Mazdaspeed 3 Port Injection Fuel Kit

Its 2021, you survived 2020 and finally got those last goodies installed on your Mazdaspeed 3…you’re finally fully bolted.  It’s been about 6 months and now you want more, but your Tuner keeps telling you you are out of fuel. What the Hell does that mean!?

Let me tell what that means and let me show you the solution via the BEST Port Injection Fuel Kit for your Mazdaspeed 3 or MPS 3.  If you know this is the kit for you don’t wait any longer (Link to ALL THE FUEL), but I do invite you to check out the great information below. 

Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Say no to “out of fuel” and say yes to enough fuel to support 750+WHP!  But first let’s take a step back to understand the basics. 

Why is your Mazdaspeed 3 “out of fuel”?

The Mazdaspeed 3 and 6 use early technology for direct injection injectors which sadly do not have an aftermarket replacement and reach their flow capacity limit quickly.  This basically puts a limit on the OEM fuel systems horsepower capacity.  From what we have seen firsthand and in the community; the limit is around 360-390whp depending on the performance parts on the engine and the fuel used.  The only current solution is to add a port injection system with either 2 extra or 4 extra injectors.  We’ll talk more about that. 

Mazdaspeed 3 8th Port Auxiliary Fuel Kit

What is an auxiliary port injection fuel system? – This is a kit that adds (does not replace) port style fuel injectors to the intake manifold so that you can increase the total fueling capacity of your Mazdaspeed or MPS.  There are a few ways this can be done and all have been done in the Mazdaspeed Community. 

2 extra or 4 extra injectors (aka 6th Port or 8th Port Injection)

While the CorkSport Port Injection Fuel Kit is designed for 4 extra injectors (8th Port Kit); there are options in the community that only use 2 extra injectors (6th Port Kit).   CorkSport believes the 8th Port Injection kit is the superior setup because it has higher capacity, is more reliable and safer for the engine.

With an 8th Port Kit there is an extra injector on each runner of the intake manifold spraying directly into that one and only runner.  With a 6th Port Kit there are two extra injectors spraying directly ahead of the throttle body and then depending on the flow distribution of the intake manifold to disperse the fuel to each runner and thus cylinder.

Return vs Returnless Setups

This is another option for Port Injection Fuel Kits in the community.  While both have their place, the CorkSport 8th Port Fuel Kit uses a “return” style setup because again it has higher capacity, is more reliable and safer for the engine because it is easier to tune for.

In a “return” style setup the fuel pressure for the extra injectors increase as boost pressure increases keeping a consistent fuel flow rate per injector duty cycle which provides the higher capacity and much more consistent tuning.  While the “returnless” style setup just plumbs the extra injectors into the OEM fuel feed to the HPFP.  The fuel pressure does not increase with boost pressure and therefore the capacity is lower, around 500-550WHP.

Integrated vs Standalone Fuel System

Lastly is the consideration of how the Port Injection Injectors are fueled.  This can come from the OEM fuel tank or from a completely separate fuel tank in the vehicle.  Unlike the bullets points above, this is not really a “one is better than the other”, but more of “what suits the needs of your vehicle and uses”. 

Integrated Setup

As the name implies this means the Port Injection Fuel Kit sources its fuel from the OEM tank and in-tank pump.  This can actually be done a couple ways 1) via the “returnless” setup as mentioned above but that has its issues or 2) via a surge tank that is mounted in the engine bay or cabin…which has some concerns.

The surge tank setup is a very common “racecar” setup and for good reason.  It handles high G load corning, acceleration, and braking great and also fuels the entire car, not just the port injection system.  However the cost is usually much higher and requires relocation of other engine bay components so you can mount the surge tank. Along with that you can only use one fuel for the entire system so if your car needs a special high octane fuel then you have to use it at all times during operation, whether cruising or full power.

Standalone Setup

In contrary this is a completely separate fuel source via a separate tank.  This can be a really great option for the enthusiast that does some spirited driving, maybe some events here and there, but also daily drives their Mazdaspeed 3.  How is this the case?

