Turbo Install

INSTALLATION INSTRUCTIONS
CORKSPORT CST4
2007-2013 Mazdaspeed 3, 2006-2007
Mazdaspeed 6, 2007-2012 Mazda CX-7 Turbo
PART #: GEN-6-777
Need Help With Your Installation? Call (360) 260-CORK PAGE 1
CORKSPORT CST4
2007-2013 Mazdaspeed 3, 2006-2007
Mazdaspeed 6, 2007-2012 Mazda CX-7 Turbo
Recommended:
• Oil Drain Pipe Gasket, Upper Mazda P#: L3K914293
• Oil Drain Pipe Gasket, Lower Mazda P#: L3K914264
• CorkSport EWG Dumptube P#: GEN-6-575-19
PRODUCT DESCRIPTION:
Thank you for purchasing a CorkSport Upgraded MATERIALS & TIME:
Turbocharger for your Mazdaspeed. Achieve your power GENERAL INFO:
goals whether your on stock block with a CST4 or going
for big power on a built engine with a CST6. Both
internal wastegate and external wastegate options offer
great boost control so you can build you car exactly how
you want it. Each turbo uses the OEM mounting location Time Est: Difficulty: CEL: Warranty:
5hr 4/5 No 2-Year
with all the lines and hardware needed for a quick and
easy install. PARTS LIST (CST4): TOOLING LIST:
• One (1) Assembled • Flat Head Screwdriver
Please let us know your feedback of the by submitting a CST4 CorkSport • Phillips Screwdriver
review at: https://corksport.com/mazdaspeed-3-and-6- Turbocharger in IWG • Channel Lock Pliers
turbo-upgrade.html or EWG configuration • Needle Nose Pliers
• One (1) Turbine to • Small Vice Grips (x2)
PRE-INSTALLATION NOTES: Downpipe Gasket • 8mm Socket &
• One (1) Turbine to Wrench
Verify that the car is on a level surface before Exhaust Manifold • 10mm Socket &
proceeding. Use appropriate load rated jack Gasket Wrench
• One (1) M12x1.25x25 • 12mm Socket &
stands to support the vehicle. Oil Feed Banjo Bolt Wrench
• Two (2) M12 Copper • 14mm Socket &
These instructions were written for reference only Crush Washers Wrench
and the use of a factory service manual is • Nine (9) Turbine Studs • 17mm Socket (1/2”
• Three (3) Drive)
recommended. M6x1.0x12mm Bolt • 19mm Socket (1/2”
• Nine (9) Crimp Nuts Drive)
A re-tune will be required to safely operate any of • One (1) Coolant Line • 21mm Socket (1/2”
the CorkSport Turbochargers. The wastegate duty • Four (4) M14 Copper Drive)
Crush Washers • Ratchet Wrench (3/8”
cycles and ignition timing maps will need to be • One (1) & 1/2”)
modified. We recommend contacting a M8x1.25x12mm Bolt • 4” Extension (3/8” &
professional tuner. IWG ONLY: 1/2”)
• One (1) Turbine Heat • 12” Extension (3/8” &
Shield 1/2”)
Make sure your vehicle is cooled down prior to • Three (3) • Oxygen Sensor
starting installation. If you are going to work on M6x1.0x10mm Cap Socket
your car within an hour of having driven it, use a Screws • 1/2” Semi-Wobbler
fan to cool off the car. EWG ONLY: Joint
• One (1) CorkSport • WD 40 or similar
EWG Elbow • Torque Wrench
These instructions were written using a 2009 • One (1) CorkSport • Coolant Drain pan
Mazdaspeed 3. GEN2 MS3 and Mazdaspeed 6 EWG v-band Clamp • Engine Coolant
will be similar. • High Temperature
Anti-Seize
PAGE 2
ORDER OF OPERATIONS & TABLE OF CONTENTS:
VEHICLE DISASSEMBLY
Section 1: Removing the OEM Intake Pg. 4-5
Section 2: Removing the Battery Box & ECU Pg. 5-7
Section 3: Removing the OEM Turbo Inlet Pipe Pg.7-8
Section 4: Removing the OEM TMIC Pg. 8-9
Section 5: Removing the OEM Heatshields Pg. 10
MAZDASPEED 3 ONLY SECTION

