General Info. Parts List Tooling List
Contents
1. Part Axl 6 216 Ax1 6 218 Axl 6 215 CHKSRPOTC CorkSport Cold Air Intake 2007 Mazdaspeed 3 Thank you for purchasing the CorkSport Mazdaspeed 3 Cold Air Intake Installing the CorkSport Power Series Cold Air Intake will reduce intake restrictions and provide an impressive improvement in power throughout the entire engines RPM range The CorkSport Mazdaspeed 3 Cold Air is Interchangeable with the CorkSport Stage Two Power Series Short Ram Intake so you can run your short ram intake during the winter and your cold air intake during the summer months for optimal performance gains We hope you enjoy your new CAI Please let us know your feedback by submitting a review at http www corksport com corksport stage iii cold air intake for the mazdaspeed 3 html Pre Installation Notes Disconnection of battery removal of battery box and Vehicle ECU are required for installation Consult factory service manual or owners manual for your car for specific details on disconnection of battery Bridging the terminals on the battery can cause SERIOUS damage to vehicle electronics and can cause injury a How our instructions work To best cover all of our customers experience levels we have nore _ included an overview checklist for the more technically advanced users along with step by step E g instructions for customers that require additional detail p 4 7 These instructions were written for reference only and the use of a factory servic2. Step 5a If you purchased the optional turbo inlet pipe continue with Step 2a Remove the battery box cover The cover is held on with two clips shown in Figure 2b Remove the Battery First Disconnect the battery terminals with a 10mm end wrench Disconnect the negative terminal of the battery first before the positive terminal Next Remove the two 10mm nuts for the battery tie down bracket shown in Figure 2c Finally lift the battery out of your car and place it in a safe location Disconnect the three wiring tie downs on the battery box and remove the front cover Remove all three connectors shown in Figure 2d and remove the front cover of the battery box Remove the cover from the engine control unit ECU if you have not already by disconnecting the latch see Figure 2e for location of ECU cover and latch Need Help With Your Installation Gall 360 260 CORK Part Axl 6 216 Axl 6 218 Ax1 6 215 Checklist 2 Removing the Factory Turbo Inlet Pipe Continued C e Disconnect the two ECU plugs by depressing the hasp below the white camlock latch of the plug housing shown in Figure 2f MAZDA PERFORMANCE When done correctly this process should be effortless L f Remove the 3 10mm bolts from the floor of the battery box shown in Figure 2g using a ratchet 10mm socket and 6 3 8 drive extension Remove the battery box and ECU L g Using pliers release the hose clamp shown in Figure2j and Fig
3. Call 360 260 CORK 6 of 8 Part Axl 6 216 Axl 6 218 Ax1 6 215 7 Installing the CorkSport Cold Air Intake a Disconnect your filter from the MAF housing if you already have a filter installed from your SRI otherwise move on to step 7b b Install the hump coupler onto the MAF using a 83 91 EB hose clamp Your intake should look like at Pi this point Depending on how low your Car is you may need to jack the side of your car up for access to the next step g If you do need to jack the side of your car up follow the manufacture recommended directions when doing so to prevent damage or injury c On the bottom of the drivers side bumper you will need to remove the 3 10mm bolts holding the fender liner see d Pull the fender liner down and you will see on the frame rail an empty bolt hole shown in e Thread the M6 head isolator provided so the isolator is on the inside of the frame rail shown in For Gen1 fitment You will need to drill a 5 16 hole inthe e location shown circled in You can then put the isolator through the hold on the engine bay side and tighten down the provided 10mm head nut Need Help With Yourtnstahlation Call 360 260 CQRK 7 of 8 Part Axl 6 216 Axl 6 218 Ax1 6 215 d or KSPR E 7 Installing the CorkSport Cold Air Intake Continued f From the top feed the cold air intake tube down connect the bracket onto the bolt end of the isolator and install the 10