With a completely separate fuel cell for the port injection system you can run the exotic race gas/ethanol in the port injection tank and run normal cheap pump gas in the OEM tank.  When you daily drive/cruise you only use the pump gas in the OEM tank and when you want power the port injection kicks in with the high octane fuel.  It’s a win/win, especially if you do not have ethanol close by and have to special order the exotic fuel like we do here in the PNW.  However this does mean you need a 2nd fuel tank for the port injection which can be a pain, BUT CorkSport has that covered in this complete kit

Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Ok let’s recap on where the CorkSport Port Injection Kit for Mazdaspeed 3 fits in:

  • 4 Extra Injectors aka 8th Port Fuel Injection Kit – one injector per runner for more precise fueling
  • Return Style Setup – Fuel pressure rising with boost pressure for more capacity and precision
  • Standalone Tank – Cheap pump gas for daily driving and high octane fuel for port injection power in the secondary fuel cell

I don’t know about you, but this sounds like you can have your cake and eat it to!

CORKSPORT MAZDA PERFORMANCE BLOG

Image Credit: Shift Sector Coalinga 2020

Let’s look at the components that make up the CorkSport Port Injection Fuel Kit.  What’s in the Box:

CorkSport Fender Mounted Fuel Cell

This is a huge element of what makes the CorkSport Port Injection Fuel Kit great.  This fuel cell is custom CAD designed specifically for your GEN1 and GEN2 Mazdaspeed 3 to fit hidden under the headlight behind the bumper cover.  At 2.6 gallons capacity you don’t need to refill the fuel cell often and there is an integrated level sensor to remind you when you are at 0.8 gallons.  No in-cab tanks and smells. 

Mazdaspeed 3 Fender Mounted Auxiliary Fuel Cell

Quantum Fuel Pump

  • A 380LPH inline fuel pump is used.  This is a Bosch 044 style pump that has the flow capacity needed and is e85 safe.
Mazdaspeed 3 8th Port Auxiliary Fuel Kit

DeatschWerks Fuel Filters

  • Two fuel filters are used in the system for complete filtration.  A pre-pump 100 micron filter filters the fuel flowing from the tank to the pump, therefore protection the pump from debris.  A post-pump 10 micron filter filters the fuel even more before entering the fuel injectors, therefore protecting the fuel injectors from very small particulates.  Both filters use a dual stage filtration design that incorporates a magnet and a stainless steel mesh media.
Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Spec’d Length 6AN Fuel Lines

  • No headaches and ready to go! Like our Mazdaspeed high pressure fuel line, the included fuel lines are the CorkSport Fuel Lines are spec’d to length and fully assembled ready to use.  The lines are PTFE lined with stainless steel braiding and a hytrel coating for a sleek finish and protection against abrasion.  All fittings minus on 150deg fitting are permanently crimped and sealed.
Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Fuel Pressure Regulator

  • An AEM fuel pressure regulator is used for this return style setup.  This provides easy adjustment and setup of the fuel rail pressure with the included Fuel Lab Analog Pressure Gauge
Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Electronics

  • Too further simplify, a 30amp relay kit is provided.  Relays are a critical component in setting up a port injection fuel system.  This allows you to safely and reliably provide power and control to the fuel pump. With that a Hobbs Switch is also provided, this acts as a trigger for the relay to apply power to the fuel pump when a set boost pressure is met.  Example: when you reach 4psi the Hobbs Switch will signal the relay to apply power to the fuel pump.  This is a great setup for daily driven cars because you only turn on the pump when needed vs running at all times.  It greatly helps the life of your pump.
Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Misc Hardware

  • Lastly is all the misc hardware and brackets to get this into your speed.  We’ve got this handled and clearly show the install process with the online color step-by-step instructions.
Mazdaspeed 3 8th Port Auxiliary Fuel Kit

Alright that’s what’s in the box for the CorkSport Port Injection Kit; now let’s talk about the other required items.  There are 2-3 critical items needed to get your port injection kit up and running.  

