Mazda6 – new Wagon, Hatchback & MZR-CD 2.0-litre Diesel

The all-new Mazda6 sedan was launched last November to high acclaim as an evolution of Mazda’s Zoom-Zoom brand promise. Its emotional and sporty styling, exclusive driving and quality experience and insightful packaging create a strong emotional tie between the car and its owner, called Kizuna. Now the news gets even better, with the introduction of new wagon and hatchback versions to the line-up, along with the MZR-CD 2.0-litre common-rail turbo diesel.

The outgoing Mazda6 represented a revolution for the Mazda brand and went on to become Mazda’s best-selling line-up in Europe. The most popular body styles have always been the sleek and sporty-looking wagon and hatchback versions with a take-rate in 2006 of about 40 and 34 percent respectively.

1^st-Generation Mazda6 Body Styles 2006 in Europe

Design – Japanese Aesthetics

The new Mazda6 inherits the same athletic look as the very successful outgoing model, but communicates this in a more radical way. Its exterior design is executed with exquisite build quality and a sense of form based on Japanese aesthetics for high emotional appeal that is unmistakably Mazda. The new Mazda6 hatchback version has the same exterior dimensions as the sedan. It is longer (4,735 mm + 65 mm), wider (1,795 mm + 15 mm), taller (1,440 mm + 5 mm) and has a longer wheelbase (2,725 mm + 50 mm) than the outgoing five- door and features a sleek roofline at the C-pillar for a coupe- like character. The new wagon is the longest (4,765 mm + 75 mm vs. previous model) of the three body styles, and it is wider (1,795 mm + 15 mm) and only slightly higher (1,490 mm + 10 mm) than the previous model with a kick-up belt line and sleek windows. On the inside, the new Mazda6 is even roomier and more inviting than before. It has higher levels of quality feel with interior forms that are appealing to look at and use. Its cockpit allows the driver to feel one with the car and it has a floating-look instrument panel that gives a sense of roominess.

Quality, Comfort & Equipment – Premium Look and Feel

Mazda6’s design appeal does not come at the expense of C/ D- segment (family-sized) roominess and practicality. In fact, it has more of both. The new Mazda6 has more rear leg room (+ 20 mm) and shoulder room (+ 9 mm) thanks to its larger exterior dimensions. The driver enjoys a better view of the road with one of the segment’s best forward-upward visibility levels and it has newly-designed rear head restraints and door mirrors for a better view to the rear. It is more convenient than before as well, with one of the segment’s widest boot/ tailgate openings, a Karakuri rear seat folding system that drops the 60/40 rear seats down by pulling a latch in the boot trim, and a new Karakuri tonneau cover that automatically rises when you open and close the liftgate (wagon only, see box). Comfort is improved too with new seat frames for good long-trip and side support and a new heating, ventilation and air conditioning (HVAC) system with separate temperature controls for the driver and the passenger. The cockpit now features blackout driver metres (depending on grade) with new amber-red illumination circled by indirect blue lighting, a new sports car-like steering wheel and gear shift lever positions that are closer to the driver for easier control and shifting.

All this is carried out to deliver an ‘exclusive experience’ with Mazda quality evolved to the next level. In an interior with lower levels of cabin noise (-2.5 dB from 70 dB to 67.5 dB at 60 km/h on coarse road), choice leathers and fabrics are used, and the floor console has a premium dimpled finish and a sliding armrest in leather with detailed stitching (depending on grade). Available as well is a new Action Illumination system with light fade up and down, and interactive light reaction when using the CD and radio. Up to five grades will be offered (depending on market), each with a long list of equipment, some onboard a Mazda for the very first time.

By employing a cross-functional network (CF-Net), for instance, more steering wheel control functionality (audio, navigation, air-conditioning, trip computer and Bluetooth® system) is used. New equipment includes Bi-xenon head lamps, adaptive front lighting (AFS), a tyre pressure monitoring system, a Bluetooth® mobile phone system with seven languages, a parking sensor system, a premium BOSE® audio system and a navigation system featuring a touch screen, voice command and a 7-inch split display (depending on market and grade).

