CorkSport Turbocharger Installation Instructions
Contents
1. amp ECU Removal continued f Disconnect the ECU plugs by pushing on the tabs red arrows in Figure 2d and pulling the white lock upward simultaneously green arrows in Figure 2d Refer to Figure 2b for location of ECU plugs and Figure 2d for close ups When done correctly this process should be effortless g Remove the battery box Remove the three 10mm bolts in the bottom of the box and remove the battery box and ECU red circles Figure 2e 3 OEM Turbo Inlet Pipe TIP Removal a Using pliers release the hose clamps red circles in Figure 3a located on the bypass valve hose Remove the hose from the car and save if you are re using it You can discard the rubber hose and spring clamps if you will be installing the optional CorkSport Silicone BPV Hose Figure 3a Need Help With Your Installation Call 360 260 CORK 5 of 25 Part GEN 6 777 CorkSpore 3 OEM Turbo Inlet Pipe TIP Removal continued b Remove the 10mm nut that holds the stock turbo inlet pipe in place blue circle in Figure 3b c Remove the two wiring harness clips red arrows in Figure 3b located on the stock turbo inlet pipe A Be very carful to not break the nipple off the boost control solenoid d Using needle nose pliers remove the hose from solenoid fitting on the stock turbo inlet pipe and the boost control solenoid see Figure 5d on next page and identified in Figure 3b by blue arrow Solenoid fitting P If you2. Phillips Screwdrivers 4 Extension 3 8 amp 1 2 Wrench Rating 4 5 Large Jaw Pliers 12 Extension 3 8 amp 1 2 Needle Nose Pliers Oxygen Sensor Socket Additional Items not included E ON 1 2 Semi Wobbler Joint Oil Drain Pipe Gasket Upper A A WD 40 or similar Mazda P L3K914293 Recommended Tomp Socket 8 Wrench torque rech 12mm Socket amp Wrench Coolant Drain pan Oil Drain Pipe Gasket Lower Mazda P L3K914264 Recommended Permatex Anti Sieze Coating for Turbo Studs Nuts Recommended Ziploc Bag Sharpie Coolant 14mm Socket amp Wrench 17mm Socket 1 2 Drive 19mm Socket 1 2 Drive 21mm Socket 1 2 Drive Part GEN 6 777 CorkSpore Order of Operations amp Table of Contents P Vehicle Disassembly Section 1 OEM Intake amp Filter Removal Pg 2 3 Section 2 Battery Box amp ECU Removal Pg 3 5 Section 3 OEM Turbo Inlet Pipe Removal Pg 5 6 Section 4 Intercooler Removal Pg 7 Section 5 Heat Shields Removal Pg 8 Mazdaspeed 3 amp Mazdaspeed 6 Separation Pg 9 Mazdaspeed 3 Only MS3 Section 6 Downpipe Disassembly Pg 10 11 MS3 Section 7 Lower Turbo Components Removal Pg 12 P Mazdaspeed 6 Only MS6 Section 6 Downpipe Disassembly Pg 13 15 MS6 Section 7 lower Turbo Components Removal Pg 16 P Vehicle Disassembly Continued Section 8 Clearing a path for the Turbo Pg 17 19 Section 9 OEM Turbo Removal Pg 20 P CorkSport Turbocharger Pre Installation amp Installation
3. coolant hard line from the OEM turbocharger shown with the red circle in Figure 10a Install this line on the CS turbocharger with the two new provided M14 copper crush washers Torque to 20 ft lb b Remove the two 8mm bolts holding the turbine heat shield circled in blue in Figure 10a Install the heat shield on the CS turbocharger Torque to 10 ft lbs Figure 10a M14 Copper Crush Washer M14 Copper Crush Washer c Install the provided upper coolant line with the OEM 17mm banjo bolt and new provided copper crush washers and Torque to 20 ft lb Shown with the red circle in Figure 10b Install the M6 10mm flange bolt provided Shown with the green circle in Figure 10b Also shown on next page with a front view of the turbo k S DY a WV Top Coolant Line 2 Figure 10b Need Help With Your Installation Call 360 260 CORK 21 of 25 Part GEN 6 777 CorkSpore 10 CS Turbocharger Installation Continued d Boost Control Setup If you are running an aftermarket Electronic Boost Control Solenoid EBCS Read the instructions provided with the EBCS carefully There is a restrictor pill located in the vacuum line that may need to be removed CorkSport recommends running a bleed setup similar to OEM All parts have been optimized for OEM boost control setup Course Threads Fine Threads Figure 10c M6x1 0x16mm M8x1 25x12mm Flange Bolt Flange Bolt e Apply a small amount o