MS3 Section 6: Disassembling the Downpipe Pg. 11-12
MS3 Section 7: Removing the Lower Turbocharger Components Pg. 13
MAZDASPEED 6 ONLY SECTION

MS6 Section 6: Disassembling the Downpipe Pg. 14-15
MS6 Section 7: Removing the Lower Turbocharger Components Pg. 16
VEHICLE DISASSEMBLY CONTINUED

Section 8: Clearing a Path for the Turbocharger Pg. 17-19
Section 9: Removing the OEM Turbocharger Pg. 19-20
TURBOCHARGER SETUP & INSTALLATION

Section 10: CST4 IWG Setup & Installation Pg. 21-23
Section 11: CST4 EWG Setup & Installation Pg. 24-26
INTERNAL WASTEGATE SETUP

Section 12: CST4 IWG Setup Pg. 27-29
EXTERNAL WASTEGATE SETUP

Section 13: CST4 EWG Setup Pg. 30-32
VEHICLE REASSEMBLY
Section 14: Reassembling the Vehicle & First Startup Pg. 33
PAGE 3
DETAILED INSTRUCTIONS:
1. Removing the OEM Intake
Air Filter
Housing
PAGE 4
1. Removing the OEM Intake

(continued)
2. Removing the Battery Box &

ECU
Battery Box
PAGE 5
ECU Plugs
ECU (cont.)
PAGE 6
ECU (cont.)
3. Removing the OEM Turbo Inlet

Pipe (TIP)
Solenoid
fitting
OEM TIP
BPV Hose
Fitting
PAGE 7
3. Removing the OEM TIP (cont.)
4. Removing the OEM

Top Mount Intercooler
(TMIC)
PAGE 8
4. Removing the OEM TMIC (cont.)
PAGE 9
5. Removing the OEM

Heatshields
PAGE 10
The downpipe disassembly has been broken up into Mazdaspeed

3 and Mazdaspeed 6 sections for clarity.
Mazdaspeed 3 owners continue on this page.
Mazdaspeed 6 owners continue on page 14.
6. Disassembling the
Downpipe
(Mazdaspeed 3)
PAGE 11
6. Disassembling the
Downpipe (Mazdaspeed 3)
(cont.)
PAGE 12
7. Removing the Lower Turbo
Components (Mazdaspeed 3)
Mazdaspeed 3
owners continue
on page 17.
PAGE 13
6. Disassembling the Downpipe

(Mazdaspeed 6)
PAGE 14
6. Disassembling the Downpipe

(Mazdaspeed 6) (cont.)
PAGE 15
7. Removing the Lower Turbo Components (Mazdaspeed 6)
PAGE 16
8. Clearing a Path for the
Turbocharger
PAGE 17
8. Clearing a Path for the Turbocharger (cont.)
PAGE 18
8. Clearing a Path for the Turbocharger (cont.)
9. Removing the OEM

Turbocharger
PAGE 19
9. Removing the OEM Turbocharger (cont.)
PAGE 20
The different wastegates have been broken down into multiple

different sections.
For CST4 Internal Wastegate, continue on this page.
For CST4 External Wastegate, continue on page 24.
10. CST4 IWG Setup & Installation
PAGE 21
(cont.)
PAGE 22
(cont.)
PAGE 23
different sections.
For CST4 Internal Wastegate, continue on page 27.
For CST4 External Wastegate, continue on this page.
11. CST4 EWG Setup & Installation
PAGE 24
11. CST4 EWG Setup & Installation
(cont.)
PAGE 25
11. CST4 EWG Setup & Installation (cont.)
PAGE 26
different sections.
For CST4 Internal Wastegate, continue this page.
For CST4 External Wastegate, continue on page 30.
12. CST4 Internal Wastegate Setup
PAGE 27
12. CST4 Internal Wastegate Setup (cont.)
Bleed Setup: Do not remove line w/

restrictor pill. The restrictor pill is
required for operation in bleed setup.
PAGE 28
12. CST4 Internal Wastegate Setup (cont.)
Interrupt Setup: Remove line

w/ restrictor pill and place
vacuum cap over the exposed
port on the wastegate actuator.
PAGE 29
different sections.
For CST4 Internal Wastegate, continue on page 33.
For CST4 External Wastegate, continue this page.
13. CST4 External Wastegate

Setup
PAGE 30
13. CST4 External Wastegate Setup(continued)
PAGE 31
13. CST4 External Wastegate Setup (continued)
Top port is just a

vent in Interrupt
Setup
PAGE 32
14. Vehicle Reassembly & First Start Up
• •
• •
• •
•
This completes the installation of your CorkSport Turbocharger.

