New Year, New Gains

As the New Year rolls around, most people are looking for a change for the better in their lives.

At CorkSport we think one of the best changes you can make is more power for your Mazdaspeed. We have all the parts you need to liven up your Mazdaspeed3 or Mazdaspeed6 in the New Year.

Safety First

One of the first things to consider when modifying your Speed is the health of its engine. Performing maintenance is very important but it only gets you so far. When adding power, one of the first modifications on your list should be the CorkSport Max Flow Fuel Pump Internals.

These pump internals allow you to maximize your stock fuel system for optimum power capabilities and safer than OE A/R ratios. This means you can add the power you want and have peace of mind that your engine will get the fuel it needs.

Put the Power Down

Like the CS fuel pump internals, the CorkSport Stage 2 RMM for Mazdaspeed 3 will not directly increase the power levels of your car; however, it helps you put all that hard-earned power down. By decreasing the amount the engine can rotate, the Rear Motor Mount allows for reduced wheel hop and torque steer while providing faster throttle response and crisper shift feel.

Even we are surprised how much this engine mount changes how a Mazdaspeed 3 feels. Donโ€™t worry Mazdaspeed 6 guys and gals, we have an RMM for you too.

Improving Airflow

Engines in an extremely simple sense are air pumps; so the faster you can get air in and out of the system, the better. That being said, some of the simplest and easiest power gains you can get from your Mazdaspeed are from upgrading the intake and exhaust. We have seen peak gains of 25ft-lbs and 33WHP from only the CorkSport Stage 2 Intake and a CorkSport Racepipe.

Checkout the dyno sheet below.

Power and torque levels will be further increased if you install a full CorkSport Turbo Back Exhaust instead of just the race pipe section.

The catback exhaust section has proven to gain up to 14WHP while the downpipe section alone has proven to gain up to 21WHP. In the dyno graph below, the downpipe car had a CorkSport Intake installed at the same time as the downpipe (hence the 50hp gain).

If that wasnโ€™t enough flow for you, we also offer 3โ€ and 3.5โ€ intakes for even more airflow into your turbo. Keep in mind though, once you get into those you will need to use a new tune to ensure your car runs optimally. But check out the extra flow you get!

Turbo Upgrade

The CorkSport Drop-In Turbo is a fantastic upgrade to the stock K04 turbo that allows your car to make more power on an equivalent boost pressure. It will work with any mods you already had on your OE Mazdaspeed turbo as the CS turbo is truly a drop in upgrade. With supplemental tuning, fueling, and supporting parts, you can push your Speed to its limits.

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The Next Level

CorkSport also manufactures parts that can take your Speed beyond the parts discussed above. A short list of the parts with the best power gains can be seen below:

  • CorkSport Intake Manifold: A higher flowing IM can support much more power than the relatively restrictive OE unit. Best when paired with a larger throttle body.
  • CorkSport Camshafts: Replacement cams with extra lift to provide increased power and torque across the entire RPM range.

  • Bigger CorkSport Turbo? Yes, there is one in development. See this blog post for details.

No matter what your goals are for this year, CorkSport is here to help you achieve them. Whether you just picked up a Mazdaspeed and are unsure where to start, or have been driving one for years and want the excitement you once had back, CorkSport has a part for you.

Daniel

CorkSport Engineer

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Diagnosing Lean Air/Fuel Mixture Codes

What Does It Mean?

At CorkSport we are glad to be a source for help with those that have questions about their Mazda. I personally enjoy helping with drivability problems or Check Engine Lights! P2187 is a good example of a common code in the Mazda world. Especially those with Mazdaspeeds. โ€œSystem too lean at idle.โ€ Now you may be asking, what does this mean, and how is it fixed?

There are other lean codes all of this could apply to; this is a typical example.

Itโ€™s quite easy to figure out yourself, and Iโ€™ll be walking you through the simple procedure to track down the cause! Using my Mazdaspeed 3, we will go through some of the diagnostic steps of Boost Leak testing, and touch on some other common causes of a lean at idle code.

Let’s get started!

