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 horsepower to 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 with the CSt5 Mazdaspeed Turbo
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 Turbo for the Mazdaspeed 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.

Upgrade Your Turbo with the CST4

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 is 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.

Mazdaspeed Intake Manifold with CorkSport fuel rail
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.

CorkSport Intake Manifold for Mazdaspeed shown to provide example of even Flow
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. 

Mazdaspeed engine making 500 WHP
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 that 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!

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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 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 of 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.

Camshafts for Mazaspeed
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.

Performance throttle body for 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!

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

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How To Achieve 400 WHP In Your Mazdaspeed

Today I want to share with you a simple blog on just one way of taking your Mazdaspeed to 400WHP. After checking out this blog, If you would like more in-depth information on upgrading your Mazdaspeed with more horsepower then check out 500 WHP post for Mazdaspeed 3.

Let’s Get Started

The MZR DISI engine in the Mazdaspeed platform has been around for just over 10 years now. CorkSport along with the community of racers, shops, and enthusiasts alike have learned quite a bit about these engines. We have learned what they like and what they don’t. How they react to certain mods, how to maintain them, and also some of their weak points. We also learned how to take this platform well over 400 WHP.

We recently hit 684 whp with the CST6 Mazdaspeed Turbo — Check it out here.

Among the many things we have learned, we have developed a great understanding of what is needed to get these engines to make power. More specifically, with the right set of bolt-on parts and tuning one can easily and safely make 400WHP on a stock bottom end of your Mazdaspeed 3 or Mazdaspeed 6. The torque will just need to be kept under control.

It’s not a secret or rocket science on how to achieve this power level in a Mazdaspeed3 or Mazdaspeed6, and it is very much doable.

Stock Red Mazdaspeed3
Stock Mazdaspeed3

Disclaimer:

There are certainly many variables that can come into play when trying to achieve 400WHP safely, such as the health of your engine, quality of engine tune, octane rating of fuel, engine management software and more. This is by no means an all-inclusive guide and the only way of making this level of power. However, this is a tried and tested method of making high power safely and reliably. We come from years of experience doing it ourselves and helping the community with their Mazdas as well. We have spent years and years developing this platform and continue to do so on a daily basis. What I aim to do is educate you on how you can make the most out of your MZR engine.

Necessary Upgrades To Make 400WHP

Now before we get too ahead of ourselves, there are two modifications that are a must before going down the 400whp quest. Those are high-pressure fuel pump internals and a tuning solution such as those provided by COBB or VersaTuner. These parts do not inherently increase hp and tq levels, but they are 100% necessary to give you most out of your hard part modifications and do so with safe and reliable power. A high-quality tune is worth every penny, and when paired with things such as an intake or exhaust, you can capitalize even more so your parts and net more horsepower.

Understanding the DISI MZR 2.3T

The DISI MZR 2.3T is not much different than any other gasoline direct injected engine that you would find on any modern automobile. Here is how it operates:

  • Air goes into your Mazdaspeed.
  • Air is combined with the correct ratio of fuel.
  • The air/fuel mixture gets compressed.
  • A spark event occurs that ignites a controlled burn.
  • This event forces the piston downwards.
  • Exhaust gases then leave the Mazda.
  • The cycle repeats.

So in an oversimplified matter, that is all an internal combustion engine is – a glorified air pump with more bells and whistles. One of the best ways to make a really effective air pump is to optimize the movement of air into and out of the cylinders. For that reason, it’s best to start at the front and back of our car to help give it a little breathing room.

Intake & Exhaust

Mazdaspeed 3 Power Series 3.5" Intake

Mazdaspeed3 Power Series 3.5″ Intake

It’s no secret that an intake and exhaust system are among the most popular first upgrades for any vehicle, and it’s for a good reason. Letting air in and out of the engine as easily as we can is a great first step to create more power. Doing this will free up restrictions with the manufacturer parts, especially on a factory turbocharged vehicle. OEM parts are by and large designed with emissions regulations and pricing priorities, rather than performance.

Upgrading your Mazdaspeed to a 3” or 3.5” intake and pairing it with a turbo-back exhaust will create the airflow efficiency that we need to reach 400 WHP. We’re able to do this by increasing the exhaust pipe diameter and either eliminating our catalytic converter or replacing it with a high-flow race cat. By increasing the efficiency of airflow from entry through the exit, the engine is effectively working less to produce the same amount of power.

By adding an intake and exhaust to your Mazdaspeed, you can net an easy 50+ whp when paired with the proper tune. As you continue down the modification road, you’ll find that this is the most effective dollars spent to horsepower ratio. Now that we are able to take more of the power stroke, we can focus on getting more power to the wheels, rather than letting it be consumed by byproducts such as waste heat, noise, and vibration.

