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Part #GEN-6-991 CorkSport DISI MZR Fuel Injector Seals

1. a as iba ies zi a i Yih ee _ f Remove the intake Loosen the hose clamp connecting the intake elbow to the turbo inlet pipe with a 10mm socket wrench red circle in Figure 1e g Remove the breather pipe from the valve cover red arrow in Figure 1e and unplug the MAF sensor green arrow in Figure 1e Figure le h Remove intake from engine bay Need Help With Your Installation Call 360 260 CORK 3 of 16 Part GEN 6 991 CorkSpore 2 Intake Manifold Accessories Removal a Disconnect the swirl vane wires in Using needle nose pliers remove the connector from the bracket by squeezing in the direction of the green arrows in b Remove the swirl vane controller box in with an 8mm socket then disconnect the electrical circuit green arrow and lay the box on top of the engine i ites 7 C lig p i PEN Y mary i Moye g ee des ta Fpi i y 7 Z eF Need Help With Your Installation Call 360 260 CORK 4 of 16 Part GEN 6 991 CorkSpore 2 Intake Manifold Accessories Removal continued c Locate the connector that runs to the spark pugs This is located at the front passenger location of the intake manifold Move the gray wrapped wires out of the way d Disconnect the wire plug and lay it on top of the engine and remove brackets Use an 8mm socket and wrench to remove the connectors bracket and the dipst
2. socket wrench Shown with the blue circle in d Remove the throttle body using an 8mm socket wrench and extension The four bolts are shown with in Peel the gasket off the intake manifold for further inspection be careful to not bend the gasket Gasket tab shown with blue arrow in Need Help With Your Installation 7 of 16 Call 360 260 CORK Part GEN 6 991 CorkSpore 4 EGR Tube Removal a Loosen the EGR tube at the intake manifold with a 22mm wrench shown with the red circle in Figure 4a b Remove the EGR tube at the engine with an 8mm socket wrench shown with green circles in Figure 4a Be sure to not lose the small gasket between the engine and EGR tube significantly easier with the TIP removed Instructions to remove the TIP are available at P The EGR tube at the engine can be removed without the removal of the turbo inlet pipe but is http www corksport com support instructions Axl 6 118 WEB pdf Need Help With Your Installation Call 360 260 CORK 8 of 16 Part GEN 6 991 CorkSpore 5 Intake Manifold Removal a Remove the fuel rail shield with a 10mm socket wrench shown with in b Remove the intake manifold with a 10mm socket wrench and 4 extension shown with in Alignment pins are located at the blue dots Need Help With Your Installation Call 360 260 CORK 9 of 16 Part GEN 6 991 CorkSpore 6 Fuel Rail Removal iw d k uae a Remove the hig
3. Part GEN 6 991 Cork Spore CorkSport DISI MZR Fuel Injector Seals 2007 2013 Mazdaspeed 3 amp 2006 2007 Mazdaspeed 6 Thank you for purchasing the CorkSport DISI MZR Fuel Injector Seals for the 2007 2013 Mazdaspeed 3 amp 2006 2007 Mazdaspeed 6 Constructed from beryllium copper the CorkSport fuel injector seals will lock in every PSI of boost so that every bit of your hard earned horsepower keeps you moving forward Please let us know what you think by submitting a review at https corksport com mazdaspeed 3 fuel injector seals html m RY V gt Pre Installation Notes k Ikes R A lt N 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 These instructions were written for reference only and the use of a factory service manual is recommended Please read these instructions thoroughly prior to starting installation note _ These instructions were made using a 2013 Mazdaspeed 3 Installation for earlier oat A Mazdaspeed 3 and Mazdaspeed 6 will be similar Materials and Time z General Info Tooling List Tooling List Se Part GEN 6 991 Flat Head Screwdriver 8mm Shallow Socket Dey Time Est 4 6 hours A Phillips Head Screwdriver 8mm Deep Socket Wrench Rating 5 5 Large Jaw Pliers 10mm Deep Socket Need Nose Pliers 12mm Deep Sock
4. ce and reduced heat transfer to the engine bay the CorkSport MS3 downpipe uses polished 3 304 Stainless steel and features TIG welds that offer superior arc and weld puddle control for a cleaner appearance and precise weld bead control CORKSPORT Mazdaspeed MZR Bypass Valve Add performance and style while protecting your turbo with the Patent Pending CorkSport Mazdaspeed MZR Bypass Valve Using an innovative patent pending design utilizing a wave spring we were able to reduce the spring height of the OEM Bypass Valve by 50 This size reduction provides the same amount of force while accelerating the speed of the valve By increasing speed the Bypass Valve effectively increases the life of your turbo by preventing premature wear since the BPV can safely move at speeds 33 faster than stock or other valves With the extra space allowed by the spring we were able to increase piston size by over 30 CORKSPORT Max Flow Fuel Pump Internals Maximize your stock fuel system while protecting your engine with the CorkSport MZR DISI Max Flow Fuel Pump Internals With well over 2 years of research and development you can count on CorkSport to bring innovation to the high pressure fuel pump on your Mazdaspeed With hardening surface treatments high strength coatings and a machined tolerance that is the best on the market our pump internals are ready to give you the most performance available for your dollar These pumps are precision machin