AFR/Fuel Trims

AFR โ€“ Measured by your primary 02, your air-fuel ratio is vital to watch and monitor if you are modding or trying to make more power.  Your Mazdaspeed is tuned to hit certain AFR targets, and relies on the 02 sensor and the MAF Sensor (Mass Air Flow) to adjust fuel delivery accordingly. However, there are things that can interfere with how these sensors communicate with the ECU, and if this happens, it will throw your system out of whack.

Examples are vacuum leaks, boost leaks, leaking nozzles/injectors, exhaust leaks, etc.

Fuel Trims โ€“ The measurement of how much your ECU needs to adjust fuel delivery. There are two kinds of fuel trims.

Short Term Fuel Trim (STFT) โ€“ Cars immediate Reaction To AFR Fluctuations, and responsible for keeping LTFT in check. This is constantly switching around. At Idle you should see close to 0 once it settles. Meaning that the RPMs are not fluctuating, and its steady.

Long Term Fuel Trim (LTFT) โ€“ Cars long-term reaction, which will change over time-based off how the short terms are doing. When you get a custom tune, your tuner will do whatโ€™s called a MAF calibration, to get this number as close to +/- 0 as possible. The less your ECU has to correct its fuel delivery the better.

Anything (-) means itโ€™s taking away fuel, so the AFRโ€™s its seeing are slightly richer than what it thought they would be.

Anything (+) means its adding fuel, so the AFRโ€™s are slightly leaner than it should be. If you are seeing high or pegged STFT, the ECU is trying it’s very best to correct AFR to target.

How To Fix

Now that you have the basic understanding of what these mean, it will be easier to read the Accessport and see just what is going on. You will be able to watch how the computer is compensating for whatever the problem is, and be able to make a more educated decision on how to track it down.

Assuming the issue isnโ€™t caused by something on the exhaust side, the most popular method would be the boost leak test. Creative name, right?

You can make one of these testers yourself, and it only costs a few bucks. All it consists of is a properly sized (And closed off) PVC section that you clamp onto your intake using a silicone coupler. It looks a little something like this.

Notice that there is a Schrader valve on top (Tire valve) This allows you to pressurize the system with air. You can use a bike pump or an air compressor. Obviously, the air compressor will be a bit easier as you can fill it up much faster.

Pinch off the line running from your intake to your valve cover or oil catch can, you donโ€™t want to be forcing air directly into your crank case.

Attach the coupler to your intake, and start filling it up. Take small intervals to listen for any air escaping. You will want to ensure that the pressure your system holds is above or equal to your boost target.

If you hear air coming from the seal for your Mazaspeed VVT solenoid on your valve cover, this is normal.

Once you start hearing excess air escaping, or your gauge on the air chuck is not showing that itโ€™s holding steady pressure, then you know you have a leak. The best way to visibly spot the leak is by spraying the suspect area with soapy water. It will reveal the leak as shown.

In this case, it was an FMIC coupler. However, these leaks can originate from a bad vacuum line, stuck open BOV, bad gasket. This method will expose any of these things.

What If Itโ€™s Not This?

If you have tested your system and found no source of a leak, then the next obvious things would be to inspect your MAF sensor, O2 Sensor, EVAP Solenoid, and exhaust system.

MAF โ€“ Sometimes these sensors fail, or get dirty. Cleaning them can sometimes render results but not always. Take it out and inspect it for grim or build up on the wire. MAF cleaner can be purchased at your local parts store.

O2 Sensor – Sometimes O2โ€™s can get sleepy or go bad. Typically, when they do go bad, the readings are a bit more all over the place, or extreme. But it does happen sometimes.

The one responsible for AFR is an expensive Wideband sensor, so unless youโ€™ve tried everything else, donโ€™t throw money at a new one unless youโ€™ve eliminated other variables.

EVAP Solenoid โ€“ This is responsible for allowing gas fumes from your EVAP system to be purged into your induction system to be burned off. However, the solenoid can sometimes be stuck open, and allow unmetered air in at the wrong times. Check to see if air passes through, or swap on a friend’s and see if it fixes the problem!

Exhaust โ€“ Cracks in the manifold, or downpipe before the 02 can trip up the sensor, thinking there is more air in the mixture than there is. The stream of the exhaust can pull in air from outside and confuse it. Look closely and listen for an exhaust leak. It’s typically easy to distinguish the sound.

