Mazda unviels New 2.2-litre Diesel Engine for Mazda6

New Mazda6 MZR-CD 2.2-litre diesel

MAJORCA, Spain : November 5, 2008 - A new Mazda-developed 2.2-litre common-rail turbo diesel engine joins the Mazda6 line-up. With a choice of 3 engine power versions up to 185 PS and 400 Nm of maximum power and torque, it provides performance at the top of its segment, while retaining the CO₂ and fuel economy level of the previous 2.0. It also adopts a diesel particulate filter with a unique ceramic support matrix structure for faster regeneration. In addition, the Mazda6 becomes the first in the line-up to offer a rear vehicle monitoring system for enhanced active safety.
Offered in three power derivatives to meet the needs of a wide range of diesel customers in Europe (depending on market and grade):

MAZDA6 MZR-CD 2.2 Engine

New MZR-CD 2.2-litre Turbo Diesel Engine

Next-generation MZR-CD 2.2-litre turbo diesel engine that combines Zoom-Zoom power with low emissions and low consumption

MZR-CD 2.2 High Power: produces 136 kW/185 PS at 3,500 rpm and 400 Nm of torque from 1,800 to 3,000 rpm, using only 5.6 litres (sedan and hatchback) and 5.7 litres (wagon) of fuel per 100 km (combined). Emits CO₂ of 149 g/km (sedan and hatchback) and 152 g/km (wagon)
MZR-CD 2.2 Mid Power: produces 120 kW/163 PS at 3,500 rpm and 360 Nm of torque from 1,800 to 3,000 rpm, using only 5.5 litres (sedan and hatchback) and 5.6 litres (wagon) of fuel per 100 km (combined). Emits CO₂ of 147 g/km (sedan and hatchback) and 149 g/km (wagon)
MZR-CD 2.2 Low Power: produces 92 kW/125 PS at 3,500 rpm and 310 Nm of torque at 1,800 to 2,600 rpm, using only 5.5 litres (sedan and hatchback) and 5.6 litres (wagon) of fuel per 100 km (combined). Emits CO₂ of 147 g/km (sedan and hatchback) and 149 g/km (wagon)

Mazda MZR-CD 2.2 litre Diesel

New common-rail system with injectors that have 10 spray holes (instead of the 6 used on the MZR-CD 2.0-litre) and higher-response solenoids for power combined with low emissions

Common-rail injection pressure increased to 200 MPa, one of the industry's highest, with high-response solenoids, providing higher power, fuel efficiency and good emissions performance
Low compression ratio of 16.3:1, made possible with highly atomizing injectors, for temperature cooling effect which contributes to low consumption

Variable geometry, high-efficiency turbo charger with curved vanes and abradable seal for strong torque at low engine speeds and lively engine response
DOHC valve system is chain-driven for maintenance-free operation
High-rigidity aluminium lower block combined with low-friction, front chain-drive balancer shaft for low engine noise
Newly-developed, high thermal-resistance Mazda unique diesel particulate filter (DPF) system with global-first ceramic support matrix structure for faster regeneration
Newly-developed EGR cooler with superior cooling efficiency

Delivering the Power - Output and Torque
To realise this kind of power and torque with 2.2-litres of displacement, the MZR-CD 2.2 employs a highly efficient variable-geometry turbo charger (VGT) with curved (instead of straight) vanes on the turbine (exhaust) side. This increases maximum available torque at both low and high engine speeds, while also increasing all-important low-end response (as low as only 1,800 rpm with a flat maximum torque curve that continues until 3,000 rpm) that contributes smooth and powerful driving feel. When combined with an abradable seal on the compressor side (intake side), which reduces the clearance between the blade and the compressor housing, these deliver superior turbocharger response at just about all engine speeds.

New injectors featuring - 10 spray holes per injector

Converting the engine's combustion energy into this much engine torque meant the pistons had to be designed to take the resulting high combustion pressure and temperatures. As a consequence, the pistons are made of an aluminium alloy with improved high-temperature fatigue strength. A half-Keystone cross-section top-ring with improved carbon scavenging abilities is used, and the groove for the top ring is made more durable with the adoption of a cooled ring carrier that increases the groove's cooling capability.
Mazda engineers also increased the fuel injection pressure to 200 MPa (by comparison, the previous generation MZR-CD 2.0-litre turbo diesel uses 180 MPa). They realised this by making functional improvements to the high-pressure pump, among other improvements, and by new injectors featuring 10 spray holes per injector (instead of the 6 spray holes for the MZR-CD 2.0-litre) that are smaller (reduced from 0.13 mm to just 0.119 mm). These changes enable more precise injection timing, and an increase in the number of times of injection and injection amount. And it allowed the fuel injection patterns at transitional states to be more precisely controlled. As a result, the Mazda6 MZR-CD 2.2 provides superior acceleration in those situations you need it most, like entering the motorway. It also surpasses its competitors in lower speed acceleration. Acceleration in 3rd gear from 50 to 100 km/h, for example, is 1.7 seconds faster than the MZR-CD 2.0-litre.