4. silicone elbow shown in Figure 5c Connect MAF sensor The CorkSport Cold Air Intake is designed to be converted back and forth from Short Ram intake to Cold Air Intake Use Step 6 for the Short Ram Intake and Step 7 for the Cold Air Intake installation Need Help With Your Installation Gall 360 260 CORK Part Axl 6 216 Checklist 6 Installing the CorkSport Short Intake L a Install CS air filter onto the end of the MAF housing using the 83 91 T bolt clamp shown in Figure 6a L b Connect the valve cover breather tube shown in Figure 1d to the fitting on the silicone elbow MAZDA PERFORMANCE L c Adjust the silicone elbow so that the MAF and filter and sitting level in the car Figure 6b and tighten the hose clamps 7 Installing the CorkSport Cold Air Intake C a Disconnect your filter from the MAF housing if you already have a filter installed from your SRI otherwise move on to step 7b _ b Install the hump coupler onto the MAF using a 83 91 hose clamp Your intake should look like Figure 6a at this point P Depending on how low your car is you may need to jack the side of your car up for access to the next step P If you do need to jack the side of your car up follow the manufacture recommended directions when doing so to prevent damage or injury L c On the bottom of the drivers side bumper you will need to remove the 3 10mm bolts holding the fender liner see Figure 7b L d Pull the fende
5. time make these extremely brittle Need Help With Yourdnstallation Call 360 260 CORK 3 of 8 Part Axl 6 216 Axl 6 218 Axl 6 215 CHKSRPOTC 2 Removing the Factory Turbo Inlet Pipe Continued j Using needle nose pliers remove the hose from ae y We P the hose to break the seal of the rubber to the plastic fitting and then pulling straight up It takes a little k Remove the plastic inlet pipe from the turbocharger Loosen the hose clamp and pull the stock turbo inlet pipe off the turbocharger 3 Assemble the CorkSport Turbo Inlet Pipe a b c solenoid fitting on the stock turbo inlet pipe and the boost control solenoid identified in Figure 2i by blue arrows and in Figure 2k with a blue arrow If you are having difficulty getting it loose try rotating force but comes off cleanly Assemble the turbo inlet pipe shown in Figure re a vy MANC 3a Add the 57 65mm T bolt clamp clamp to al n FOR fitting the turbo side and the 63 71mm T bolt clamp to the turbo inlet pipe side The T bolt band clamp that holds the silicone tubing to the turbocharger compressor housing should just be tightened down slightly but still loose on the silicone coupling Remove the factory mounting grommet and washer from the factory TIP and install it on the CorkSport TIP location circled in green in Figure 3a and blue on factory TIP shown Figure 21 Add the 6 of silicone tubing to the CorkSport TIP Shown
6. with blue arrow in Figure 3a 6 Silicone 4 Installing the CorkSport Turbo Inlet Pipe Tubing a Place the CorkSport TIP in a similar orientation to the factory pipe Feed the silicone coupler end of the TIP toward the turbocharger inlet Align the bracket on the CorkSport Turbo Inlet pipe with the stud on M the valve cover bracket and connect the silicone e7 x A y 63 71mm coupler over the end of the turbocharger compressor inlet taking care to keep the loose hose clamp in 3 65mm place shown in Figure 4a on next page This should E g Clamp fit easily if not the t bolt band clamp is probably too tight Clamp Need Help With Yourdnstallation Figure 3a Call 360 260 C RK A of 8 Part Axl 6 216 Axl 6 218 Axl 6 215 4 Installing the CorkSport Turbo Inlet Pipe Continued b Attach the bracket on the CorkSport Turbo Inlet over the c d e f g h 5 Installing the CorkSport Intake a b stud on the factory valve cover bracket and start the nut onto the stud shown in Figure 4a Check to ensure that the silicone coupling is still fully engaged between the turbocharger and turbo inlet pipe and tighten the nut the rest of the way Adjust as needed before tightening the nut Then tighten the t bolt band clamp at the turbocharger compressor inlet Connect the 6 silicone tubing to the boost control soleniod shown in Figure 2k Figure 4a Install the factory recircu