1) New Mazda6 wagon – designed for demanding customers

The Mazda6 wagon has a new luggage compartment design for even more practicality. With one of the segment’s widest openings (1,066 mm), its load floor is 45 mm longer (1,926 mm) than the outgoing wagon and has a maximum load volume of 1,751 litres. The first 700 mm from the tailgate opening inward are a segment- leading 1,146 mm wide, after which it narrows to 1,030 mm between the wheel wells. This design means smaller items can be placed further in where loading is more difficult and heavier items like two large suitcases can be placed closer to the opening where they are easier to load.

“With regard to the rear seat, we found that Europeans rated foot and knee space as their number one concern, shoulder room as their number two concern. For us, then, the key was to realise plenty of knee space. By taking this kind of customer-need-focused approach throughout the cabin, we were able to create a sense of roominess far superior to that experienced in the current model,“ explains Masanori Kodaira, engineer for vehicle base design. In fact, the new Mazda6 wagon, as well as the hatchback and sedan, have 9 mm more front shoulder room and a full 13 mm more rear knee room – just what Europeans are looking for in a family-sized wagon.

2) Tonneau cover – a new Kararuki chapter

The insightful automatic tonneau cover of Mazda6’s new wagon was inspired in part by the Japanese Origami tradition of folding. This has a long history in Japan and is so ingrained in Japanese culture that even today you can find truly amazing folding mechanisms in things like the covers of bathtubs. Developers studied carefully desk drawers and curtain rails for their smooth sliding mechanisms and durability. Development began in 2004 and more than 10 prototypes of the automatic tonneau cover were created over the next two years in a long process of trial-and-error. At the start, engineers also tested an electric motor, but this was not retained – under Mazda’s strict weight-savings programme and for reasons of durability – in favour of a simple and durable mechanical solution. The same applied to development of the tonneau cover material, which had to be stored when not in use, had to be large enough for Mazda6’s wide tailgate opening and still be rigid and durable, lightweight and heat resistant. Not only did engineers deliver all these attributes, Mazda6 wagon’s automatic tonneau cover employs a mesh material that allows the user to see through it and to provide thermal insulation to the passengers when the tailgate is open. When not in use, the tonneau cover can be stored under the boot floor.

Powertrains – New MZR 2.5-litre Petrol

The new top of the line engine, the MZR 2.5-litre petrol, replacing the MZR 2.3-litre petrol of the outgoing model, not only produces more maximum power of 125 kW/170 PS (+ 4 PS) at 6,000 rpm and more maximum torque of 226 Nm at 4,000 rpm (+ 19 Nm) than the 2.3-litre, it also uses 6.8 percent less fuel per 100 km (wagon). It is smooth and cultivated with low engine noise thanks to its high-rigidity cylinder block, a stronger crankshaft, two balancer shafts and a dual-mass damper and a flexible flywheel. It employs sequential-valve timing (S-VT) and a variable intake system (VIS). At the same time, the new MZR 2.5-litre petrol has reduced exhaust resistance for even better engine efficiency.

The second-generation Mazda6 inherits three fun and frugal engines from the previous model, all of them updated to use less fuel than before. The most popular engine of the line-up is onboard: the MZR-CD 2.0-litre common-rail turbo diesel with diesel particulate filter (DPF). It produces 103 kW/140 PS at 3,500 rpm and 330 Nm of maximum torque at just 2,000 rpm, and uses 6.7 percent less fuel than the outgoing 2.0- litre turbo diesel version (sedan). Also carried over from the previous model are two MZR petrol engines in 1.8-litre and 2.0-litre displacements. The 2.0-litre produces 108 kW/147 PS of maximum power at 6,500 rpm and maximum torque of 184 Nm at 4,000 rpm, while using 10 percent less fuel (wagon). The MZR 1.8-litre base engine produces 88 kW/120 PS of maximum power at 5,500 rpm and maximum torque of 165 Nm at 4,300 rpm, while using 11.4 percent less fuel than the outgoing base petrol (wagon). The second-generation Mazda6 comes with a choice of three transmissions (according to model) including Mazda’s five-speed and six-speed manual gearboxes for all models. To this it adds a five-speed automatic with manual shift mode for the 2.0-litre petrol version for near-manual- like shifting in every gear.