Low Fuel Consumption
This new diesel engine also meets the requirements of Mazda's 'Sustainable Zoom-Zoom' plan by being frugal at the pump: all power derivatives use between 5.5 and 5.7 litres of fuel per 100 km (combined), some of the segment's lowest.

It achieves this by employing highly responsive solenoids for the common-rail injection system that achieve a minimum injection interval of just 0.2 ms (the MZR-CD 2.0 is 0.3 ms), which speeds up the minimum injection interval by about 30 percent, improves its responsiveness and lowers fuel usage. Fuel is also saved by lowering the compression ratio to 16.3:1 and utilizing the temperature cooling effect this causes, which secures more mixing time until ignition, and allows a more precise fuel-injection pattern. As a result, fuel consumption is a low 5.5 to 5.7 litres (depending on derivative) with CO₂ emissions from between 147 to 152 g/km. In fact, the MZR-CD 2.2-litre offers substantially higher power and torque than the previous-generation MZR-CD 2.0-litre, while delivering equal levels of fuel consumption and CO₂ emissions.

Low Emissions - Particulate Filter with World's First Ceramic Support Matrix Structure
Mazda engineers not only made the new 2.2-litre turbo diesel powerful and low consumption, they also lowered the amount of raw emissions and raised the efficiency of its after-treatment technologies. The engine's highly responsive fuel-injection technologies have new injectors (see above) that yield better atomized spray characteristics. These are combined with an exhaust-gas recirculation (EGR) system with a cooler bypass structure - that decreases unburned gases and NOx - and the high-response solenoids described above, to realise superior emissions performance without sacrificing power.

Mazda unique diesel particulate filter (DPF) system

Emissions are then treated by a diesel particulate filter that uses a unique Mazda-developed, ceramic support matrix structure, which is the first of its kind to go into production in the world. Previous diesel particulate filters converted particulate matter (PM) into CO₂ by reacting the PM with the oxygen in the exhaust gas at the When the temperature of the exhaust gas is raised to quicken the regeneration time, then technological issues - like higher fuel usage or the ceramics exceeding their thermal resistance limit - can occur. Mazda solved these issues by using highly thermal resistant material for the ceramic monolith of its new diesel particulate filter, and designing the internal structure of the ceramic support matrix with passages for oxygen to enable a large amount of oxygen to be utilized for PM combustion. With this, Mazda has succeeded in significantly increasing the PM combustion speed. As a result, the number of times the diesel particulate filter has to regenerate (in combined mode) is cut in half, and the time necessary for each regeneration phase is shortened by one third. For owners of the new Mazda6 MZR-CD 2.2-litre turbo diesel, this means worry-free filter regeneration and, because fewer regeneration phases are required and each takes less time, less fuel consumption overall.

MZR-CD 2.2 Engine - Balancer

Running Quiet
The new Mazda6 MZR-CD 2.2-litre common-rail not only offers superior output, fuel economy and emissions performance, it is also one of the quietest engines in its segment with this amount of torque. This ensures a driving experience that is one of the non-premium segment's most exclusive. To achieve this, the new engine has a lower block with a very rigid aluminium-alloy structure, with the bottom of the cylinder block skirt and the cylinder block's main bearing caps bolted to the lower block at 18 separate locations. This high structural rigidity is combined with a front chain-driven cassette-type balancer shaft to suppress booming noise and lower radiated noise, and to deliver optimised pedal response and engine sound for a refined acceleration feel.

Packaging and Weight Management
Keeping the new MZR-CD 2.2-litre engine as close as possible in size and weight to that of the MZR-CD 2.0-litre diesel was a key factor in ensuring exhilarating performance combined with fuel efficiency and low emissions. Some of the newly adopted technologies, such as the balancer shaft and DOHC, result in increased size and weight. Nonetheless, numerous innovations were added to manage size and weight increases, with the goal of maintaining packaging and keeping the weight increase within just 6.0 kg of the previous MZR?CD 2.0-litre turbo diesel.