Port Injection Controller

  • The OEM ECU and Cobb/Versatuner tuning options cannot control the extra 4x injectors in the kit so you will need a separate controller and software for this.  There is a simple and proven option with the Split Second Additional Injector Controller AIC1.  It comes with a ready to run harness for EV6 injectors and the harness integration for power, signal and control are very simple.  Check it out here and add it to your CorkSport Port Injection Kit for a one stop shop.
Split Second Injector Controller AIC1-V4H EV6 for Auxiliary Fuel System

Injectors

  • You will need 4x injectors for the CorkSport 8th Port Fuel Kit.  The injectors need to have 14mm o-rings top and bottom and the length of 34mm or 48mm (if using the CorkSport intake manifold).  To use with the Split Second Additional Injector Controller AIC1; you will want the EV6 connection style. For capacity we recommend at least 1000cc/mm.  To cover all these requirements just use the Injector Dynamics ID1050x.  They are proven and reliable, you can grab a set right here with the CorkSport Port Injection Kit.
Injector Dynamics 1050x Port Injectors for Auxiliary Fuel System

Bonus!

  • While this is not required for operation, it is highly recommended.  The N2MB Racing WOT Box allows you to change the type of Redline and Launch Control cut to a safer method.  OEM will deactivate the injectors for this vs the WOT Box deactivates the spark plugs.  This is much safer for your engine, especially with running a port injection fuel kit.  With this you can also Flat Foot Shift which is faster and way too much fun. (Insert Fireball Emoji Here)

Why doesn’t the CorkSport Port Injection Fuel Kit include these items? 

That’s a good question and we have a good reason.  Originally the kit was going to, but we asked the community how they would want the kit and the answers surprised us.  A lot of people wanted the kit minus the Controller and the Injectors because they already had those items.  So we pulled those out of the kit as solo items you can choose to add if needed.   

Installing this kit into your Mazdaspeed 3 is a day project with some buddies.  Bank on 6+ hours due to the wiring (its always tedious, but important to do right). Read the installation instructions before starting the install so you are ready with all the needed tools and supplies for wiring. 

Mazdaspeed 3 8th Port Auxiliary Fuel Kit

I do want to note that like any project that involves wiring, there will be some wiring required for the install and the extra wiring and connection you decide you need are not included in the CorkSport kit.  Every car is different and how each person wants to get things wired up is different.  There is also some very minimal drilling required to install the tank mounting brackets. 

CORKSPORT MAZDA PERFORMANCE BLOG

I hope you found this blog helpful and informative not just to learn about the CorkSport Port Injection Fuel Kit, but to also learn about the other setups and options you can choose from.  I hope this helps you decide what is best for your car and goals.  Give us a call if you have any questions, we’d be happy to help. 

Barett @ CS

Mazdaspeed 6/Mazda 6 Rear Adjustable Camber Arms

CorkSport is pleased to reintroduce the the 1st Gen Mazda 6 and Mazdaspeed 6 Adjustable Rear Camber Arms to complement the return of the CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6!

By replacing the stock camber arms with the CorkSport Adjustable Camber Arms, you can adjust your suspension to accommodate for lowering springs or coilovers and fine tune your Mazda 6 or Mazdaspeed 6 to the appropriate camber setting needed to balance uneven tire wear and improve cornering performance.

Mazda 6 and Mazdaspeed 6 Adjustable Rear Camber Arms

Our design offers +OEM to – 4.5 degrees of adjustability along with cross camber adjustment allowing drivers the ability to align their suspension to match their enthusiastic driving style on and off the track.

Unlike other adjustable camber arm options on the market, our unique design includes spherical bearings that replace the soft rubber bushings on the OEM camber arms, providing a true attachment to the suspension of the vehicle for improved handling and road feel.

Mazda 6 and Mazdaspeed 6 Adjustable Rear Camber Arms

The ease of adjustability on the vehicle and the unique nature of the spherical bearings will provide you with improved cornering control that can’t be matched by any other options on the market today.

