If you have CorkSport Fuel Pump Internals, you need to read this!!

[goHAMM]

So, as posted in a previous thread, I was having issues with chattering at throttle tip-in. Most people said VVT, then to check the pulleys, and I even found out my k04 had eaten a rock and the compressor was soon to go. After checking and replacing all of that, I STILL had the chatter. Not only did I have that tip-in chatter, but in a matter of days, it turned into loud chatter at ALL engine speeds (other than idle, and only at tip-in at neutral).

Determined to not just "deal with the chatter", I listened around the engine with the old "screwdriver stethoscope" trick, and finally isolated the noise to the HPFP housing. The next night, I pulled the spill valve, which had some carbon build up, but no damage, so that wasn't the issue. Then, I pulled the internals.

What I found: The spring, retaining clip, tappet, and cam follower all looked to be in good condition, but the piston was a different story. As you can see in the pictures, there are sizable chunks missing from where the retainer meets the piston head, which would explain the chattering. There was zero pressure loss during this time, but I do believe that I was lucky to catch this when I did.

Moral of the story: If you have CorkSport HPFP internals, and they start chattering, IT'S NOT NORMAL!!!! Pull them and check them ASAP! This is the first occurrence of this happening, but I also have about 15k miles on them. I bought mine out of the first batch of "post-recall" internals, and followed their install instructions 1000% accurately (I'm OCD about this stuff, so I take my time). I'm not here to bash CorkSport, and they have been contacted and are fully aware of the issue.

This post is just here to let people know about this issue, and hopefully save a motor or 2. Thanks to @edgeautosport for hooking me up with a new set of AutoTech internals overnight on late notice.

[danmillerok]

Glad you went with your gut and pulled it apart.

[[R]usty]

@goHAMM;

Are you talking about this?



Was something inside the retaining clips causing this? Are there any visual issues with the clip? Can we possible get pictures inside the clip?

[JgamB]

@goHAMM;'s videos do sound like "normal" DISI chatter - so this is also a good lesson to go with your gut and not a diagnosis from people listening to it through speakers. Hopefully this was just an isolated part failure, but it's a good PSA regardless.

[goHAMM]

There was nothing in the clip when I pulled it. Like I said, It made be a one-time thing. But, if it DOES happen to anyone else, there is now a reference for them.

[SpencerC]

@goHAMM;

Thanks for the info. We have already worked with you on this and I appreciate that you came to us first to inform us of the issue.

This is definitely the first we have seen this. I can't imagine what would cause the top to get eaten like that but I'm glad you pulled it, even if it was working fine.

Two things of note for everyone else. Make sure to pull them if you hear noise, and make sure you follow the instructions clearly including hammering the tappet into place in the retainer. I know I have told a few people that the pressure from the camfollower and HPFP housing would cause the tappet to be seated if it wasn't fully installed, but that was misinformation. It must be seated fully first. I remember talking to @goHAMM; on the phone about the retainer and tappet, sadly I don't remember if it was to let him know that it the camfollower and HPFP housing would seat the tappet for him, or to let him know that he needed to seat the tappet and retainer all the way. Either way though, it was my fault for misinformation, or he installed it right. I know because he called me during install to make sure, but I could see this happening if for some reason the tappet and retainer were not flush together.

Mostly I just want everyone to make sure you keep your car safe, if you feel like something is not right, check it, don't just trust the opinion of others. The video, and symptoms definitely did not point at the HPFP having a problem, perfect fuel pressure and what "most people" though was a normal sound, turned out to not be normal.

Also, if you hear an odd noise from ANY Corksport part feel free to let us know. I feel confident in saying that we will err on the side of caution everytime and have you inspect it if it does not seem normal.

[ALPINEST4RS]

Did you find the chunks??

[SarcasticOne]

I must commend OP for going to corksport first before posting on forums

[ASHMS3]

Op thanks for the heads up and the thread. Also for keeping CS in the loop.

Using bad grammar from my cell phone.

[davespeed1]

Good call!!! Ty

[Matt H.]

I will always think good things about a after market company that replies in this way. Even if it really was a the customers fault on the install. With the information at hand maybe know one will know. With this being said i think Corksport is trying to push forward with some of there products to help the platform and there will be bumps in the road.

[goHAMM]

Originally Posted by Matt H. I will always think good things about a after market company that replies in this way. Even if it really was a the customers fault on the install. With the information at hand maybe know one will know. With this being said i think Corksport is trying to push forward with some of there products to help the platform and there will be bumps in the road.