Due to the increase in displacement, the stroke of the MZR-CD 2.2 was lengthened by 8 mm compared to the MZR-CD 2.0. At the same time, the overall length of the connecting rods was shortened by optimizing their design. As a result, their weight remains at the same level as in the MZR-CD 2.0. The adoption of a balancer shaft that decreases vibration caused by reciprocating motion made a thinner cylinder block with fewer ribs possible (if the MZR-CD 2.2 had no balancer shaft, the cylinder block would have been 1.9 kg heavier than that of MZR-CD 2.0, and its crankshaft 1.3 kg heavier.). Furthermore, decrease in size and weight was achieved by making the balancer housing, oil pump housing, and the oil suction pipe a single structure. To achieve even more weight reduction, while increasing the cooling capability of the new engine, the oil cooler is made of aluminium (-0.6 kg). The weight of the cam cover is also reduced by making it out of plastic (-1.0 kg).

New Mazda6 2.2-litre diesel features :

New Rear Vehicle Monitoring System

New Rear Vehicle Monitoring System

First application among Japanese brands sold in Europe (depends on market and grade)
A fully independent active safety feature that detects and warns the driver of an approaching vehicle before he has a chance to change lanes by mistake
Uses two wide-angle, 24 GHz microwave radar units on the right and left side of the rear bumper to cover both sides of car within a range of about 50 m
Automatically calculates distance of the following vehicle, and its speed relative to the speed of the Mazda6
Uses one of two 'proximity indicator lights' in the inner garnish sails at the base of each A-pillar to warn the driver at approach of vehicle from left or right rear, or if a vehicle is already in the driver's blind spot
If the driver switches on the turn signal in the direction of the approaching vehicle, the proximity light blinks and a beeper sounds to warn the driver not to change lanes

Other Powertrains

MZR 2.5-litre petrol engine produces maximum power of 125 kW/170 PS at 6,000 rpm and maximum torque of 226 Nm at 4,000 rpm
MZR 2.0-litre petrol produces 108 kW/147 PS at 6,500 rpm and maximum torque of 184 Nm at 4,000 rpm
MZR 1.8-litre petrol produces 88 kW/120 PS at 5,500 rpm and maximum torque of 165 Nm at 4,300 rpm
MZR-CD 2.0-litre turbo diesel remains in the line-up in some markets. It produces 103 kW/140 PS at 3,500 rpm and maximum torque of 330 Nm at 2,000 rpm.
Five and six-speed manual transmissions according to model, five-speed automatic with manual-shift mode for 2.0-litre petrol

Exterior

Eye-catching design based on Japanese aesthetics
Three distinct body styles - sedan, hatchback, wagon (depending on market)
One of the segment's lowest coefficient of drag, Cd 0.27 for sedan and hatchback and 0.28 for wagon
Minimal gaps between body panels reflect high quality
Rear lamps with LED standard in Europe
Choice of 16, 17 and 18-inch wheels
Sports appearance package is standard for sporty high-grade version

Interior

Floor console with sliding leather armrest (depending on grade)
More rear leg room (+ 20 mm) and shoulder room (+ 9 mm) for even more comfort
Optimal rearward visibility with special door mirror shapes and new rear head restraints
Gear shift lever placed closer to driver for easier shifting
Welcome mode with gradual illumination
Action illumination light system with fade in/out for audio commands

Chassis & Safety

Larger with more equipment than previous Mazda6, yet up to 35 kg lighter
Use of high and ultra-high strength steels
Higher flexural and torsional rigidity than any Mazda6 before it for improved handling and safety (sedan, 32% and 14% higher respectively)
High-mount double wishbone front suspension
E-type multilink rear suspension
Rack-drive electric power assist steering for a more firm steering feel and reduced fuel consumption
Improved active safety with large front disc brakes (299 mm)
ABS, electric brake distribution (EBD), brake assist, traction control system (TCS) and dynamic stability control (DSC) standard for all models
High-intensity Bi-xenon headlamps, Adaptive Front Lighting System, tyre pressure monitoring system and parking sensor system (optional)
Daytime running lights
Standard active front head restraints that lower the chance of neck injury during rear impact
Collapsible clutch and brake pedals for improved lower leg injury prevention
Front passenger, side and curtain airbags standard for all models
A further improvement of pedestrian protection including energy-absorbing space between the bonnet and the engine
Special foam in the bumper beam and plastic reinforcements at the bottom of the front bumper to help lower the chance of leg injuries

Equipment

Up to five equipment grades (depending on market)
Heating, ventilation and air conditioning (HVAC) system with separate controls for front seats (depending on grade)
Cross-functional network (CF-Net) in steering wheel enables more and easier control of audio, navigation, air-conditioning, trip computer and Bluetooth system
Advanced Keyless Entry and Start System and push on/off ignition button (optional)
Bluetooth mobile phone system with one-button (on steering wheel) operation in seven European languages (optional)
8-speaker premium Bose? audio system with digital amplifying technology (optional) and AUX jack for MP3 players that use car's audio system
Navigation system with touch screen, voice command and a 7-inch split display (optional)

Images : MAZDA6 SAP