkSport seal works flawlessly, but because of the design they are not reusable like any other crush seal.
So, now that we are done with all the technical stuff let’s take a look at the used seals. First, I would like to remind you what the injector looked like with the OEM crush washer and only 4000 miles.
Extremely dirty with an excessive amount of combustion gases blowing by the OEM injector seal. This makes for a very unhappy MZR. Second, in the images you are about to see, the seals have not been cleaned in any way, shape, or form. I pulled these out of the car and immediately took the pictures. Prepare to be WOW’d; I know I was…
Besides the clean injector body, there is a more subtle detail that needs to be pointed out. If you look at the very edge of the flared lip on the seal you will notice that the black soot does not go all the way to the edge. This further confirms that the seals are working the way Brock (@Tokay444 on MSF) had envisioned them and we can also see this “clean ring” in the cylinder head below.
In the image below you will notice that the seal is dirty on the inside, but that’s okay – that happens by design. The “shelf” that you see midway up on the inside of the seal seals against the injector body instead of in the OEM location further down around the injector nozzle. This change in sealing location allows the flared edge to deflect how it needs.
If I haven’t convinced you yet why you need injector seals for your Speed3 then you’re hopeless…you should go get a Civic or something else that’s slow…
Between our results and the reviews given to us from our alpha testers we have great confidence in the seals and you should too! Keep an eye out for these to be released very soon! Zoom – Zoom! -Barett, CS Engineering
Why You Need Injector Seals for your Mazdaspeed, Part 2 February 7th, 2019CorkSport
We talk a lot about the next Mazdaspeed, will it be AWD, will it be FWD, will it be a 3? the 6? a 2? Though little is known or confirmed, I want to point out a few things we DO know as a fact.
Mazda has been working on their SkyActiv D engines for a few years. They have already shown their SkyActiv D engines, they even race them. What many people fail to realize it that the SkyActiv D runs in the Mazda 6 with a two-stage turbocharger.
The two-stage turbocharger gives you the best of both worlds, it will run a smaller turbo in the low RPM range in order to give you more power and cut emissions, then at higher RPM ranges it flips a lever and runs the bigger turbo to produce more power with no noticeable lag between the two. According to Mazda’s own website “SKYACTIV-D utilizes a two-stage turbocharger in which one small and one large turbo are selectively operated according to driving conditions.” (Source)
What else do we know? Well, Mazda has been actively racing the SkyActiv D engines in several endurance races. This is a mildly modified version of the SkyActiv D that is known to put down about 400hp.
So why would Mazda try and rework a new regular gas powered engine with a turbocharger for the next speed? Why not take the 400 hp Two-Stage turbo diesel that they already have, and pull a little power from it, and release it as a street legal vehicle?
More questions: Why has the SkyActiv D release been delayed? Is it emissions related? According to Mazda their engines pass with flying colors, no treatment necessary. So it can’t be that. In fact when the SkyActiv D was delayed Mazda spokesman Jeremy Barnes was quoted as saying: Skyactiv technology can meet it [emissions] — and it can — but the challenge is engineering a car that delivers the kind of performance that a Mazda needs to have and we’re unable to do that given where we are right now.”
Wait a minute. So what you are saying is that the 2.2L passes emissions, (source) but doesn’t have enough performance? If Mazda has already passed the emissions testing for the engine then why delay it. We know they have released it in the CX-5 in other markets, they even confirmed they will be releasing it in the Mazda 3 in Australia come September. (Source) Along with this the CX-5 has been selling in Japan at a rate of “four 2.2L SKYACTIV-D purchases for every one 2.0L SKYACTIV-G.” (Source) So why would they work on a turbo gasoline variant when the Diesels (which already have a turbo) are already clearly being sold at such a significantly greater rate? My answer? I don’t think they will.