The CorkSport Adjustable Rear Camber Arms are also available for all Mazdaspeed 3 and Mazda 3 vehicles and back for Mazdaspeed 6 and 2004-2008 Mazda 6 vehicles. They come as a set for just $199.00.

Mazda 6 and Mazdaspeed 6 Adjustable Rear Camber Arms

The CorkSport Advantage:

  • Superior Design: Spherical bearings replace the soft rubber bushings used in OEM and other aftermarket camber arms. This will truly attach the camber arm to the suspension of the vehicle for more control and added road feel
  • Made from reinforced high strength extruded bent steel tubing: Stronger less brittle and more durable than aluminum
  • Fine Tuned Adjustability: +OEM to – 4.5 degrees of camber adjustment and cross camber adjustability for fine tuning of your suspension
  • Full Adjustment: Can be adjusted on-car with a wrench while still installed in the vehicle
  • Sold as a Set: We know you need two so we simplified the math for you by selling them as a set
Mazda 6 and Mazdaspeed 6 Adjustable Rear Camber Arms

For more information about the CorkSport Adjustable Rear Camber Arms, check the listing here!

Mazdaspeed 6/Mazda 6 Front Adjustable Camber Arms

We are happy to announce the return of the CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6 and GEN1 Mazda 6 to complement the return of the CorkSport Adjustable Rear Camber Arms. Back and better than ever, the CS control arms provide improved handling and easier wheel fitment through front camber adjustability. An impressive 4.5 degree adjustment range ensures you are able to get the camber you want. Whether you are dialing in your handling for the track, correcting your added camber from lowering, or even just adding in more camber for that new wheel and tire setup, the CS adjustable control arms are a good fit for your build.

CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6 and Mazda 6

The focus of the CorkSport Adjustable Control Arms is an easy modification of the OEM camber setting. You only need to jack up your car to easily access the four bolts on top of the control arm. Once loosened you can adjust as needed before tightening everything back up and lowering your car, without even removing a wheel! It’s a great setup for correcting camber from pothole damage or lowering, optimizing your alignment for the track, or adding negative camber to get the stance you want to fit that new wide wheel setup.

Modify your Camber setting without needing to remove your wheel!

At CorkSport lowering spring height (1.5” lower than OEM), our local race alignment shop measured an adjustment range of approximately +0.5° to -4.0°. During the measurements they even complimented how easy the CS arms are to adjust! If you’re lower than CS spring height, you are able to go even more negative due to the natural camber gain of the MS6 double wishbone front suspension. While if you are higher than CS springs, you won’t be able to go as negative.

CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6 and Mazda 6

Truly an easy bolt-in installation with no strange handling geometry changes

Because the CorkSport upper control arms replace the entire OEM upper control arms, we knew that fitment was vital to ensure correct handling characteristics, and an easy installation. These arms were designed directly from the OEM control arms so they are truly an easy bolt-in installation with no strange handling geometry changes. With the added camber adjustment, we also verified clearance throughout the suspension travel and at all camber settings to prevent any strange noises or damage to your vehicle.

CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6 and Mazda 6

Long lasting strength for your Mazdaspeed6

We have put the CS adjustable front camber arms through extensive real-world testing to ensure long lasting strength for your car. We have been testing an early production unit on a MS6 for around 6 months at the time of writing. This car has been used in everything from daily driving, to aggressive driving in the twisties, to even hauling heavy loads around. Throughout all of this, the car has been setup with -3° of camber with a 255/40-18 summer tire on a 9.5” wide wheel.  We have seen consistent performance out of the CS control arms with no issues whatsoever, so you can be sure they can take whatever you can throw at them!

CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6 and Mazda 6

Each set of CorkSport Adjustable Control Arms is made from A513 steel for long lasting strength and durability. The camber adjustment box on the arms are gusseted for added strength and rigidity. The arms are then finished off with a black powdercoated finish for long lasting corrosion protection and a great look. Each kit also comes with brand new ball joints, castle nuts, and cotter pins to keep everything operating correctly. Plus, we upgraded the rubber bushings where the arms mount to the chassis to spherical bearings. This change ensures good consistent handling feel and reduces slop that can result from old worn out rubber.