Um, no. We do know. I am not at fault. Had I installed them incorrectly, they wouldn't have ran 100% efficiently for 15k miles. I get what you're saying, but even CorkSport has acknowledged that I am not at fault.

[littleloogy]

Was there chunks of metal in your cam follower?

Sent From a Galaxy, Far Far Away...

[Raider]

Originally Posted by SarcasticOne I must commend OP for going to corksport first before posting on forums

This was my first reaction, honestly. I did not see a mention in the OP that it was discussed with them, and this is not in their section. This is also the first issue I have seen from the new release.

It seems that yes, bad info given, part shit the bed, and the vendor is helping resolve the problem. This is how it should happen, and I commend the OP for going to the vendor to get it resolved, before blowing up MSF with a 27 paragraph tirade, as others have done before, with other vendors (just some guy did this over a $2 part once obtainable easily, true story).

That said. I am compelled to put this into the @CorkSport; section, since this is directly related to their product, and may catch the eye of more owners.

[YoursTruly]

I think I have CS internals in my 6, but they were installed by the PO. The car makes all kinds of noises (clutch chatter, axles popping, loud angry exhaust, @JgamB; and his epic flatulence, etc.), so making sure there is no unusual noise from the hpfp could be difficult.

[goHAMM]

This problem wasn't related to bad advice given. I tapped down the tappet onto the retainer, because it was in their directions, and then called Spencer as a "I wonder if I even needed to do that" follow-up. These were installed correctly. I remember doing it because I thought "they gave me these fancy tools to use, and even though it's preassembled, I want to use them anyway!" I took the butt end of a screwdriver and pounded the thing down (it didn't move BTW). And let's all remember that I put 15k miles on these things, holding 1800+ psi during WOT logs, and there wasn't even a performance drop the morning of the day that I pulled these internals out. I doubt they would've performed so well for that long had it been an install error. Not to mention the pressure that these things are put under, you would think that it would've seated the tappet even had I not done it (which i did!!). lol

As far as where @Raider wants to put this thread, do what you feel is best. I'm new to actually posting important stuff instead of just reading, so I expect my work to be sorted out and corrected.

Finally, I always feel that it's important to go to a company first, before running your mouth. Life is 20% how you act, and 80% how you REact, so what makes a company high quality isn't just how well they make their parts, but also how they respond to failures/issues. Derrick and Spencer made it a point to rectify the situation, even after dealing with a frustrating and disrespectful employee, so I greatly appreciate them doing that. It meant a lot.

[goHAMM]

Originally Posted by littleloogy Was there chunks of metal in your cam follower? Sent From a Galaxy, Far Far Away...

I did not find anything in the cam follower, the only solid particles I found were in the spill valve and around the O-ring on the internals side of the pump.

[CorkSport]

We spoke with the OP about what happened before he posted up. We SUPER HAPPY he posted up on the forum.

-Derrick

[Gr8Speed]

Since someone else has now had a similar issue- I've got this issue too (except on KMD). Making odd chattering noise and I know it's the fuel pump. I pulled it the other day to find I had the "clear death" from running a 50/50 e85 mix. Cleaned it all up and reinstalled and it's still making the noise. Fuel pressure is normal at idle/cruise/WOT too. No visual issues with the internals. I'm baffled. I also noticed that whenever it makes the chattering noise it has a little bit of a fuel pressure bump and the engine revs a little higher.

[goHAMM]

Originally Posted by CorkSport We spoke with the OP about what happened before he posted up. We SUPER HAPPY he posted up on the forum. -Derrick

Like I said, after all was said and done, I appreciate you following up. I strictly put this here as proof that people should always trust their gut and not the interwebz when they think something is wrong. It's like in nursing, no matter what the monitors at the nurse's station tells you, if something looks or feels wrong, step 1 is to lay eyes on the patient.

Also, I 100% don't find @Spencer@CorkSport at fault on this issue. I also don't "find @CorkSport at fault" as far as the part issue goes. Shit happens, you wanna be a racecar, you're gonna have racecar problems.

[littleloogy]

You had metal particles in your spill valve??? I'm not sure how that could have happened. That's scary, I hope metal did not get past the pump and into the fuel rail.


Sent From a Galaxy, Far Far Away...