7. e manual is NOL recommended Please read these instructions thoroughly prior to starting installation je Materials and Time General Info Tooling List Parts List Part Axl 6 216 3 8 Drive Ratchet 1x Cold Air Intake Pipe Cold Air Intake Upgrade Parts wie Time Est 60 90 min 6 3 8 Drive Extension 1x Silicone Hump AX Pole pun MIRaS Pe Wrench Rating 2 5 12 3 8 Drive Extension 1x Rubber Isolator 1x Silicone Hump 8mm long socket 2x M6 nut 1x Rubber solator 10mm long socket 4x 83 91mm T Bolt Clamps 2x Mine 12mm long socket 1x 63 71mm T Bolt Clamp 2y BB AM I Bolt Clamps Phillips Screwdriver 1x45 Degree Silcone Elbow Longnose Angled Pliers 1x MAF assembly Wire Cutters 1x Dryflow Filter Channel Lock Pliers Optional Turbo Inlet Pipe Silicone Spray CorkSport Turbo Inlet Pipe Flashlight 1x 58 63mm T Bolt Clamp 1x 63 71mm T Bolt Clamp Gen1 Mazdaspeed3 Only 1x 2 to 2 25 Silicone Reducer Drill and or 5 16 drill bit 6 Long Small1ID Silicone Hose Need Help With Yoursdnstallatione Call 360 260 CORK Part Axl 6 216 Axl 6 218 Ax1 6 215 MAZDA PERFORMANCE Checklist This is an overview of each step in the build You can use this as a reference and a checklist as you button up the work on your car These instructions were written for a install of the CorkSport Cold Air intake replacing all the Original intake from the factory If you purchased this as an upgrade to an existing intake start at S
8. ith Yourdnstallatione Call 360 260 C RK 2 of 8 Part Axl 6 216 Axl 6 218 Ax1 6 215 2 Removing the Factory Turbo Inlet Pipe Continued d Remove the cover from the engine control unit ECU if you have not already by disconnecting the latch for location of ECU cover and latch MAZDA PERFORMANCE e Disconnect the two ECU plugs by depressing the hasp below the white camlock latch of the plug housing When the hasp is depressed lift the white latch mechanism which will unlock and disconnect the ECU plugs shown in wren done correctly this process should be effortless f Remove the 3 10mm bolts from the floor of the battery box shown in using a ratchet 10mm socket and 6 3 8 drive extension Remove the battery box and ECU g Using pliers release the hose clamp shown in on next page and with a yellow arrow located on the recirculation hose that is attached to the recirculation valve BOV and solenoid plasticturbo inlet pipe Move the hose clamps fitting away from the fittings and remove hose h Remove the 10mm nut that holds the stock turbo inlet pipe in place location shown in i Disconnect Boost Soleniod Line using as a reference Then remove the two wiring harness clips Shown with in located on the stock turbo inlet pipe i Be very carful to not break the nipple off the boost control solenoid It is plastic so the solenoid can be e broken easily Heat and
9. l 360 260 CORK 1of8 Part Axl 6 216 Axl 6 218 Axl 6 215 1 Removing Factory Intake Continued g Loosen hose clamp circled in green from intake elbow to factory turbo inlet pipe and remove elbow h Loosen the hose clamp and remove the valve cover fitting from the factory elbow a a i AN 1 40h ahd i Ma gt 2 Removing the Factory Turbo Inlet Pipe If you did not purchase a turbo inlet pipe with your CorkSport f N Cold Air Intake proceed to Step 5a If you purchased the Sam Optional turbo inlet pipe continue with Step 2a a Remove the battery box cover The cover is held on with two clips shown in Pry the clips outward by hand and lift the front of the lid off the box b Remove the Battery First Disconnect the battery terminals with a 10mm end wrench Disconnect the negative terminal of the battery first before the positive terminal Next Remove the two 10mm nuts for the battery tie down bracket shown Finally lift the battery out of your car and place it in a safe location c Disconnect the three wiring tie downs on the battery box and remove the front cover Remove the three wiring harness loom straps by compressing their push lock connectors with a pair of angled or straight needle nosed pliers and pushing them back through the hole they are attached to Remove all three of these connectors shown in and remove the front cover of the battery box Need Help W
