Part #Gen-6-501-10 CorkSport Mazdaspeed Performance Camshafts 2007-2013 Mazdaspeed 3, 2006-2007 Mazdaspeed 6 Thank you for purchasing the CorkSport High Performance Camshafts. Developed with the latest design, manufacturing, casting technologies and CNC ground to CorkSport precision for the best performance for your Mazdaspeed. Please let us know your feedback by providing a review here: https://corksport.com/mazdaspeed-3- camshafts.html Pre-Installation Notes: 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. These installation instructions were written using a 2013 Mazdaspeed 3. Other year Mazdaspeed 3 and Mazdaspeed 6 models will be similar. The install of the camshafts will require the replacement of two camshaft bolts, two camshaft friction washers, one fuel pump housing gasket and adjustment of the valve tappets. The camshaft installation can average 5-8 hours and is rated a 5 out of 5 for difficulty. It will require some preparation and a clean workspace. If you have doubts in your skills do not attempt this installation. We strongly recommend professional installation. We recommend changing your oil before installation. Clean oil gives the camshafts the best chance to ensure proper lobe break in and long life. Materials and Time: General Info. Parts List Additional Parts List (not included) Part #: Gen-6-501-10 One (1) CorkSport Intake Camshaft Two (2) Camshaft Friction Washers (L3K9-12-429) Time Est: 5-8 hours One (1) CorkSport Exhaust Camshaft Two (2) Camshaft Bolts (LF17-12-428) Wrench Rating: 5/5 Two (2) M6x1.0x25mm Bolts One (1) Fuel Pump Housing Gasket (L3K9-10-193) Tappets for valve adjustment Tooling List 3mm Hex Socket 1/4” Drive Ratchet 8mm Socket 10mm Wrench OEM Engine Workshop Manual 3/8” Drive Ratchet 10mm Socket 12mm Wrench MZR Camshaft Alignment Tool 1/2” Drive Ratchet 12mm Socket 14mm Wrench MZR Crankshaft TDC Locater Pin 1/2” Breaker Bar 17mm Socket 17mm Wrench Black/Grey Silicone Sealant Impact Wrench 21mm Socket 19mm Wrench Engine Assembly Lubricant Torque Wrench 12” Extension 21mm Wrench Anti-Seize Lubricant Jack and Jackstands E8 Torx Socket 24mm Wrench Telescoping Magnet Feeler Gauge T30 Torx Socket Needle Nose Pliers Telescoping Mirror Razor Blade 5/8” Spark Plug Socket Flat Head Screw Driver Need Help With Your Installation? 4 Call (360) 260-CORK Part # GEN-6-501-10 Order of Operations & Table of Contents Disassembly Section 1: Access the Valve Cover Pg. 1-4 Section 2: Support the Car on Floor Jack/Jackstands or Lift Pg. 5 Section 3: Remove the Factory Camshafts Pg. 6-10 Installation Section 4: Measure and Adjust Valve Lifter Clearance Pg. 11-12 Section 5: Install the CorkSport Camshafts Pg. 13-16 Section 6: Set the Camshaft Timing Pg. 16-17 Assembly Section 7: Final Assembly Pg. 18-21 Need Help With Your Installation? Call (360) 260-CORK Part #Gen-6-501-10 Detailed Instructions These instructions were made using a 2013 Mazdaspeed 3. Installation for earlier Mazdaspeed 3 and Mazdaspeed 6 will be similar. 1. Access the Valve Cover a) Remove the negative battery terminal and place the plastic cover back over the battery (green arrow in Figure 1a). Figure 1a b) Remove the two 10mm bolts fastening the 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). We recommend using plastic Ziploc bags and a sharpie to label all bolts and parts throughout the install. Figure 1b 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 i ntake. Remove the vacuum signal hose ( red arrow), and the large BPV to the intake Figure 1c hose by compressing the clamp with pliers ( green arrow in Figure 1c). Leave the bypass valve attached to the intercooler pipe. 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). Figure 1d Need Help With Your Installation? 