Enjoy the upgraded horsepower & torque.
PAGE 33
WHAT’S NEXT?
CorkSport Camshafts
_______________________________
The CorkSport Performance Camshafts

are developed with the latest design,
manufacturing, and casting
technologies and ground to CNC
precision for the best performance for
your Mazdaspeed. Near factory idling
cams for the daily driver and even the
aggressive track driver bringing
improvement in throttle response,
horsepower, and torque to your CorkSport 13” Big Brake Kit
Mazdaspeed. ______________________________________
The Stage 2 CorkSport 13” Big Brake Kit for

Mazdaspeed 3 provides a drastic improvement to
braking by offering improvements to each
component in the system. Larger rotors, 4-piston
calipers, stainless steel brake lines, upgraded pads,
and everything you need to install on your Speed 3
is included in this kit. If the CorkSport Big Brake
Caliper Kit was not enough for you and your MS3,
look no further than the CorkSport 13” BBK.
Also available for Mazdaspeed 6!
CorkSport Front Mount Intercooler

Kit
______________________________________
Cool down your boost air temperatures without

compromise with the CorkSport Front Mount
Intercooler Kit with a small or large intercooler.
Featuring all new piping for better fitment and
performance, the CorkSport Front Mount
Intercooler Kit comes standard with the high
flow small core or the optional big core with
crash bar. Whether you are sporting a few bolt-
ons or a ground breaking big turbo build, this
FMIC Kit has the performance to support your
goals.
PAGE 34
TURBOCHARGER TROUBLESHOOTING GUIDE:
This Turbocharger Diagnostic Tool was created to help understand how to diagnose potential engine and
turbo issues. It tells you the possible causes when your engine shows failure symptoms. Often a root engine
problem is the cause of the symptom and may result in damaging the turbocharger if not resolved quickly. In
these situations, replacing the turbocharger only will not solve the root problem. With this diagnostic tool
you can determine the true nature and extent of the issue and resolve the root problem.
BLACK SMOKE: BLUE/WHITE SMOKE:

EBCS does not raise boost as commanded Coke and sludge in turbocharger center housing
(CHRA)
Dirty air filter system
Crankcase ventilation/PCV clogged and distorted
Dirty compressor or charge air cooler
Engine air intake leakage post MAF
Excessive flow resistance in exhaust system/
leakage upstream of turbine Excessive flow resistance in exhaust system/
leakage upstream of turbine
Foreign object damage (FOD) on compressor or
turbine Oil feed and drain lines clogged, leaking or
distorted
Fuel system/injection feed system defective or
incorrectly adjusted Piston ring sealing defective
Insufficient oil supply to turbocharger Turbocharger bearing damage
Turbine housing/flap damaged Valve guide, piston rings, engine or cylinder liners
worn/increased blow by
Turbocharger bearing damage
Valve guide, piston rings, engine or cylinder liners
TURBO CREATES ACOUSTIC NOISE:

Dirty compressor or charge air cooler Foreign object damage on compressor or turbine
Engine air leakage of intake and/or charge piping Insufficient oil supply to turbocharger
Excessive flow resistance in exhaust system/ Turbine housing/flap damaged
Exhaust gas leakage between turbine outlet and
exhaust pipe
PAGE 1
BOOST PRESSURE TOO HIGH: COMPRESSOR/TURBINE WHEEL
EBCS not commanding correct boost pressure and/or
DEFECTIVE:
missing boost/vacuum line
Foreign object ingestion of compressor or turbine
Insufficient oil supply of turbocharger
incorrectly adjusted
Turbine housing/flap damaged
Insufficient/blocked flow through wastegate
OIL LEAKAGE AT TURBINE: OIL LEAKAGE AT COMPRESSOR:

Coke and sludge in turbo center housing (CHRA) Coke and sludge in turbo center housing (CHRA)
Crankcase ventilation/PCV clogged and distorted Crankcase ventilation/PCV clogged and distorted
Oil feed and drain lines clogged, leaking or Dirty/Restricted air filter system
distorted
Piston ring sealing defective leakage upstream of turbine
Turbocharger bearing damage Oil feed and drain lines clogged, leaking or
distorted
worn/increased blow by Piston ring sealing defective
HIGH OIL CONSUMPTION:

Coke and sludge in turbocharger center housing Oil feed and drain lines clogged, leaking or
distorted
Crankcase ventilation clogged and distorted
Piston ring sealing defective
PAGE 2
INSUFFICIENT POWER/BOOST:
EBCS not commanding correct boost pressure and/or Foreign object damage on compressor or turbine
missing boost/vacuum line
Insufficient oil supply to turbocharger
Pipe assy. to swing valve/poppet valve defective
Suction and pressure line distorted or leaking
Engine air leakage of intake and/or charge piping
Turbine housing/flap damaged
incorrectly adjusted
RECOMMENDATIONS FOR SERVICE & CARE

GOOD TURBO MAINTENANCE: BAD FOR A TURBOCHARGER:
Turbochargers are designed to last the life of an 90 % of all turbocharger failures are due to the
engine when operated at modest power ranges for following causes:
the turbo’s capability. A shorter (but still long) life
These failures can be avoided by regular
can be expected if the turbo is pushed to its working
maintenance of the engine and engine subsystems
limits.
that affect the turbocharger.
To ensure the turbocharger lives a long and potent
Blocked/Closed BPV/BOV Port
life, follow routine maintenance with quality fluids.
Penetration of foreign objects into the turbine or
the compressor
Oil change intervals
Dirt/metal/non-oil fluids in the oil supply
Oil filter system maintenance
Inadequate oil supply (oil pressure/filter
Oil pressure control system/restricted oil drain)
Air filter system maintenance High exhaust gas temperatures (ignition
system/injection system)
We hope this Turbocharger Diagnostic Tool is helpful to you and your build! When modifying cars there are
always many variables to consider, we aimed to provide this troubleshooting tool so you can quickly and
accurate diagnose your car and get it back on the road for you to enjoy.
Please shoot us an email or call for any support!
PAGE 3

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INSTALLATION INSTRUCTIONS

MAZDASPEED 3 ONLY SECTION

MAZDASPEED 6 ONLY SECTION

VEHICLE DISASSEMBLY CONTINUED

TURBOCHARGER SETUP & INSTALLATION

INTERNAL WASTEGATE SETUP

EXTERNAL WASTEGATE SETUP

1. Removing the OEM Intake

1. Removing the OEM Intake

2. Removing the Battery Box &

3. Removing the OEM Turbo Inlet

4. Removing the OEM

4. Removing the OEM TMIC (cont.)

5. Removing the OEM

The downpipe disassembly has been broken up into Mazdaspeed

6. Disassembling the Downpipe

6. Disassembling the Downpipe

9. Removing the OEM

The different wastegates have been broken down into multiple

10. CST4 IWG Setup & Installation

11. CST4 EWG Setup & Installation

12. CST4 Internal Wastegate Setup

Bleed Setup: Do not remove line w/

Interrupt Setup: Remove line

13. CST4 External Wastegate

13. CST4 External Wastegate Setup(continued)

13. CST4 External Wastegate Setup (continued)

Top port is just a

14. Vehicle Reassembly & First Start Up

This completes the installation of your CorkSport Turbocharger.

The CorkSport Performance Camshafts

The Stage 2 CorkSport 13” Big Brake Kit for

Also available for Mazdaspeed 6!

CorkSport Front Mount Intercooler

Cool down your boost air temperatures without

BLACK SMOKE: BLUE/WHITE SMOKE:

TURBO CREATES ACOUSTIC NOISE:

OIL LEAKAGE AT TURBINE: OIL LEAKAGE AT COMPRESSOR:

HIGH OIL CONSUMPTION:

RECOMMENDATIONS FOR SERVICE & CARE

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