CorkSport Adjustable Front Upper Control Arms for Mazdaspeed 6 and Mazda 6

That about sums up the CorkSport Adjustable Control Arms for Mazdaspeed 6 and GEN1 Mazda 6! Be sure to check out the product listing for more images, as well as our product video to see these arms in action. If you have any questions, shoot us an email or give us a call, we’re always happy to help!

Mazdaspeed High-Pressure Fuel Pump Rebuild Kit

We are proud to introduce the CorkSport HPFP Rebuild kit for the Mazdaspeed 3, Mazdaspeed 6, and Mazda CX-7 Turbo. Replace every seal in your HPFP with a brand new, E85 safe O-ring/X-ring made to exact OEM specifications. The perfect reliability upgrade to install with your CS HPFP internals, we even include new hardware and a security Torx bit to help the install go smooth. Read on for more details and be sure to give us a call if you have any questions!

The best and most complete Mazdaspeed HPFP seal kit
Mazdaspeed E85 Safe HPFP O-Ring Rebuild Kit

The potential for HPFP failure

While the HPFP internal upgrade is a must-have mod for any Speed, the rest of the HPFP is commonly ignored. As the cars get older and ethanol blends are used more often, the factory O-rings can begin to break down, causing fuel dilution in your oil, and the potential for HPFP failure. The CS HPFP rebuild kit replaces all your seals so you can be confident that your HPFP is performing exactly as intended.

Save $35 off the CorkSport Mazdaspeed Fuel Pump internals when purchased at the same time as the COBB Accessport

Was the HPFP system designed with ethanol in mind?

With the MS3 and MS6 coming out right around the time ethanol mixes in gasoline were becoming more common, it’s hard to say if the HPFP system was ever designed with ethanol in mind. We spent months researching and testing on a car and in isolated conditions to find the best O-ring material for gasoline and ethanol blends. Each seal in the CS HPFP rebuild kit uses this material so your Speed will operate properly no matter if you’re using the standard pump gas E10 mix, and E30 mix, or even straight E85!

CorkSport

To ensure the correct size for all seals, we were lucky enough to come across a zero mile DISI MZR engine. The HPFP was disassembled and all seals were carefully measured to ensure each O-ring exactly matches the OEM specification. We even had tooling made to produce a custom X-ring that matches the exact specification of the OEM X-ring. This is vital as the X-ring fits on your HPFP piston and needs a precise fit to ensure an OEM quality seal between the fuel chamber and your cam follower.

High-Pressure Fuel Pump Troubleshooting Blog

Lastly, we include hardware to replace the annoying Torx screws that are used in the OEM HPFP assembly. The small security Torx can be notoriously difficult to remove, so we even include a bit to help with removal. As with all CS products, the HPFP rebuild kit comes with full-color installation instructions to guide you through the rebuild and ensure you know where each and every component goes.

Mazdaspeed E85 Safe HPFP O-Ring Rebuild Kit

Check out CorkSport.com.

Recipe to Make a 500 HP Mazdaspeed 3

400 Whp not enough for you and your Mazdaspeed3? 

Searching for more power for your speeds MZR engine? 

Are you building your DISI motor, and trying to figure out your next setup? Say no more… 

This next Mazdaspeed focused blog is going to focus on making some big power numbers, and what it takes to get there. Now is the time to go beyond the scope of the 400 wheel horspower look at what it takes for 500 horsepower at the wheels. 

In our 400 WHP blog, this is not an all-inclusive guide and the only way to achieve these power levels… However, it’s something that’s been tried and tested for years and proven to be a reliable method of making the power you’re after. We are aiming to educate you in the best way to make the most out of your MZR engine.