4. Part GEN 6 777 CorkSpore CorkSport MZR DISI Performance Drop In Turbocharger 2007 2013 Mazdaspeed 3 amp 2006 2007 Mazdaspeed 6 Thank you for purchasing the CorkSport Performance Drop In Turbocharger for the 2007 2013 MS3 amp 2006 2007 MS6 Replace the smoky K04 and get a boost in performance without the hassle of a big turbo build Please let us know what you think by submitting a review at https corksport com mazdaspeed 3 direct fit turbocharger html Pre Installation Notes Make sure your vehicle is completely cooled down prior to starting installation If you are going to work on your car within an hour or two of having driven it use a fan to cool off the car working correctly A re tune will be required to safely operate the CorkSport Turbocharger The wastegate duty cycles and ignition timing maps will need to be modified We recommend contacting a professional tuner A When using jack stands make sure the vehicle is on a level surface and the parking brake is E z r These instructions were written with a 2009 Mazdaspeed 3 and are for reference only and Not the use of a factory service manual is recommended were applicable Please read these instructions thoroughly prior to starting installation Materials and Time General Info _ Parts List Tooling List Part GEN 6 777 See cover Page ad Flat Head Screwdriver Ratchet Wrench 3 8 amp 1 2 ee Time Est 4 6 hours t
5. Section 10 CS Turbocharger Installation Pg 21 24 P Tuning Recommendations Before Operation Section 11 Torques Specs Pre Running amp Tuning Recommendations Pg 24 25 1 of 25 Part GEN 6 777 Detailed Instructions g These installation instructions were written using a 2009 Mazdaspeed 3 H wore We recommend using plastic Ziploc bags and a sharpie to label all bolts and parts throughout the install A oe S hy i AREATA FE s cal 7 1 OEM Intake amp Filter Removal Se ae ee ts oe oe A wee eer ene E E a Remove the top mount intercooler cover TMIC by removing the two 10mm bolts in h Now is a good time to look at your intercooler and see if P you have any bent fins or debris lodged in the intercooler fins Removing debris and straightening the fins will improve the performance of the intercooler b Loosen the two 2 10mm hose clamps on the factory rubber intake elbow and green circle in c Unplug the MAF housing sensor located on the air filter housing green circle in d Remove the two 10mm bolts on the air filter housing bracket and remove the bracket shown in in Need Help With Your Installation Call 360 260 CORK zh aes 2 of 25 Part GEN 6 777 CorkSPpore 1 OEM Intake amp Filter Removal continued e Remove the valve cover breather tube Push the hose f connector toward the valve cover and p
6. are having difficulty getting it loose try rotating the hose to break the seal of the rubber to the plastic fitting and then pulling straight up It takes a little force but cleanly comes off Figure 3b e Remove the plastic inlet pipe from the turbocharger Loosen the 10mm hose clamp at the turbo inlet pull the stock turbo inlet pipe off of the turbocharger and remove it from the car Need Help With Your Installation 6 of 25 Call 360 260 CORK Part GEN 6 777 CorkSpore 4 Intercooler Removal a Remove the clamps for the throttle body and turbo boost tubes from the intercooler Use a 10mm socket to loosen the clamps green circles in Figure 4a Figure 4a b Detach the bypass valve BPV from the intake Remove the vacuum signal hose red arrow Leave the bypass valve attached to the intercooler pipe Figure 4b e Remove the three 3 12mm nuts fastening the intercooler to the top of the engine and remove the intercooler from the vehicle by pulling upward Figure Ab f Remove the outlet boost tube from the turbocharger Use a 10mm socket and ratchet or 2 Phillips screwdriver Figure 4c Figure 4c Need Help With Your Installation 7 of 25 Call 360 260 CORK Part GEN 6 777 CorkSpore 5 Heat Shields Removal a Remove thin silver firewall heat shield shown with the green arrow In There are three plastic clips that unscrew b Remove the six 8mm bolts in then r