10. l 6 216 Ax1 6 218 Axl 6 215 CHKESRPOTC Detailed Instructions P These installation instructions were written using a 2010 Mazdaspeed 3 Other year Mazdaspeed3 models will be similar i These instructions were written for a install ofthe CorkSport Cold Air intake replacing all the Original intake from the factory If you purchased this as an upgrade to an existing stage II am intake start at Step 7a All other intakes will start at the beginning of these instructions 1 Removing Factory Intake a Remove the top mount intercooler cover TMIC by removing the two 10mm bolts Now would be a good time to take a look at your intercooler and see if 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 Se als we oe a E Seta b Unplug the MAF housing sensor located on the air box shown in green circle c Loosen the 10mm hose clamp bolt connecting the factory rubber intake elbow to the air box d Remove the two 10mm bolts on the air box bracket and remove the bracket_ e Pull up on the intake box to pop it free from the car and remove it f Remove the valve cover breather tube connected to the factory rubber intake elbow You will need to press in on both sizes of the blue clip to pull it off of the connection Need Help With Your Installation Gal
11. lation valve hose between the recirculation valve and the lower pipe on the CorkSport Turbo Inlet reuse the factory spring clips circled in Figure 4b Install the battery box back into place with three 10mm bolts shown in Figure 2g Feed the battery terminal lines through the cutouts in the box Install the ECU connectors and latch the cam locks to seat the Figure 4b connectors into the ECU Install the ECU cover over the connectors shown in Figures 2e amp 2f Install the battery into the battery box First position and install the battery tie down Next install the positive battery cable onto its terminal and tighten the 10mm nut Install the negative battery cable onto its terminal and tighten the 10mm nut Install the front cover onto the battery box and snap the wiring harness clips into place shown in Figures 2b 2d Finish by installing the battery box top Install the intercooler cover making sure that the metal bracket under the cover is latched onto the tab in the back of the intercooler tank casting Lower the front of the intercooler cover and install the two 10mm head bolts hand tight Shown in Figure 1a Install the breather tube fitting that was removed in Step 1h into the CS silicone elbow facing up as shown in Figure 5a It may need to be adjusted to the correct angle when elbow is installed Install the CorkSport silicone elbow onto the factory or CorkSport turbo inlet pipe using the 63 71 T bolt clamp D
12. mm nut provided in the kit see Figure 7f and Figure 7d for a close up g Install the air filter on the end of the CAI cold pipe using a 83 91 hose clamp see Figure 7g Figure 7f h Reinstall the flap on the bottom of the bumper with the three 10mm bolts i Connect the CAL into the hump silicone using a 83 91 hose clamp see Figure 7h With everything aligned tighten all of the hose clamps This completes the installation of your Cold Air Intake You are now ready to start the car If there are issues with the idle check your connections hose clamps for tightness and check to make sure the MAF sensor is fully seated in the housing and not cocked at a non parallel angle relative to the housing surface After atest drive recheck all hose clamps again for tightness Check out our for additional install information What s Next Figure 7h Get optimal flow and minimal back pressure with the CorkSport Power Series Cat Back Exhaust for the 2010 Mazdaspeed 3 The CorkSport exhaust features mandrel bent 80mm piping and a straight through high flow muffler for a smooth flow increased power and faster spool up In initial testing the peak power gains on the dyno showed as increase of 14 wheel horsepower over stock with only an added CorkSport Short Ram Intake modification on the tested vehicle Need Help With Yourdnstallatione Call 360 260 CORK 8 068