Let’s get started 

With the MZR engine being out for over 10 years, it’s had a lot of time under the knife. We know how the engine responds to different airflow mods, tuning characteristics, fuel, etc.

We also know that 400 Whp is about the limit of the stock bottom end on the Mazdaspeed 3. If you have a Mazdaspeed 6, then you can assume it’d be a bit less given you have AWD and need to account for further drivetrain loss.

It is beyond this point that the motor is in danger and could potentially let go. Keep in mind that at 400 Whp you are nearly doubling OEM power output, and that’s a lot of strain on those pistons and rods that were never designed to endure that power long term.  If you are wanting to go beyond 400 Whp then you should know that you are also looking at the price tag of a Built motor.

What it takes to Make 500 Whp In Your Mazdaspeed
CorkSport

Now, if you are relatively new to this, and aren’t very familiar with the basic building blocks of the platform such as the Cobb Accessport, and Upgraded Fuel Pump Internals, then I invite you to read our 400 Whp Blog to build a good foundation. Do you feel you have a good understanding of what it takes to get to 400 Whp? Then you are ready to read on!

When you’re at a point in your build that you are seeking 500 Whp then it’s safe to say that you probably have gotten the more tedious stuff out of the way… You probably have about every bolt-on modification, and you understand what it’s like to work with a professional tuner.

That being said, let’s do a bit of a recap on the 400 Whp mods, so you have a good idea of where we need to go from here.

These are all the recommended/required mods to increase engine airflow and efficiency to make 400 WHP.

Basic Bolt Ons: (Less Expensive / easily removable parts )
Fuel Pump Internals
3.5” Intake (Requires ECU relocation or battery box)
Upgraded EBCS
Upgraded Map Sensor
Upgraded Downpipe
Upgraded Intercooler
Upgraded Catback Exhaust
Oil Catch Can

Advanced Bolt Ons: ( More expensive / more difficult to remove )
Upgraded Turbocharger
Upgraded Intake Manifold (Optional but Recommended)
Upgraded Exhaust Manifold (Optional but Recommended)

Fuel:

Stock Fueling on Pump Gas usually nets around 330-350 Whp depending on octane and gas quality.

Stock Fueling on E85 blend fuel usually nets around 370-390 Whp depending on Tune aggression and also Quality of the gas and E85.

With Aux fueling such as port fuel, or methanol you can easily bump up over the 400 Whp mark and beyond. (I’ll get into the differences more in a bit)

Putting down 500 Whp pretty much requires many of the same mods that 400 Whp does, BUT the primary game changers are the Advanced Bolt On’s and Fuel.

(If you’d like to refresh your memory on the basic bolt-ons and how they affect your Mazda please refer to the 400 Whp blog.)

I’m ready for more POWAHH

In the grand scheme of things, making the 400whp is relatively easy and affordable considering it can be done on the stock block. With bolt on parts, fuel, and a tune you can easily hit that number. But as soon as you want to make more, you’re looking at a built engine, as previously mentioned, And that’s a whole new can of worms.

So, what’s all involved in a built motor? That’s a bit of an open-ended question as there are so many variables to take into consideration. However, “built” engines usually contain forged pistons and rods with upgraded bearings to handle more abuse. From there, the complexity increases as you get into port work, cams, etc. I will touch on that a bit more later. 

Fortunately for you, most engine builders have their entry level engine ready to handle 500 wheel horsepower and it’s a pretty basic build that features stronger internals. But, the tedious stuff like port work is usually reserved for the higher tier engines that are usually built for more power.

I won’t get into the engine building side of things, as that could turn into a whole other tangent. But you can assume that a built motor may cost you anywhere from 5k and up dependent on the level of motor you go with. From there we can start piecing together our 500 Whp build.

What it takes to Make 500 Whp In Your Mazdaspeed
CorkSport

Let’s Talk TURBO’S (Crowd Cheers) 

The turbo is the heart and soul of the Zoom-Zoom, so it seems like a suitable place to start.