5. ed then treated then coated and then machined again for a perfect fit and an ultra high efficiency That difference in the real world is going to be higher horsepower capability safer air fuel ratios and the ability to go that much further in the quest for power without worrying about fuel supply Need Help With Your Installation Call 360 260 CORK 16 of 16
6. et Parts List 8mm Wrench T 40 Torx Socket One 1 Set of Four 4 CorkSport DISI MZR Fuel 22mm Wrench 4 Extension Injector Seals Small Vise Grips or C Clamps 3 8 Drive Ratchet One 1 Booklet of CorkSport Installation Scotch Brite Small Fuel Catch Container Instructions Additional Parts List not included Four 4 Fuel Injector O Ring L3K9 13 253 Recommended Four 4 Fuel injector O Ring Grommet L3M8 13 252 Recommended Need Help With Your Installation One 1 Intake Manifold Gasket L3K9 13 111 Dependent on Condition Call 360 260 CORK One 1 Throttle Body Gasket L3K9 13 655 Dependent on Condition Part GEN 6 991 CofkSpore Order of Operations amp Table of Contents P Engine Disassembly Section 1 Intercooler and Intake Removal Pg 2 3 Section 2 Intake Manifold Accessories Removal Pg 4 6 Section 3 Throttle Body Removal Pg 7 Section 4 EGR Tube Removal Pg 8 Section 5 Intake Manifold Removal Pg 9 Section 6 Fuel Rail Removal Pg 10 11 Section 7 Fuel Injector Removal Pg 12 P Injector Seal Installation Section 8 Fuel Injector Assembly Pg 13 Section 9 Fuel Injector Installation Pg 14 P Engine Assembly Section 10 Engine Reassembly Pg 15 P Fuel System Priming Section 11 Priming the Fuel System amp Initial Start Up Pg 16 Need Help With Your Installation Call 360 260 CORK 1of16 Part GEN 6 991 CorkSpore Detailed Instructions These instructions were made using a 2013 Mazdaspeed 3 In
7. fuel injectors Rotate the injectors back and forth while pulling them out of the cylinder head Rotation direction shown with blue arrows in Figure 7a d Remove the OEM seal Shown in Figure 7b The OEM seal may have fallen off during injector removal and therefore is still in the injector port CS Seal OEM Seal Figure 7b Need Help With Your Installation 12 of 16 Call 360 260 CORK Part GEN 6 991 Cok Spore 8 Fuel Injector Assembly a Clean the injector and cylinder head ports Use a scotch bright pad to scrub the injector body clean of any debris Clean the injector port in the cylinder head and use a vacuum to suck any debris from the cylinder Shown in Figure 8a A A clean and smooth injector and cylinder port is critical to the sealing performance of the Corksport Seals Figure 8a Figure 8b b Inspect the fuel injector O rings Verify that the O ring still has a round profile not square Inspect for tears nicks cracks or anything that might compromise the seal ability If replacement is necessary the part numbers are located on the cover page of these install instructions CorkSport recommends the replacement of the fuel injectors O rings The CorkSport Seals are manufactured from a softer N malleable material special care must be taken when handling them c Install the CorkSport injector seals onto the injectors DO NOT push the seals onto the injectors from the outer lip DO push
8. h pressure fuel line bolts with a 10mm socket wrench shown with red circles in Figure 6a b Remove the fuel return line Twist the flathead screwdriver to pop the clip loose Shown in Figure 6b Figure 6a c Loosen the high pressure fuel line brackets with a 8mm socket wrench shown with red circles in Figure 6c Use a rag and small container to catch the fuel in the fuel rail d Remove the high pressure fuel line from the fuel rail Pull the end out far enough to empty the fuel rail Shown in Figure 6d Figure 6d Figure 6c Need Help With Your Installation Call 360 260 CORK 10 of 16 Part GEN 6 991 CorkSpore 6 Fuel Rail Removal continued e Disconnect the fuel pressure wire shown the in f Remove the fuel injector wiring harness from the fuel rail Use a Philips screwdriver to push the plastic clip in the directions of the red arrows Push from underneath Shown in g Remove the fuel rail bolts with a 10mm socket wrench shown with in h Remove the fuel rail by pulling it off the injectors starting at the driver s side and working your way across in Need Help With Your Installation Call 360 260 CORK 11 of 16 Part GEN 6 991 CorkSpore 7 Fuel Injector Removal a Remove the fuel injector wiring harness from the injectors b Remove the fuel injector clamps Use a T 40 torx socket and wrench with a 4 extension Red circles in Figure 7a Figure 7a c Remove the