13. nstall the battery box back into place with three 10mm bolts shown in Figure 2h Feed the battery terminal lines through the cutouts in the box Install the ECU connectors and latch the cam locks to seat the connectors into the ECU Install the ECU cover over the connectors shown in Figure 2f Install the battery into the battery box shown in Figure 2d Finish by installing the battery box top Install the intercooler cover making sure that the metal bracket under the cover is latched onto the tab in the back of the intercooler tank casting Lower the front of the intercooler cover and install the two 10mm head bolts hand tight shown in Figure 1a 5 Installing the CorkSport Intake L a C b oo LJ a LJ e Install the breather tube fitting that was removed in Step 1h into the CS silicone elbow facing up as shown in Figure 5a It may need to be adjusted to the correct angle when elbow is installed Install the CorkSport silicone elbow onto the factory or CorkSport turbo inlet pipe using the 63 71 T bolt clamp Do not tighten hose clamp yet C You may have to remove the nut from the clamp to fit it over the silicone It s a tight fit Remove MAF sensor from factory air box and install into the CS MAF housing using the supplied Allen screws Allen screws shown in Figure 5b that are preinstalled in the MAF housing Install the MAF and sensor shown in Figure 5c Install MAF using the 83 91 T bolt clamp into the CS
14. o not tighten hose clamp yet Figure 5a Need Help With Your dnstallation 5of8 Call 360 260sCORK Part Axl 6 216 Ax1 6 218 Axl 6 215 or KSPR E 5 Installing the CorkSport Intake Continued b Install the CorkSport silicone elbow onto the factory or CorkSport turbo inlet pipe using the 63 71 T bolt clamp Do not tighten hose clamp yet c Remove MAF sensor from factory air box and install into the CS MAF housing using the supplied Allen screws Allen screws shown in Figure 5b that are preinstalled in the MAF housing Install the MAF and sensor as shown in Figure 5c You may have to remove the nut from the clamp to fit it over the silicone It s a tight fit Figure 5c Figure 5b d Install MAF using the 83 91 T bolt clamp into the CS silicone elbow Figure 5c e Connect MAF sensor The CorkSport Cold Air Intake is designed to be converted back and forth from Short Ram intake to Cold Air Intake Use Step 6 for the Short Ram Intake and Step 7 for the Cold Air Intake installation 6 Installing the CorkSport Short Intake a Install CS air filter onto the end of the MAF housing using the 83 91 T bolt clamp Figure 6a b Connect the valve cover breather tube shown in Figure 1d to the fitting on the silicone elbow c Adjust the silicone elbow so that the MAF and filter and sitting level in the car shown in Figure 6a and tighten the hose clamps Figure 6a Need Help With Yoursdnstallatione
15. r liner down and you will see on the frame rail an empty bolt hole shown in Figure 7c L e Thread the M6 head isolator provided so the isolator is on the inside of the frame rail shown in Figure 7d P For Gen1 fitment You will need to drill a5 16 hole in the location shown circled in Figure 7e You can then put the isolator through the hold on the engine bay side and tighten down the provided 10mm head nut o f From the top feed the cold air intake tube down connect the bracket onto the bolt end of the isolator and install the nut provided in the kit see Figure 7f and Figure 7d for a close up L g Install the air filter on the end of the CAI cold pipe using a 83 91 hose clamp see Figure 7g oO h Reinstall the flap on the bottom of the bumper with the three 10mm bolts i Connect the CAl into the hump silicone using a 83 91 hose clamp see Figure 7h With everything aligned tighten all of the hose clamps This completes the installation of your Cold Air Intake You are now ready to start the car If there are issues with the idle check your connections Check hose clamps for tightness and check to make sure the MAF sensor is fully seated in the housing and not cocked at a non parallel angle relative to the housing surface After a test drive recheck all hose clamps again for w tightness Check out our knowledgebase for additional install information Need Help With Your Installation Gall 360 260 CORK Part Ax