MZR-CD 2.0-litre Common-rail Turbo Diesel

Evolved refinement

The MZR-CD 2.0-litre common-rail for the new Mazda6 line-up was updated to be even more refined and quiet. The powertrain control module was newly calibrated with optimised mapping for fuel injection quantity and injection timing, which not only reduced knock even more, but also resulted in better drivability, fuel efficiency and emission performance.

Engineers also changed the layout of the intake/exhaust. The engine’s EGR cooler efficiency is improved by 10 percent. These enhancements, combined with the engine’s ultra high-pressure common-rail technology with six-hole injectors and a relatively low compression ratio of 16.7:1, resulted in the latest version of Mazda6’s 2.0-litre turbo diesel using just 5.6 litres of fuel per 100 km (combined), which is 6.7 percent less than the outgoing 2.0-litre diesel.

The new Mazda6’s updated 2.0-litre turbo diesel also produces less harmful emissions than its predecessor. The engine has an EGR valve to reduce the production of NOx, and it comes standard with a diesel particulate filter system. This system’s filter captures diesel particulate matter (PM) in the exhaust then burns it off after filter capacity has been reached by temporarily raising exhaust gas temperatures. And the system requires no special fuel additive and is maintenance-free because the channels of the filter are coated with platinum, which lowers the light-off temperature of the collected PM and allows filter regeneration at a lower exhaust gas temperature of between 350º C to 500º C.

Chassis & Safety – Sporty, Predictable and Safe

To deliver on the ‘emotional and sporty’ key Mazda brand value, engineers improved Mazda6’s renowned handling and steering qualities even further. This was not easy, since the car is larger and better equipped. To avoid any gain in weight, which would negatively affect handling and fuel consumption, engineers strictly controlled the weight during development as was done previously with the third-generation Mazda MX-5 and the new Mazda2. For instance, Mazda6’s all-new body shell has 7 percent more high and ultra-high-strength steel, which result in double-digit increases in both flexural and torsional rigidity for all body styles – without a gain in weight. These efforts resulted in the new Mazda6 being up to –2.4 percent or 35 kg lighter than the outgoing model for better handling and fuel efficiency, with enhanced crash resistance.

Weight-saving measures on the new Mazda6

A high-mount double wishbone front suspension system is employed with two new perimeter frame mounting points (now six vs. four of the outgoing model), new dynamic dampers for the upper arms to absorb noise and vibrations and stiffer damper settings for excellent overall rigidity and ride comfort. This is combined with a new front suspension, single-pivot type lower arm (the outgoing model uses a double-pivot type) which gives more precise steering and predictability. Mazda’s E-type multilink rear suspension is employed at the back axle with several updates, including larger-diameter (+ 10 mm) trailing arm bushes now placed 25 mm higher to create a different geometry for improved rear lift control and a more linear toe-angle change during the rebound. The rear dampers now have an upright layout which realises linear vehicle movement and a feeling of stability. Rack-drive electric power assist steering is new as well for a firmer steering feel and less fuel consumption overall (approximately -2 percent).

Mazda6 also has vastly improved aerodynamic performance and stability at high speeds thanks to its dynamic and sleek exterior design. All external components were streamlined to produce a coefficient of drag (Cd) of only 0.27 (sedan and hatchback) and just 0.28 (wagon).

Active and passive safety systems round out the new Mazda6’s outstanding package of attributes. It has larger diameter ventilated front disc brakes (now 299 mm + 16 mm) and 280 mm rear brake discs for dependable deceleration; backed up by ABS, electronic brake distribution (EBD), brake assist, dynamic stability control (DSC) and traction control system (TCS) as standard on all models. An Adaptive Front Lighting

System is available as well. The new body shell has a newly- introduced perimeter frame extension at the front of the car, and extended joints between the front side members of the perimeter frame, for a 10 percent improvement in impact- absorption here compared to the previous model. On the inside there are new active head restraints for the front seats to protect the neck in case of rear impact, six airbags, front seat belts with pretensioners and load-limiters and collapsible brake and clutch pedals to reduce the chance of leg injury in a frontal impact. Also onboard are ISOFIX child safety seat mounts and tethers in the outer rear seats, a visual seat belt warning system for rear passengers, pillar trim with energy absorbing ribs and a further improvement of pedestrian protection measures.

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