1 of 22 Call (360) 260-CORK Part # GEN-6-501-10 1. Access the Valve Cover (continued) 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 Figure 1e arrow in Figure 1e). h) Pull the intake out of the engine bay. i) Unplug the five (5) engine wiring harness connectors Figure 1f (red arrows in Figure 1f and 1g). Do NOT unbolt the coil pack grounding wire (green arrow in Figure 1f ) j) Unbolt the wiring harness bracket (red circles in Figure 1f and 1g) with an 8mm socket wrench and lift it away from the motor. Figure 1g k) Remove the evap. solenoid and brake booster hoses (red arrows in Figure 1h). Disconnect the spring clamps and pull off the hose. Push the two hoses out of the way toward the radiator. l) Unbolt the evap. solenoid from the bracket with a 10mm wrench (red circle in Figure 1h). Push it out of the way toward the firewall. Need Help With Your Installation? Figure 1h 2 of 22 Call (360) 260-CORK Part # GEN-6-501-10 1. Access the Valve Cover (continued) m) Remove the turbo inlet pipe bracket by removing the three (3) 10mm fasteners with a socket wrench (red circles in Figure 1i). n) Unplug the coolant temperature sensor and fuel pump electrical connectors (green arrows in Figure 1i). Figure 1i o) Unplug the four (4) spark plug coil connectors (red arrows) the camshaft position sensor & oil control valve (green arrows) and pull the wiring harness away from the motor towards the radiator (Figure 1j). Figure 1j p) Unbolt the bracket holding the grey harness to the intercooler bracket with a 10mm wrench (green arrow in Figure 1k). q) Disconnect the grey wiring harness from the engine and pull it aside over the oil filler neck (red arrows in Figure 1k). Figure 1k Need Help With Your Installation? Call (360) 260-CORK 3 of 22 Part # GEN-6-501-10 1. Access the Valve Cover (continued) r) Remove the high pressure fuel pump. Use the open end of a 19mm wrench to loosen the hard line connection (green arrow in Figure 1l). s) Use a flat head screw driver to carefully pry out the blue and yellow clips and pull the fuel lines off the pump (red arrows in Figure 1l). Figure 1l t) Use an E8 reverse Torx to remove the three (3) Torx screws from the pump (red circles in Figure 1l) and remove the fuel pump from the car. Take care not to drop the lifter located inside the housing upon removal. u) Remove the fuel pump lifter housing. Use a 10mm Figure 1m socket wrench to remove the four (4) screws (red circles in Figure 1m) and pull the lifter housing off the engine. v) Remove the four spark plug coils (red arrows in Figure 1j) with an 8mm socket wrench. Shown removed in Figure 1n. w) Remove all four (4) spark plugs with a spark plug socket and extension (red arrows in Figure 1n). Figure 1n Need Help With Your Installation? Call (360) 260-CORK 4 of 22 Part # GEN-6-501-10 2. Support the Car on Floor Jack/Jackstands or Lift a) Use a floor jack and jackstands to gain access to the underside of the vehicle. Always refer to the floor jack and jack stand manufacturers instructions as well as the factory owners manual for your vehicle to determine jacking points and support points. Alternately, use an automotive lift to gain access to the underside of the vehicle. Redundant support mechanisms are recommended. b) Remove the passenger’s side front wheel with a 21mm lug wrench. Push Clip c) Remove the passenger’s side fender well Figure 2a splashguard. Use a 10mm socket wrench to remove the two (2) screws (red circles) and a flat blade screw driver to remove the clip (green arrow in Figure 2a). 3. Remove the Factory Camshafts a) Use an 8mm socket wrench to remove the fourteen (14) 8mm bolts fastening the valve cover to the head (valve cover removed exposing camshafts in Figure 3a). Figure 3a b) Remove the serpentine belt. Use a long 14mm wrench to turn the belt tensioner clock wise (red arrow in Figure 3b). Loosen the belt and remove it from the car. Figure 3b Need Help With Your Installation? Call (360) 260-CORK 5 of 22 Part # GEN-6-501-10 3. Remove the Factory Camshafts (continued) c) Turn the crankshaft with the 21mm bolt clock wise, to approximately 15° Before Top Dead Center (Figure 3c). BTDC is located before the holes on the crankshaft 15° BTDC pulley line up, and when the #1 camshaft lobes are 0° TDC pointed toward each other as shown in Figure 3d. Figure 3c d) Locate the crankshaft blind plug (red circle in Figure 3e). Remove it with a 10mm wrench. Figure 3d (#1 cam lobes pointed toward each other) e) Screw the TDC locator pin into the cylinder block all the way by hand (Figure 3f).