New Mazda5 Diesel

Press Release

MZR-CD 2.0-litre Euro Stage IV compliant

 

With the introduction of the new Mazda5, Mazda breathes new life into the European C-MAV segment with a stylish, flexible and fun to drive vehicle offering two spirited petrol powertrains and two derivatives of Mazda’s improved MZR-CD 2.0-litre common-rail direct injection turbocharged diesel engine coupled to a new 6-speed manual transmission. Both diesel derivatives come standard with a diesel particulate filter system that is maintenance-free and Euro Stage IV compliant. Added to Mazda5’s unique Karakuri seating system with room for up to seven, class-first sliding doors, comfort and convenience, Mazda5 will offer customers just the right vehicle to meet their needs.

 

Positioning – the Zoom Zoom Alternative

 

• Only C-MAV in Europe with sliding doors

• Room for up to seven

• Highly flexible Karakuri seating and storage concept

 

Mazda has been successful with its compact van, the Mazda Premacy, selling 333,000 worldwide and over 140,000 in Europe between 1999 and mid-2005. The all-new Mazda5 is the Premacy’s successor and Mazda’s fifth new-generation product since the launch of the Mazda6 in 2002. Designed from the inside out, it provides insightful interior functionality, stylish exterior designing and spirited driving dynamics for a balance that makes it the Zoom-Zoom alternative in its segment in Europe.

 

The Mazda5 is Mazda’s first Zoom-Zoom venture into the C-Multi-Activity Vehicle (C-MAV) segment. This is one of the most important segments in Europe with growth of over 60 percent between 2000 and 2004. A total of approximately 1.4 million C-MAVs were sold last year. The Mazda5 enters this segment offering smart seating and storage solutions in a dynamic looking and surprisingly fun-to-drive vehicle.

 

Mazda5 is the only car in its segment with sliding doors. It is the only vehicle with a unique and innovative Karakuri seating and storage concept. This system uses the open, communicative space in the centre of its 2+3+2 interior to transport up to seven people in comfort. It is fun to drive and fun to look at on a daily basis. A full range of engines including two common-rail, Euro Stage IV compliant turbo diesels allow customers to choose just the right Mazda5 for their needs, regardless of where they live. Customers will be in their late thirties, either with or without children. They will be style conscious, sporty and perhaps a bit self-indulgent. For these customers, Mazda5 is the ideal vehicle.

 

Interior Functionality – Communicative and Flexible

 

• Superior functionality with innovative Karakuri seating and storage concept

• 45 storage compartments

• One-touch walk-in functionality for easy in- and egress

 

Mazda5 was designed from the inside out with high levels of comfort and convenience. It is designed around a space at the centre of the interior that promotes front to back communication, and takes full advantage of this space via an innovative Karakuri seating and storage concept to deliver superior seat flexibility and room for up to seven.

 

Front Row Environment

The driver environment of the new Mazda5 has been optimized for adjustability and operating comfort. The driver’s seat features 260 mm of slide adjustment and 56 mm of height adjustment. The seatback has adjustable lumbar support and can be reclined. The steering wheel is adjustable in height, 40 mm, and telescopically, by 50 mm. The shift lever is placed at the bottom of the centre instrument panel for high levels of shift comfort. The driver pedals have a layout that helps prevent discomfort in the legs, feet and ankles, including a specially developed accelerator pedal pad designed to stay snug to the driver’s foot during operation.

 

In front of the driver is a three meter instrument cluster with the speedometer in the middle. The centre instrument panel is raised to position audio controls and climate controls where they can be easily seen and reached. An aluminium-look finish gives the centre stack a refined appearance, which matches the front door switch bezels and inner handles for added quality. Yellow-green backlighting is used for meters and switches giving a cool, clean look to the driver area. And, of course, the passenger seat can be slid forward and backward, and reclined to a horizontal position if need be.

 

Second and Third Row Flexibility

Mazda5’s second row seats have 270 mm of slide adjustability and can be reclined. They feature one-touch walk-in functionality that provides easy access to the third row. After sliding the door open, pull lightly up on a lever on the outside of the cushion and the seatback automatically tips forward and slides to its front-most position. The resulting walk-in space between the C-pillar and the second row seat is large enough (628 mm at top of seatback, 240 mm at foot level) to make getting in and out of the third row easy. The second row seats can also be double-folded without

removing any headrests and without having to retract the seat belt separately. Simply pull on a strap at the back of the cushion, tip the cushion forward against the front seatback, then lift the same lever used for walk-in functionality, which automatically tips the seatback onto the floor.