So what’s the delay. My guess is that they plan on announcing the SkyActiv D release date at the same time as the performance oriented version, the Mazdaspeed SkyActiv D which may be a variant of the engine seen above. Even the SkyActiv D that is currently running in the CX-5 pushes 310 lb ft of torque and 173 hp. Still impressive, especially that torque! Imagine bumping the hp by even 100 and the torque would be incredible!
Last but not least, check out these two videos from Mazda that were released almost 2 years ago. Starting at minute 2 they say some interesting things.
https://youtu.be/cK5SQkEUBdo?t=2m
“An exceptionally high redline or 5200rpm. When we were done we had created a beast … delivers the driving performance of a 4.0L V8.”
A 4.0L V8!! Just do a quick google search for standard HP from common 4.0L V8s and you should be more than impressed with the results. Is this Mazda teasing us and we just failed to notice?
In the long run, whether we get a Mazdaspeed version of the SkyActiv D or not, I can’t wait until it hits our shores for good. Let’s hope it’s soon!
Until next Time,
-Spencer@CorkSport
2016 Diesel Mazdaspeed 3 Rumors December 18th, 2017CorkSport
If you’re a car enthusiast that wants performance, reliability, and of course cost effective upgrades, then injector seals should be on your wish list…wait doesn’t everybody want that for their Mazda? I think so; let me tell you why…
As car enthusiasts we all ultimately seek more power. It starts with an air intake, and then we need more fuel, which leads to the high flow pump internals, but that only scratches the surface. Oh then, Mr. Cobb finds himself plugged into your OBD II port and you’re running 20+ psi grinning ear-to-ear. It’s OK, we are all guilty; some more than others, but something has to give and so it does. What that is that gives, well it’s easy to miss, because your car is smart and compensates for it, but it’s happening. You’ve got bad injector seals! Don’t believe me? I’ll prove it!
You have probably run across injector seals while shopping for various other parts, but didn’t pay attention to them. Essentially, they are fancy little cups that fit over the nozzle of the injector. Now for the real question: have you ever seen an OEM injector seal? Doubtful. They are tiny steel washers designed to crush and seal…the stock ones are pitiful.
What happens when a seal doesn’t seal? All of your hard earned power escapes around it, making a mess of the injector and fuel rail. Look below you’ll see that the injector ports in the cylinder head are filthy.
Starting on the left, the injector port is clean and shiny like freshly machined aluminum. Now look at the port farthest to right; black as night and a bit gritty. That seal gave up before the rest and I have a sneaking suspicion that it has to do with the EGR going through mainly that cylinder, but we will save that for another day. Here is a close up of the dirty injector before and after a scotchbrite rub down.
Now that is a big difference huh! Do you believe me yet? Maybe? Let’s compare the seals…
Look at that picture below and let that sink in…
New Seals:
OEM Seals:
Are you flabbergasted like I am? Huge difference! So, why do the differences matter? First off, it’s no longer just a washer with one sealing surface. It’s a cup, so it seals in the OEM location AND along the side of the cup. That’s not all! The secret is in the design (which is all thanks to @Tokay444; from MazdaSpeedForums.org). Here is how it works. The lip at the bottom of the cup is flared just a bit so that it crushes down tight against the cylinder head, and as it crushes down it also crushes outward, pushing against the wall of the port much like an O-ring.
These four little beryllium copper cups are cheap and reliable, but how do they improve performance? Let’s go back to our power hungry example running 20+ psi; with blow-by around the injector seal. That leak has now disappeared, which means if it’s not escaping there then it must be doing “something”. That “something” is more power to your wheels and a happy MZR. Our previous dyno testing with the OEM seals and 21psi were never consistent, declining with each consecutive run. Our new seals restore that decline, each dyno pull now falls on the previous line perfectly and that was in 90+ degree weather.
Have I convinced you yet? Stay tuned for part 2; we are going to put some hard miles on the MS3 and then inspect the seals.
-Barett
Why You Need Injector Seals – Part 1 February 7th, 2019CorkSport