What it takes to Make 500 Whp In Your Mazdaspeed
CST5 Turbo Upgrade – 2006-2013 DISI MZR

As we know, the CST4 is happy up to around 400+ Whp. Which is why it was the recommended turbo in the 400whp blog. But now we are ready to take a step up to the CST5 which is happy up to… You guessed it! 500+ Whp. With the ability to hit 20 PSI by 3500-3600 RPM and Carry out 30 PSI it really packs a punch for its size. You may be needing to upgrade your intake to pair to the T5, I’d recommend our Power Series 3.5” Intake I mentioned earlier. It will come with the 4” coupler required to mate up to the turbo.

The turbo is available with an internal gate, or an External Gate so you can choose what works best for you. Both options can hit the same power numbers.

Let’s Talk Fuel

What it takes to Make 500 Whp In Your Mazdaspeed
HPFP System

“What options do I have for bigger injectors?”

At CorkSport I get this question rather often. Unfortunately, I must tell them “There aren’t any”

Without going too off topic here I will explain why.

Our cars feature a Direct Injection fuel system or DI… And by today’s standards, it’s a bit primitive. The MZR DISI was one of the first pioneers of modern DI, which is probably why the OEM high-pressure fuel pump can’t even sustain the full potential of the factory injectors. Don’t worry, the CorkSport Fuel Pump internals fixes that problem.

Port Injection is simple and easy to maintain. It works by spraying low pressure fuel into the intake runner where it atomizes in the air stream before entering the combustion chamber.  For car guys, it’s fantastic and easy to swap out injectors when you are ready for more fuel.

Direct Injection takes a whole new approach. Instead of the fuel going in through the intake manifold, it goes DIRECTLY into the combustion chamber.

In order to overcome the force of compression, the fuel must be highly pressurized in order to atomize correctly. It also must deliver more volume in a shorter amount of time. This is why your Mazdaspeed has a high-pressure fuel pump. 

This causes a whole lot of complications for injector developers because things like fuel pressure also become a huge variable when attempting to create a larger Direct Injector. The bigger the hole on the injector, the more fuel pressure required to create adequate atomization. Combining that with the rarity, and size of the Mazdaspeed platform, it’s just not worth it for any manufacturer to develop one.

So, what’s the solution to getting more fuel? Well… As previously mentioned, you pretty much have 2 choices Port Injection, or Methanol. Since both of these are considered Auxiliary fueling, they are controlled by separate controllers, unless you want to ball out and get a Motec ECU that can control the OEM engine systems, as well as your port fuel.

Choosing which system, you want to go with solely depends on your power goals, and how much money you have to spend. Those 2 factors are pretty much the only question you need to ask yourself.

What it takes to Make 500 Whp In Your Mazdaspeed
Leo dropping that cash on a port Injection fuel system

Methanol – Cheap and simple 

Port Injection – Expensive and Reliable 

You must remember that the OEM fuel system, even with E85 in your tank is only good up to around 370-390 whp. So, everything beyond that is supported by your AUX fueling. If your extra fuel system stops spraying for any reason, that could lead to catastrophic damage depending on how much you’re relying on it. When you’re just trying to nudge over the 400 whp mark on a CST4 or CST5 then Methanol is usually fine in my opinion. But beyond that, I’d be concerned with the reliability aspect.

When you have a properly set up port fuel kit (Manifold with fuel rail required) it behaves almost as if there is no AUX fueling system. This is especially the case when you have it all integrated into your factory gas tank and don’t need to fill up a separate cell. A quality Port Fuel Kit is pretty full-proof.

You’ll have to make the decision that’s best for you, but I’d recommend a port fuel kit to support 500 Whp, vs a heavy spraying methanol kit.

What it takes to Make 500 Whp In Your Mazdaspeed
CorkSport Manifold With Fuel Rail For Port Injection

Let’s Talk Manifolds 

Manifolds are responsible for transferring all the air in and out of the motor from their respective cylinder. This job is an important one as it needs to distribute the gases as evenly as possible. The more even the flow, the better the performance!