Check out our latest CorkSport youtube video to catch a little more detail on this subject!

If all else fails, our staff at CorkSport is here to assist you over the phone the best we can for any of your Mazda or Mazdaspeed needs. Give us a call anytime for quality technical support at 360 260 2675.

Regards,

Brett@CS

The First and Only Performance Mazdaspeed Throttle Body with NO Sacrifices

Mazdaspeed3 intake manifold and throttle body installed

Many have tried, but few have succeeded to retrofit or modify an existing throttle body to work with the Mazdaspeed DISI MZR platform.

As you know, CorkSport does things a little differently, and as a result, we started from the ground up to create the best performance throttle body possible with no sacrifices to drivability or reliability. Introducing the CorkSport 72mm Throttle Body for 2007-2013 Mazdaspeed 3, 2006-2007 Mazdaspeed 6, and 2007-2012 Mazda CX-7.

Starting from the ground up means 100% brand new parts, no reworked or refurbished components anywhere.  

We start with an aluminum investment cast body that is made to our specific design specifications.

A flat faced throttle plate is added to gain a little bit of extra flow by avoiding the bump of a traditional round pivot shaft.

Finally, new electronics are added that are based upon OE logic to avoid any tuning and calibration issues.

To retain easy installation, we knew we had to keep the OE bolt pattern. With this, we wanted to maximize the throttle plate diameter for maximum flow. We ended up increasing from 60mm to 72mm. This may not sound like a huge increase, but the OE Throttle Body fits inside the CorkSport Throttle Body with plenty of room! The 72mm size also fits well with both 3โ€ and 2.5โ€ intercooler piping to fit almost any TMIC or FMIC setup. Finally, we did away with the OE gasket (which is too small anyway) and replaced it with a durable O-ring that will hold up to oil, gasoline, methanol, and other fueling options that it may come in contact with.


The CorkSport Throttle Body underwent extensive testing to ensure that it will not fail during daily use and to ensure it performs as well as we expect. The throttle plate underwent endurance testing to validate the D-shaped pivot can stand the test of time. During flow bench testing, we found that the CS flows about 150CFM (~33%) better than the OE throttle body when 75% open (accelerator pedal fully depressed).

Check out the graph below for the full data.
Mazdaspeed Throttle Bdy Graph for flowbench testing

In daily driving testing, we noticed better throttle response with no CEL or choppiness. In power testing with a midsized turbo (~GT30 size) we found the throttle body caused faster spool, but when we moved to a big turbo, things got interesting. With a GT35R, the CorkSport Throttle Body caused 100-200RPM faster spooling and an increase in power. Check out the dyno graph down below to see the difference between the CS Throttle body (blue) and the OE throttle body (green).

Dyno stats for the Mazdaspeed 3 Throttle Body

Each throttle body ships with fresh stainless steel mounting hardware, a 3โ€ stainless t-bolt clamp, and your choice of silicone. We have options for FMIC, Mazdaspeed 3 TMIC (which also works for you CX-7 guys), and Mazdaspeed 6 TMIC.

Mazdaspeed Intake Manifold with Throttle Body
If youโ€™re looking to take your Mazdaspeed3, Mazdaspeed6, or CX-7 to the next level, or squeeze that last bit of power out of your big turbo build, the CorkSport Throttle Body can help you meet your goals.

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

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CorkSport Injector Puller

For the Mazdaspeed 3, Mazdaspeed 6 & CX7

After years of popular requests, we have something that we are very excited to announce! The CorkSport Injector Puller is here, and ready to assist you with your DIY, or shop needs.

With great power comes great responsibility! Owning a Mazdaspeed may have made you aware by now of how troublesome removing a GDI injector can be. We designed this to assist you.

CorkSport Mazdaspeed Injector Seals
YOU CAN NOW SAY GOODBYE TO:
  • Twisting a seized injector until it breaks loose
  • Rigging up some method to pull or pry out the injector
  • Beat up hands
  • Beat up injectors
  • Hours of lost time

Now, I know what you are thinking: we may be late to the party. We are aware that we are not the first ones to make such a tool, however, we wanted to ensure that we made one of the highest quality that can be used time and time again.ย We love that you guys buy our injector seals, and we wanted to help ease the installation as much as possible.