7. bo continued d Disconnect the four electrical connectors in we To Ara e Remove the two 10mm flange bolts holding the EGR valve The mounted EGR valve is shown in and the bolt locations are shown in in 2 Do not loose or damage the EGR Valve NOTE lt gasket it can be reused Need Help With Your Installation Call 360 260 CORK 18 of 25 Part GEN 6 777 CorkSpore 8 Clearing a Path for the Turbo continued f The result of clearing a path should look similar to below The turbo can be removed and installed through the opening 9 OEM amp BNR Turbo Removal a Remove the 14mm oil feed banjo bolt in Need Help With Your Installation Call 360 260 CORK 19 of 25 Part GEN 6 777 9 OEM amp BNR Turbo Removal b Remove the 12mm flange nut connecting the coolant line brace to the turbo Red circle in Figure 9b c Remove the four 14mm nuts holding the turbo to the exhaust manifold circled in red in Figure 9c y n TE _ Penetrating oil may be needed to break the turbine nuts loose e Removing the turbine nuts will allow the turbo to fall if not held d Remove the turbo from the vehicle through the opening shown in Figure 8f on Pg 18 Cork Spore Figure 9b Figure 9c a Need Help With Your Installation 20 of 25 Call 360 260 CORK Part GEN 6 777 CorkSpore 10 CS Turbocharger Installation a Remove the 17mm lower
8. emove the heat shield b Remove the four 8mm bolts holding the lower heat shield shown with the in and the in c Remove the three 8mm bolt circled in green in Need Help With Your Installation Call 360 260 CORK 8 of 25 Part GEN 6 777 CorkSpore The downpipe disassembly and removal of the lower turbo components has been broken down into two separate categories between the Mazdaspeed 3 and the Mazdaspeed 6 Mazdaspeed 3 Owners Continue to Page 10 Mazdaspeed 6 Owners Continue to Page 13 Need Help With Your Installation 9 of 25 Call 360 260 CORK Part GEN 6 777 CorkSpore MAZDASPEED 3 ONLY 6 Downpipe Disassembly a Remove the oxygen sensor using the oxygen sensor socket and drive ratchet Circled in green in CS Downpipe shown in Oxygen Sensor Socket b Remove the five 14mm nuts in and shown with the in Need Help With Your Installation 10 of 25 Call 360 260 CORK Part GEN 6 777 MAZDASPEED 3 ONLY 6 Downpipe Disassembly continued c Remove the second oxygen sensor with an oxygen sensor socket and ratchet in in d Remove the two 17mm 14mm for OEM bolts between the downpipe and the catback exhaust CBE in If applicable Remove the 17mm 14mm for OEM bolts between the race pipe and upper downpipe e Remove the exhaust hangers from the downpipe shown with the in f Remove the lower remaining two 14mm nuts from the downpipe
9. f anti seize coating to the course threads of the provided studs as shown in Figure 10c f Install all nine studs into the turbo housing hand tight as shown in Figure 10d Then install the exhaust manifold gasket Figure 10d Need Help With Your Installation 22 of 25 Call 360 260 CORK Part GEN 6 777 CorkSpore 10 CS Turbocharger Installation Continued g Install the CS turbocharger through the opening shown in Figure 8f on Pg 18 h Tighten the four studs shown in Figure 9c to 45 50 ft lbs i Once the CS turbo is installed in the vehicle install the provided heat shield j Use the provided cap screws as shown in Figure 10e M6x1 0x10mm Cap Screws Exhaust Manifold Turbine Heat Hole Shield Figure 10e TO Need Help With Your Installation ee Call 360 260 CORK Part GEN 6 777 CofkSpore 10 CS Turbocharger Installation Continued ca Notes before moving on e The CorkSport turbocharger is lubricated before the balancing process but we recommend pouring a small amount of new engine oil or assembly lube into the oil feed port before operating the turbo This will provide lubrication before initial oil pressure builds The oil feed port is shown in Figure 10f with the red circle Torque to 15 ft lbs Required M12x1 25x25mm Oil Feed Banjo Bolt Ng M12 Copper Crush Washer Figure 10f 11 Torque Specs Pre Running amp Tuning Recommendations e Fo