16. s the silicone tubing to the turbocharger compressor housing should just be tightened down slightly but still loose on the silicone coupling L b Remove the factory mounting grommet and washer from the factory TIP and install it on the CorkSport TIP location circled in green in Figure 3a and blue on factory TIP shown Figure 2i L c Add the 6 silicone tubing to the CorkSport TIP shown with blue arrow in Figure 3a Need Help With Your Installation Gall 360 260 CORK Part Axl 6 216 Axl 6 218 Ax1 6 215 MAZDA PERFORMANCE Checklist 4 Installing the CorkSport Turbo Inlet Pipe L a LJ b O LJ a oe g LI g oh Place the CorkSport TIP in a similar orientation tothe factory pipe Connect the 2 diameter silicone coupling over the end of the turbocharger compressor inlet taking care to keep the loose hose clamp in place shown in Figure 4a This should fit easily if not the t bolt band clamp is probably too tight Attach the bracket on the CorkSport Turbo Inlet shown in Figure 4a Check to ensure that the silicone coupling is still fully engaged between the turbocharger and turbo inlet pipe and tighten the nut the rest of the way Connect the 6 silicone tubing to the boost control soleniod shown in Figure 2k Install the factory recirculation valve hose between the recirculation valve and the lower pipe on the CorkSport Turbo Inlet Reuse the factory spring clips circled in Figure 4b I
17. tep 7a All other intakes will start at the beginning of these instructions 1 Removing Factory Intake ga Remove the top mount intercooler cover TMIC by removing the two 10mm bolts Figure 1a p Now would be a good time to take a look at your intercooler and see if you have any bent fins or debris lodged in the C b O C d L e O f LJ g Ll h intercooler fins Removing debris and straightening the fins will improve the performance of the intercooler Unplug the MAF housing sensor located on the air box shown in green circle in Figure 1c Loosen the 10mm hose clamp bolt connecting the factory rubber intake elbow to the air box shown in red circlein Figure 1b Remove the two 10mm bolts on the air box bracket and remove the bracket Shown in red circle in Figure1c Pull up on the intake box to pop it free from the car and remove it Remove the valve cover breather tube connected to the factory rubber intake elbow circled in Figure 1d You will need to press in on both sizes of the blue clip to pull it off of the connection Loosen hose clamp circled in green in Figure 1b from intake elbow to factory turbo inlet pipe and remove elbow Loosen the hose clamp and remove the valve cover fitting from the factory elbow shown in Figure 1e 2 Removing the Factory Turbo Inlet Pipe AN If you did not purchase a turbo inlet pipe with your CorkSport Cold Air Intake proceed to CJ a LJ b L o C d
18. ure 2i with a yellow arrow located on the recirculation hose that is attached to the recirculation valve BOV and plastic turbo inlet pipe Move the hose clamps away from the fittings and remove hose LJ h Remove the 10mm nut that holds the stock turbo inlet pipe in place location shown in Figure 2i L i Disconnect Boost Soleniod Line using Figure 2i as a reference Then remove the two wiring harness clips shown with the red arrows in Figure 2i located on the stock turbo inlet pipe Be very carful to not break the nipple off the boost control solenoid Figure 2k It is plastic so the solenoid can be broken easily Heat and time make these extremely brittle j Using needle nose pliers remove the hose from solenoid fitting on the stock turbo inlet pipe and the boost control solenoid identified in Figure 2i by blue arrows and in Figure 2k with a blue arrow If you are having difficulty getting it loose try rotating the hose to break the seal of the rubber to the plastic P fitting and then pulling straight up It takes a little force but comes off cleanly o k Remove the plastic inlet pipe from the turbocharger Loosen the hose clamp and pull the stock turbo inlet pipe off the turbocharger 3 Assemble the CorkS port Turbo Inlet Pipe C a Assemble the turbo inlet pipe shown in Figure3a Add the57 65mm T bolt clamp to the turbo side and the 63 71mm T bolt clamp to the turbo inlet pipe side The T bolt band clamp that hold
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