Mazdaspeed3 Exhaust Setup
Mazdaspeed3 Exhaust Setup

Intercooler & Turbo

Another great way to make more power with your Mazdaspeed, and to get closer to 400whp, is to increase the level of boost pressure running through the engine. OEM boost levels are around the 14-15 PSI. But once we have our intake and exhaust installed on our Mazdaspeed, our tuning solution can allow us to start increasing that level into the 19-21 range.

A natural byproduct of increasing the pressure within the system is a corresponding rise in air temperature. To be able to make the most of the increased boost levels, it’s important to keep the temperature at a lower level. To do this, you’ll want to upgrade to a larger top mount intercooler (TMIC), or even go a step further and upgrade to a large front mount intercooler (FMIC) core.

The intercoolers primary function is to act as a heat exchanger, and we know that heat is the #1 roadblock for any engine to make more power. The more efficiently we can remove heat from the system, the more power we can create safely and reliably. We should also note that the stock TMIC in the Mazdaspeed platform is a terrible bottleneck in the system so this will free up extra flow.

Mazdaspeed Front Mount Intercooler
Mazdaspeed Front Mount Intercooler

Now that we have a good way of getting air into, out of, and keeping it cool at the same time, we want to increase the total volume. An easy way to do this is by upgrading the turbocharger in your Mazdaspeed. This is an easy process that replaces your factory k04 and creates the potential to throw down some serious power. When you reach this point in your build, you open up options on how to proceed:

  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!!!

If we are shooting for 400whp on our Mazdaspeed, then we generally like to choose door #3.

CST4

Side note: We highly suggest / possibly need a 3.5 bar MAP sensor and an electronic boost control solenoid (or EBCS). Once we start to increase our boost pressures north of 21psi, the OEM electronics begin to lose resolution and can negatively affect our tuning if not addressed.

By upgrading our MAP sensor we are allowing the powertrain control module (PCM) to recognize and look up higher boost targets than those equipped from the OEM unit. With this upgrade, the computer can now accurately record and look up these values. We also upgrade our electronic boost control solenoid (EBCS) to allow more fine-tuning of our maps and boost targets. An OEM EBCS just won’t allow us as fine of control of our boost pressure, which can result in some headaches as we approach higher horsepower levels.

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The Finishing Touches To Reach 400 WHP

With the above combination of mods and proper tuning on a healthy engine, a medium frame turbo on pump gas can get you into the 330-340whp range. If we go another step further, we will open up more ‘breathing’ mods such as the intake manifold, taller lift camshafts, or a larger throttle body. This will stretch us into the 350-360 whp range.

That being said without the help of e85 or aux fueling we can’t go any closer to our 400whp mark. We simply hit the limits of the Mazdaspeed factory fuel system and need to look into upgrading that system as well.

Making the switch over to e85 allows us to get in the 380 range, but we soon run out of fuel injector headroom in the Mazdaspeed at this point and max out our injector duty cycle. We then have to look at aux fueling (Meth or Port Injection) as a solution to get us to our 400whp mark safely. What’s unfortunate is that at this point we are also looking at upgrading our hard parts such as our in-tank fuel pump to keep up with demand if you plan to run PI. There are quite a few options for AUX fueling which are beyond the scope of this blog.

Now, as mentioned this is not the only way of making these power levels, but it could be said that it is one of the easiest and most popular. It’s important to remember that along the way we supplement the engine with other supporting mods to ensure we are safe and can make full use of our power. Things like lower heat range spark plugs and a stage 2 rear engine mount can go a long way.

Thanks for following along and feel free to leave us a comment if you have any questions or want some more specific information on a product.

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Product Release – Camshafts for DISI MZR Motor –

Mazdaspeed Camshafts for DISI MZR Motor

After two years of testing, design and research, CorkSport is proud to announce the release of our Mazdaspeed Camshafts for the 2007 – 2013 Mazdaspeed 3 and the  2006 – 2007 Mazdaspeed 6. Specifically designed around the MZR DISI engine platform, this camshaft set is engineered to reliably provide an increase of power and torque without sacrificing lower rpm power and torque.

Mazdaspeed Turbo Camshafts

 

Mazdaspeed Turbo Camshafts

Dyno Test of CorkSport Cams -vs- OEM Cams

The cams have been thoroughly tested on our in-house Dyno Dynamics Dynamometer. Controlling test conditions to rule out power differences from tune, gas, temperatures, and other factors our camshaft set produces dyno proven power gains of up to 26 horsepower on a OEM motor! We accomplished our goal; a large band of power increase, limited lower rpm power loss, and a smooth idle.

We regularly beta test our products with customers. These cams have already been daily driven and track proven by multiple cars.

Camshaft! What the heck is that? We break it down for you in our whitepaper and give you the gory details about our development process.

Order your CorkSport Camshaft Kit  today – Click Here

The perfect upgrade for every 2007 – 2013 Mazdaspeed 3 and 2007 – 2009 Mazdaspeed 6 owners that wants to fine tune their motor to perfection.