10. in g Leave the downpipe loose in the engine bay Need Help With Your Installation 11 of 25 Call 360 260 CORK Part GEN 6 777 CorkSpore MAZDASPEED 3 ONLY 7 Lower Turbo Components Removal a Drain approximately gallon from the coolant system Use a large flathead screwdriver to loosen the drain valve located on the lower driver s side of the radiator in b Remove the lower coolant line from the turbo shown with in c Remove the four 10mm bolts holding the oil drain line shown from under the car with the green arrow amp circles in Be careful to not loose or damage the oil drain gaskets if you _ plan to reuse them They can be reused if in good condition gt i Ro N The oil drain line M8 bolts in the turbo are shorter than the M8 bolts in the engine block Note this for install d Remove the three 14mm bolts holding the turbo support bracket circled in blue in ae Mazdaspeed 3 Owners Continue to Page 17 a Need Help With Your Installation 12 of 25 Call 360 260 CORK Part GEN 6 777 CorkSPpore MAZDASPEED 6 ONLY 6 Downpipe Disassembly Figure 6a Figure 6b a Drain approximately gallon from the coolant system The drain is centered on the bottom of the radiator Picture can be found in the Mazdaspeed 3 Only section with Red arrow in Figure 6a b Remove the four 8mm bolts holding the lower inner fender Red circles in Figure 6a c Remove
11. llow the instructions in reverse order to complete the vehicle assembly Refer to torque specs below e Install wiring and EGR removed in Section 8 Clearing a Path for the Turbo e Install the lower Turbo Components removed in Section 7 e Install the Downpipe removed in Section 6 e Install the Heat shields removed in Section 5 e Install the Intercooler removed in Section 4 e Install the OEM turbo inlet pipe removed in Section 3 e Install the Battery and ECU removed in Section 2 e Install the intake and filter removed in Section 1 Torque Specs e 8mm Nut Bolt 8 10 ft lbs e Oil Banjo Bolt 15 ft lbs e 10mm Nut Bolt 15 17 ft lbs e Coolant Banjo Bolt 20 ft lbs e 12mm Nut Bolt 19 21 ft lbs 14mm Turbine Nuts 45 50 ft lbs e 14mm Nut Bolt 30 32 ft lbs Need Help With Your Installation 24 of 25 Call 360 260 CORK j Part GEN 6 777 CorkSpore 11 Torque Specs Pre Running amp Tuning Recommendations Continued e Are tune will be required to safely operate the CorkSport turbocharger The wastegate duty cycles and ignition timing maps may need to be modified We recommend contacting a professional tuner e Do not use an aftermarket oil feed restrictor bolt you must use the provided oil feed banjo bolt e This banjo bolt has been designed to allow the correct amount of oil to the turbo and is not the OEM thread pitch This completes the installation of your CorkSport DISI MZR Performance Drop In Turbocharger Enjoy the new found po
12. re MAZDASPEED 6 ONLY 7 Lower Turbo Components Removal a Remove the lower coolant line from the turbo shown with in c Remove the four bolts holding the oil drain line shown with the green arrow amp circles in Be careful to not loose or damage the oil drain gaskets if you plan to reuse them They can be reused if in good 8 condition wore It may be easier to only remove the lower M8 bolts on the oil drain line and leave the drain line attached to the e OEM turbo during removal d Remove the three 14mm bolts holding the turbo support bracket circled in blue in Mazdaspeed 6 Owners Continue to aana Paroa aaa AO The oil drain line M8 bolts in the turbo are shorter than the M8 bolts in the engine block Note this for install Need Help With Your Installation Call 360 260 CORK 16 of 25 Part GEN 6 777 CorkSpore 8 Clearing a Path for the Turbo a Remove the three 10mm flange nuts holding the brake booster heat shield in b Disconnect the electrical connector from the OEM electronic boost control solenoid EBCS The ports on the OEM EBCS are fragile and can break off easily wt The OEM EBCS is located on the compressor housing near the outlet c Remove the OEM EBCS Using a 10mm wrench remove the flange nut Shown with the in Need Help With Your Installation Call 360 260 CORK 17 of 25 Part GEN 6 777 CorkSpore 8 Clearing a Path for the Tur