9. ick bracket e Disconnect the MAP sensor connector with a flathead screwdriver if needed Green circle and arrow Need Help With Your Installation 5 of 16 Call 360 260 CORK Part GEN 6 991 CorkSpore 2 Intake Manifold Accessories Removal continued f Remove the vacuum hose with the blue tab Use a flathead screwdriver to pop the clip out as shown in the blue circle in Figure 2e g Remove the vacuum line with the red collar Use a flathead screwdriver to hold the red collar down while gently pulling the vacuum hose upward Shown with the blue arrow in Figure 2e h Open the two black plastic hose clamps Use a flathead screwdriver to pop the clamp open as shown in the green circle sin Figure 2e Move the hose to the top of the engine out of the way Need Help With Your Installation 6 of 16 Call 360 260 CORK Part GEN 6 991 CorkSpore 3 Throttle Body Removal a Unclamp the throttle body coolant line and slide the clamps back Use the needle nose pliers to grab and loosen the clamps Green circles in Do not remove the hoses off the ports until the vise grips or c clamps have been installed in the next step Failure to do so will led to messy coolant everywhere b Clamp the coolant hoses with the vise grips or c clamps to stop the coolant flow Excessive clamping force is not required Clamping location shown with the green arrows In c Remove the throttle body inlet hose using a 10mm
10. ing the Fuel System and Initial Start Up a Verify that everything is assembled correctly before start up b Prime the Fuel System a Keyed Ignitions With your foot off the clutch cycle the key on off until the electric fuel pump stays on for only 1 2 seconds typically 6 8 cycles b Push Button Ignitions With your foot off the clutch cycle the push button start on off until the electric fuel pump stays on for only 1 2 seconds typically 6 8 cycles c Initial Start Up The engine may start and die quickly this is due to some air being in the fuel system Wait 30 seconds and start the engine again The engine should stay running at this point It may take a few seconds before the engine revs up to its normal start up RPM This is due to the air in the fuel system being pushed out This completes the installation of your CorkSport Fuel Injector Seals Inspect for fuel leaks and any loose fasteners after a few miles of driving then enjoy Need Hel D VVIUT YOUI Installations 15 of 16 Part GEN 6 991 CorkSpore e What s Next CORKSPORT 2010 2013 Mazdaspeed 3 Downpipe Get maximum turbo performance and dramatically increase torque with the Mazdaspeed 3 Power Series Downpipe The CorkSport downpipe has been expertly designed to replace the restrictive element in the Mazdaspeed 3 stock downpipe Mandrel bent piping is used to create smooth exhaust flow for dramatic increases in power For lasting corrosion resistan
11. stallation for earlier Mazdaspeed 3 and Mazdaspeed 6 will be similar 1 Intercooler and Intake Removal a Remove the negative battery terminal and place the plastic cover back over the battery green arrow in Figure 1a b Remove the two 10mm bolts fastening intercooler shroud to the intercooler Push the shroud towards the firewall to unhook it and remove it from the vehicle red circles in Figure 1b nore We recommend using plastic Ziploc bags and a sharpie A to label all bolts and parts throughout the install c 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 1c d Detach the bypass valve BPV from the intake Remove the vacuum signal hose red arrow and the large BPV to intake hose by compressing the clamp with pliers green arrow in Figure 1c Leave the bypass valve attached to the intercooler pipe y a i R bo Figure 1c Need Help With Your Installation 2 of 16 Call 360 260 CORK Part GEN 6 991 Cok Spore 1 Intercooler and Intake Removal continued 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 1d aa aS CEE V ANTERE TEEN iai A a a oa riaa beanies e EL i A E E e i an i T TAPAE SAAT PAUE h D i T Antet
12. the seal on by applying pressure close to the injector nozzle shown with the red arrows in Figure 8c The seal will be snug going on and should leave a very small gap shown with the blue arrow in Figure 8b Figure 8c Need Help With Your Installation Call 360 260 CORK 13 of 16 Part GEN 6 991 CorkSpore 9 Fuel Injector Installation a Install the injectors and the place the clamps around the injectors b Torque the injector clamps to OEM specs Use a T 40 torx socket and torque wrench with a 4 extension to torque the bolts to 17 18 ft lb in c Connect the fuel injector wiring harness d Install the fuel rail The fuel rail must be pushed onto the injectors strait and parallel To help the installation dab a small amount of engine oil onto the injector O rings Use a 10mm socket and torque wrench with a 4 extension to torque the bolts to 13 16 ft lb in The intake manifold and fuel rail bolts are slightly different in length Verify that you are using the correct longer bolts for the fuel rail Failure to do so will result in stripped threads Need Help With Your Installation Call 360 260 CORK 14 of 16 Part GEN 6 991 CorkSpore 10 Engine Reassembly a Follow the instructions in reverse order for reassembly b Torque all fasteners to OEM specifications Toque Specs e 8mm Bolts gt 71 97 in lb 6 8 ft lb e 10mm Bolts gt 13 16 ft lb e 12mm Bolts gt 21 25 ft lb 11 Prim

Part #GEN-6-991 CorkSport DISI MZR Fuel Injector Seals

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