Mazda 2008 MazdaSpeed3 Wartungshandbuch

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MAZDASPEED3/6 and MPS Service Bulletin
Table of Contents
Introduction................................................................................................................................................1
Suggested Servicing From the Factory......................................................................................................2
Factory Technical Service Bulletins (TSB)................................................................................................2
Which AccessPORT calibration do I install on my ECU?.........................................................................3
Which map (AKA calibration) do I choose for installation?.................................................................3
What is the difference between Stage1 and Stage2?.............................................................................3
What do all of the numbers in the map name mean?............................................................................3
What do all of these +SF, +TIH, and +IC acronyms stand for?............................................................4
What if I upgraded my turbo / air intake / Intercooler (IC) / etc?.........................................................4
Issues you will likely run into while modifying your vehicle....................................................................5
Rapidly wearing spark plugs.................................................................................................................5
Inability for the stock BOV to hold turbo boost pressure above 17-18psi............................................5
Excessive crankcase pressures due to poor Positive Crankcase Ventilation (PCV) design – Burning
oil at idle................................................................................................................................................5
Solution 1..........................................................................................................................................6
Solution 2..........................................................................................................................................6
Solution 3..........................................................................................................................................6
Solution 4..........................................................................................................................................6
Insufficient fuel supply from the stock Camshaft Driven Fuel Pump (CDFP).....................................6
Excessive carbon build up on your intake valves..................................................................................8
Failure of the stock DI fuel injector seals in high horsepower applications (350+WHP).....................9
Service Bulletin Update - Appropriate Spark Plugs.................................................................................10
Service Bulletin Update - Installing a Catch Can or Air/Oil Separator...................................................11
Service Bulletin Update - Intake Valve Cleaning....................................................................................18
What is the most beneficial upgrade path for my car?.............................................................................32
1) AccessPORT + free flowing intake system.....................................................................................32
2) CDFP upgrade + Turbo Inlet Hose (TIH).......................................................................................32
3) COBB DP or free flow exhaust system + upgraded BOV...............................................................32
4) IC upgrade + modified fueling system............................................................................................32
5) Upgraded turbo...............................................................................................................................33
6) Upgraded exhaust manifold (EXM)................................................................................................33
Introduction
This Service Bulletin has been created to help keep you informed about properly
maintaining your MAZDASPEED3/6 and MPS vehicle running the L3T DISI (Direct Injection Spark
Ignited) engines. This bulletin will also keep you informed of some engineering short-comings from
the factory that you may experience while modifying your vehicle and to keep you up-to-date with
some extended service techniques that can be used to make sure that your vehicle is performing
optimally at all times.
All service manual information is Copyright © 2008-2011 Information of Mazda Motor Corporation
All Other Information Copyright © 2011 Cobb Tuning Products, LLC All Rights Reserved.
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Inhaltsverzeichnis

Seite 1 - Table of Contents

MAZDASPEED3/6 and MPS Service BulletinTable of ContentsIntroduction...

Seite 2

false knock is to fill your fuel tank with 2-4 gallons of higher octane unleaded race fuel, around 100 octane will suffice. If the KR is still present

Seite 3

Service Bulletin Update - Installing a Catch Can or Air/Oil SeparatorBrought to you by Tim Bailey ofInstalling an oil catch can or air/oil separator a

Seite 4

The system consists of the following items:1. Approximately 6 feet of vacuum resistant 5/8 inch ID tubing. This tubing must be reinforced so as to res

Seite 5 - COBB TUNING

4) Attach the tube with the in-line PCV valve to the intake manifold fitting.• All service manual information is Copyright © 2008-2011 Information of

Seite 6

5) Using a hose clamp, secure the 5/8 barbed adapter to the stock tube which has been removed from the intake manifold.6) Attach the longer section of

Seite 7

7) Locate the catch can behind the lower passenger side bumper, just ahead of the front wheels.• All service manual information is Copyright © 2008-20

Seite 8 - Stock CDFP Failure

8) Secure lines between catch can, intake manifold, and crank case so they do not rub and wear against any of the undercarriage.9) Reinstall the plast

Seite 9 - (350+WHP)

Service Bulletin Update - Intake Valve CleaningBrought to you by Evan Goldberg ofThis update is a brief summary explaining how to clean the intake val

Seite 10

for the cylinder closest to the Exhaust Gas Recirculation (EGR) port, pictured above, have the greatest amount of carbon build up. This carbon build u

Seite 11

Cylinder #2Unfortunately, we managed to not capture a picture of the #1 cylinder before the cleaning. As we mentioned, the carbon build up was less in

Seite 12 - Remove the plastic under tray

Suggested Servicing From the FactoryIn order for the AccessPORT to work properly on your vehicle, your vehicle must be in proper mechanical order. The

Seite 13

I. Denatured Alcohol – Had the strongest effect on the buildup and did the best job in turning the solution inside the port into a homogenous liquid s

Seite 14

II. Sea Foam – Had a strong effect on the buildup but unlike the alcohol, did not dissolve the build up as much as it broke it down into a removable “

Seite 15 - Front wheel

minimal compared with the alcohol and Sea Foam. The cleaning ability is similar to carburetor & choke cleaner.IV. Carburetor & Choke Cleaner –

Seite 16

To physically clean the valves, we used a combination of gun cleaning tools, consisting of various picks and wire brushes to agitate and remove the ca

Seite 17

Cylinder #1 AfterCylinder #2 After• All service manual information is Copyright © 2008-2011 Information of Mazda Motor CorporationAll Other Informati

Seite 18

Cylinder #3 AfterCylinder #4 AfterAfter the car was put back together and started, it was immediately noticeable that a smoother idle was achieved. We

Seite 19

The above dyno graph is the before and after intake valve cleaning comparisons on the same vehicle running the exact same tuned calibration. The “befo

Seite 20

even though these numbers cannot describe smoothness. We are now also able to run up to 18* of timing up top where that was not possible before the cl

Seite 21

5) Upgraded turbo.At this point in time, the stock turbo is working at its maximum capacity and you can see this through the WGDC values that you log

Seite 22

Which AccessPORT calibration do I install on my ECU?Brought to you by Braden Bergher ofIf you have any difficulties installing your AccessPORTTM pleas

Seite 23

● The “v2XX” number is the revision of the calibration, the higher the number, the newer the calibration. We recommend you install the most current ca

Seite 24 - Cylinder #2 After

COBB TUNINGIssues you will likely run into while modifying your vehicle.This section has been put together to help explain what mechanical issues you

Seite 25

chamber blow-by and engine oil into the crankcase gases. If these gases are immediately sucked into the PCV system, the probability of having signific

Seite 26

We've created Safe Mode calibrations for Mazdaspeed3 vehicles that will limit the achievable boost levels in order to keep the fueling demands wi

Seite 27

The above graph is from the same datalog. Boost builds and holds steady at around 17psi across the RPM range, but starting at 3000 RPM, the DIFP start

Seite 28

– Poor fuel economy– Excessive valve train wear &– Poor power productionWe've documented a cleaning process that you can use to help keep you

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