On the Mazdaspeed Platform, the OEM intake manifold is known to be the bigger restriction over its exhaust counterpart. With very unequal flow distribution across the 4 runners, it has been proven not only to restrict power but also cause premature wear and tear on cylinder #3; here’s why.

This is caused by “over-feeding” air to #3 in comparison to the other cylinders. Over time this #3 is actively running leaner than its counterparts which is why it’s been deemed the most common cylinder to blow if an engine does give way.

What it takes to Make 500 Whp In Your Mazdaspeed
CorkSport Intake Manifold shown to provide example of even Flow

It is because of this, that I always recommend a CorkSport intake manifold for even stock power levels. It may not be required to make 500 Whp, since you can essentially just turn up the boost to counteract the restriction. But in the name of reliability and efficiency, you should always try to help your engine breathe with the most minimal effort while also helping it maintain its health. 

What it takes to Make 500 Whp In Your Mazdaspeed
CS manifolds, FMIC, and 3.5” intake in picture

The OEM Exhaust manifold may not be as bad as the intake manifold, but it’s still not ideal, especially at this power level. A performance exhaust manifold needs to be designed with exhaust scavenging in mind. 

Exhaust scavenging is a very cool effect. The exhaust gases leaving the combustion chamber travel out the individual runners and enter the collector. It’s at this point where it creates a vacuum-like effect on the runners, assisting the exhaust gases to escape from the other cylinders. This constant scavenging helps improve exhaust flow dramatically, especially when you start making power over 400 Whp.

You can learn more about exhaust Scavenging in our Blog that dives deep into it and shows examples comparing our Exhaust Manifold to OEM!

What it takes to Make 500 Whp In Your Mazdaspeed
CS Exhaust Manifold vs The OEM Manifold

When you replace both the Intake and Exhaust Manifolds with a performance unit you are drastically helping your motor improve its efficiency, which can mean 3 things.

1. Make the same power on less boost.
2. Make more power on the same boost.
3. Make Way more power on way more boost. 

When you have to push your car less to make the power you want, reliability improves, and it also needs more room on the table for when you want to make even more power later on.  That leads us to our next topic, Efficiency Mods.

The Cherry’s On Top 

With a built motor, full bolt ons, fuel, and a big enough turbo you can easily hit 500 whp.

However, efficiency mods such as Camshafts or Throttle Body will help you make more power easier, or really push the limits your turbo by improving its ability to perform.

Our CS Camshafts are ideal when you start getting into this power range. It helps with everything from turbo spool, midrange power, and top end. Even on K04 powered speed 3’s / 6’s our cams netted around 20 Whp. You can imagine the kind of exponential improvements it can make as you move up in power.

What it takes to Make 500 Whp In Your Mazdaspeed
Mazdaspeed Camshafts for DISI MZR Motor

That being said, if you’re already having a motor built, or you happen to be going inside your motor, its not a bad idea at all to toss these cams in. They will only help you, and if anything, help your car to not need to work so hard when you’re pushing its limits.

What it takes to Make 500 Whp In Your Mazdaspeed
Performance Throttle Body for 2006-2013 DISI MZR Mazdaspeed

To top that off something like our CorkSport Throttle Body has been proven to make more horsepower and flow 33% more CFM than the OEM unit. Up until recently, no other throttle body has been a viable option due to drivability issues. But CS now offers a drop in plug and play unit that doesn’t come with the problems and utilizes OEM ECU logic to function. Modifications like the throttle body are the awesome little bonuses you can do to help the car hit that 500 Whp mark even easier.

Let’s Recap

So, to cover everything that we’ve learned:
This is what we recommend to achieve 500 WHP

1. Built Motor with upgraded Cam Shafts
2. Auxiliary Fueling
3. Full Bolt-Ons, CS Throttle Body recommended.
4. CST5 Turbocharger
5. Manifolds

We hope you enjoyed reading this blog, and now have a better understanding of the details that go into making 500 whp. Next, we will be reviewing the in’s and out’s of 600 whp!