[goHAMM]

Originally Posted by littleloogy You had metal particles in your spill valve??? I'm not sure how that could have happened. That's scary, I hope metal did not get past the pump and into the fuel rail. Sent From a Galaxy, Far Far Away...

I don't know if they were metal, i just know they were small black particles. Could've just been carbon for all I know. They looked like the stuff that was on the picture that i posted in my last response.

[cyclist20]

I currently have about 2500 on mine with no issue. I shall be listening for abnormalities. Thanks for the info so I can keep an ear out.

[tegxsi]

I haven't put mines in yet but seeing stuff like this makes me nervous.

[everton99]

In all fairness failure can happen with any part, no matter who makes the part. It just comes down to what company you prefer/trust the most. I personally support CorkSport because they're a Mazda specific company. I've got about 10K on my internals and so far I've had no issues. Fuel pressure has always been spot on since the day I installed them. Much love for CorkSport and the way they handle issues.

[danmillerok]

Additionally despite the damage the internals show the pump was holding pressure and everything else seems to be in order. No cause for alarm yet I would say.

[ROTAgé]

Glad to hear this story, just proof that crazy things happen for no apparent reason and once we all head down this road of modifying our cars there is an intrinsic value that "we/they might cock something up." Glad to see the two parties come together for a solution before another completely useless flame war breaks out. +1 inter-web decorum

[Gr8Speed]

Originally Posted by ROTAgé crazy things happen for no apparent reason

No. Everything happens for a reason. Although it may be a random failure and the only one that ever fails, there was still a reason it failed.

[ItsNox]

I'm impressed with the lack of rants in this thread regarding the issues with corksports new products. And with how cool the OP is about the issue - not sure I could stay so cool after dropping so much cash trying to isolate the problem. While I very much appreciate CS's support & development for our platform, I sure am glad I went with Autotechs. Fuel pump internals aren't something I wanna fuck around with.

Good to see Corksport handling it so well. Its what keeps them in good graces, I think. Lets hope this doesn't turn into another recall. Thanks for letting everyone know @goHAMM;, and for being so civilized about it lol.

[littleloogy]

Originally Posted by tegxsi I haven't put mines in yet but seeing stuff like this makes me nervous.

Worry not. Just because this happened to one person does not mean every single unit is going to do the same thing. Now if we see 2 or 3 of the same type of failure then yes, you should be skeptical.

This unit could have failed for many different reason. It could have been dropped at the factory, installed improperly, or maybe someone used it as a bottle opener. If something was wrong with the product, CorkSport would say something.

All companies have failures, we are just becoming more aware of these failures though social networking. This thread was created to let everyone know what happened and to see if anyone else has had the same problem. Since NOBODY has had the same issue, this is a fluke and should be treated as such.

Sent From a Galaxy, Far Far Away...

[SarcasticOne]

Originally Posted by Raider This was my first reaction, honestly. I did not see a mention in the OP that it was discussed with them, and this is not in their section. This is also the first issue I have seen from the new release.

He said he contacted them in OP

Originally Posted by goHAMM I'm not here to bash CorkSport, and they have been contacted and are fully aware of the issue.

[Raider]

But no @ mention. So neener neener

[Blue Speed3]

Originally Posted by goHAMM Shit happens, you wanna be a racecar, you're gonna have racecar problems.

This. I love this quote.

Also, kudos to Corksport for stepping up to try to help the OP and not just blame him. Hopefully it's just an isolated incident

[Jkspeed]

I kind of predicted something happening when they released this...but glad to hear they're helping out now.

[Raider]

This is not a defect, so not sure what you predicted.

[Jkspeed]

Predicted there would be some issue upon release. Never said there was a defect or "fatal flaw". On the plus, this only seems to be a first isolated incident.

[faeker]

^ posting just to post. could probably do without em.

[Jkspeed]

You could say that about a lot on here...but yes you are more or less correct, I didnt need to post. But I do have a distaste for corksport. And expressing my thoughts on the topic.

Ignore my posts then. Continue with discussion.

[camry90]

I was going to get a corksport internals just because it comes in a fancy box. Then I saw the OP's thread, I was dissapointed.... But then when I saw Corksport taking care of business like a good company should, now I will still want a Corksport internal!

[ROTAgé]

Originally Posted by Gr8Speed No. Everything happens for a reason. Although it may be a random failure and the only one that ever fails, there was still a reason it failed.

understood, but CS did not develop the part to fail. The point being shit happens and it usually looks a lot worse than this