13. ress both sides of the colored clip simultaneously Pull the hose away from the valve cover Figure 1d Pull up on the filter housing to pop it free from the car and remove it along with the intake elbow and breather tube ie Figure 1d 2 Battery Box amp ECU Removal a Remove the battery box cover The cover is held on with two clips shown with red arrows in Figure 2a Pry the clips outward by hand and lift the front of the lid off of the box Figure 2a Need Help With Your Installation Call 360 260 CORK 3 of 25 Part GEN 6 777 CorkSpore Detailed Instructions 2 Battery Box amp ECU Removal continued b Disconnect the battery Disconnect the battery terminals with a 10mm end wrench Refer to Figure 2b for negative and positive terminals Disconnect the negative terminal of the battery first then the positive terminal c Remove the two 10mm nuts for the battery tie down bracket shown with in d Remove the battery from the battery box e Remove the front battery box panel Remove the MAF wiring harness clip blue circle and negative battery cable clip purple circle from the front battery box panel using needle nose pliers to compress the clips on the inside of the battery box Then slide the panel upwards and remove it green arrow in Need Help With Your Installation Call 360 260 CORK 4 of 25 Part GEN 6 777 CorkSpore 2 Battery Box
14. the six 10mm bolts holding the engine undertray Red circles in Figure 6b Remove undertray d Remove the six Phillips push clip screws holding the inner fender access panel Red circles in Figures 6c through 6e Remove access panel Figure 6c Figure 6d Figure 6e Need Help With Your Installation 13 of 25 Call 360 260 CORK Part GEN 6 777 MAZDASPEED 6 ONLY 6 Downpipe Disassembly continued e f g h Remove the upper oxygen sensor using the oxygen sensor socket and drive ratchet Circled in green in Oxygen Sensor Socket Remove the four 10mm bolts in Then remove the heat shield covering the turbine studs Remove the five 14mm turbine stud nuts attaching the downpipe to the turbo and in Remove the lower oxygen sensor Green circle in Figure 6h Remove the two 14mm bolts attaching the racepipe to the cat back exhaust Need Help With Your Installation Call 360 260 CORK 14 of 25 Part GEN 6 777 CorkSpore MAZDASPEED 6 ONLY 6 Downpipe Disassembly continued j Remove the two 14mm nuts attaching the racepipe to the downpipe Red circles in Figure 6i Figure 6i k Remove the four 14mm bolts holding the downpipe support bracket Red circles in Figures 6j amp 6k I Leave the downpipe loose in the engine bay for turbo removal Figure 6j Figure 6k Need Help With Your Installation 15 of 25 Call 360 260 CORK j Part GEN 6 777 CorkSpo
15. wer and let us know what you think online at CorkSport com What s Next CORKSPORT Mazdaspeed Boost Control Solenoid Take control of your boost and performance with the CorkSport Mazdaspeed Electronic Boost Control Solenoid EBCS Utilizing the latest technology in solenoid controlled air valves the CorkSport EBCS outflows and out responds the competition It builds boost faster and minimizes boost spikes and creep The CorkSport replacement EBCS features a 3 port design that has the flexibility to control all boost control setups such as bleed and interrupt for internal wastegates and interrupt or push pull for external wastegates CORKSPORT 3 Power Series intake System Dramatically reduce intake restrictions and get an impressive improvement in power throughout the entire RPM range with the CorkSport Mazdaspeed 3 Power Series 3 Intake System The Power Series 3 Intake System is fabricated with a high polished 3 inch turbo inlet pipe and a true 3 inside diameter MAF housing The velocity stack design smooth s air flow for maximum performance If you plan on upgrading or have already upgraded your turbo this upgrade is a must to keep your MAF sensor functioning within its calibrated range Fs Help With Your Installation Call 360 260 CORK 25 of 25
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