Mazdaspeed Injector with CorkSport Injector Seal and Injector Puller

With its stainless construction, Nator can truly make use of this when it gets passed around, because it wonโ€™t deteriorate with use.

Dirty Mazdaspeed Injector - How to remove your Injector

As the OE seals fail, carbon starts to build up around the injector and seal and really locks that sucker in there over time. Sometimes, a Mazdaspeed injector has to be sacrificed, as seen above. But, Itโ€™s amazing how much easier the proper tool can make the job.

Stainless steel Injector Seal

Although it may resemble a shake weight a bit, it’s just your normal slide hammer-style tool with a custom head designed to perfectly fit the DISI Injector.

HOW TO USE:

  1. Take off the O-Rings on the tip of the Injector where it goes into the Fuel Rail. Be sure to store those in a safe place.
  2. Slide the head of the tool into position as shown.
  3. You will then put tension on the tool, pulling it backwards.
  4. Use your other hand to slide the hammer backward until it hits the lock nut on the back. Repeat until the stubborn injector finally breaks free.
Mazdaspeed Injector Puller
How to use the Mazdaspeed Injector Puller

โ€“ The CorkSport Team

Be sure to check out our full product video on YouTube and remember to subscribe!

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CorkSport BIG Turbo for the Mazdaspeed & CX-7

Mazdaspeed 3 big turbo upgrade

Good day boosted enthusiast!

We wanted to take some time to give you all a quick update on one of the many projects we have brewing up here at CorkSport Headquarters.

The project Iโ€™m referencing, in general, is our 2nd turbocharger upgrade for the Mazdaspeed 3, Mazdaspeed 6, and CX-7. This unit is a substantial upgrade over our current 18G turbocharger. This Turbo will cater to those looking to take their performance and power goals to a higher level.

Not only will it be capable of putting you well into the 465whp range but this CorkSport Turbo upgrade will be able to do it without giving up on reliability and throttle response.  

It will be very beneficial to those who have mildly-built blocks and a supporting fuel system that will allow them to get higher in the HP range.

So, letโ€™s talk about some of the features you can expect on the upgrade and why we decided to utilize them.

Letโ€™s start at the heart of the Turbocharger.

The new CorkSport Mazdaspeed turbo will take full use of a GTX3076R center housing and rotating assembly (CHRA). The unit is equipped with a fully sealed ball-bearing cartridge, which is a nice upgrade when compared to a standard journal-bearing unit. We chose to go with a ball-bearing unit for a few reasons.

  1. The enclosed design of a ball bearing system allows us to eliminate the need for a thrust bearing, which can account for about 40% of the bearing system drag on the turbo rotor assembly.
  2. Ball bearings reduce the viscous drag, which allows a ball-bearing unit the ability to spool up about 15% faster than its journal-bearing equivalent.

The next thing you will notice on the new Mazdaspeed Turbocharger upgrade is the holes that are drilled into the compressor cover. These little holes are known as anti-surge ports and are intended to expand the turbochargers compressor map. The ports function to move the surge line further left on the compressor map which gives the Mazdaspeed turbo some more headroom before it falls out of its efficiency island. Anti-surge ports are becoming increasingly popular in modern performance turbochargers and with great reason. They offer some unique benefits as mentioned and will be fully integrated into our unit.

Last but not least, as with our CorkSport Turbo, this bigger Mazdaspeed Turbo will once-again be a true drop-in unit; minus the 4โ€ compressor inlet.

There will be no cutting, modifying, sourcing oil and coolant lines, running to the store to buy couplers, etc. This unit will come with everything you need to have a trouble-free install. As with the current CorkSport 18G turbocharger, the new Garrett-based design will come with all studs, gaskets, washers, and knowledge that you need to have a nice weekend install.

So keep your eyes peeled as we get closer to delivering more performance for the Mazda community!

โ€“ The CorkSport Team

SOURCES: Miller, Jay K. Turbo: Real World High-Performance Turbocharger Systems. CarTech, 2008.