 

Comfort for all rows

Comfort is further ensured by ample cushion widths of 510 mm in the first row, 500 mm per seat in the second and third rows. Since body-pressure distribution significantly influences seating comfort, each seat has a structure that evenly disperses body pressure regardless of the user’s physique, thereby minimizing fatigue and enabling long journey comfort. The S-spring structure in the first-row seatbacks and second- and third-row seat cushions enable thin cushioning panels to provide performance similar to that of conventional seats. This combination of comfort and space efficiency makes it possible for under-cushion storage areas and realization of the Karakuri seating and storage concept.

 

Karakuri Seating and Storage Concept

Mazda5 takes this basic seat flexibility and convenience to a new level by adding an innovative Karakuri seating and storage concept, which can convert the vehicle into a seven-seater in a matter of seconds and without having to remove or add anything. A seventh seat cushion is stored under the left second row seat. After locking the wide armrest between the second row seats into the up position, the left hand seat cushion is tipped forward, the seventh seat cushion folded out into the space vacated by the armrest, and the left hand seat cushion put back into its original position.

 

The armrest/seventh seatback is designed with a headrest integrated at the front, which can then be extended for added safety. If storage is a priority, a practical Karakuri utility box can be folded out of the right seat cushion into the space between the two second row seats using the same process. If neither the seventh seat nor the Karakuri utility boxes are in use, the centre armrest can be folded up and tilted towards the left hand seatback, which allows communication between the third and second rows and reach-through convenience.

 

The third row seats are bench-type in a 50:50 split design. Both seatbacks can be tipped forward, individually or together, by pulling lightly on a strap integrated into the seatback. The seatbacks drop in a single motion onto the cushion to form a flat load surface that extends the luggage floor area. With the third row seats folded down there is a load area that is 1,100 mm long, 1,040 mm wide with a capacity of 720 litres (VDA). When the second row seats are double-folded as well, the load floor is 1,700 mm long with a load volume of 1,566 litres (VDA). With the five-seat version, the Mazda5 has a load volume of 832 litres (VDA) with all seats up, and a load volume of 1,678 litres (VDA) with the second row seats folded down. The luggage area of the new Mazda5 also delivers high levels of functionality and is large enough, with all seats in the up position, to carry items used on a day-to-day basis—like two beverage cases with six 1.5-litre bottles each, or a standard baby stroller folded together. There are also four hooks in the luggage area to secure whatever is being transported. Below the luggage compartment floor is a handy subtrunk with 15 litre capacity. Its lid can be propped up vertically into a recess for ease of loading.

Interior Storage

Mazda5 has a total of 45 storage compartments, including 10 cupholders located throughout the interior, enough for about any small item or beverage occupants might want to bring along. The front row features three storage trays in the instrument panel, one on each side of the steering wheel and one on the passenger’s side, an illuminated glovebox with 11 litres volume and 500 ml bottle holders in each front door pocket. Located on the floor between the front row seats is a practical centre console that includes a double-bottom compartment with a top tray and a box below large enough to hold up to seven CDs.

 

The front seatbacks also contain strong pop-up tables and there is an additional pocket in the driver’s seatback. When the Karakuri storage box is in use, it has a top tray big enough to hold smaller toys, snacks or baby bottles. Beneath the tray is a box with a net that can hold various items. Under-seat storage is also possible when the seventh seat or Karakuri utility box are folded out for use, which creates a box-shaped compartment under either the left hand or right hand seat cushion with approximately 6.3 litres of storage capacity.

 

Comfort

Mazda5 offers a host of standard features that make the flexible interior comfortable to be in, including driver lumbar support, air conditioning (depending on market), heated front seats and electric heated side mirrors. Mazda5’s heating and air conditioning systems also include, besides dashboard vents, heat/air vents underneath the front row seats at foot level, which provide good air circulation in winter and summer for the second and third row seats.

 

Low Cabin Noise

New acoustic material is used in the vicinity of the Mazda5 dashboard that blocks out external noise and absorbs internal noise. This helps make the Mazda5 quieter than vehicles with traditional materials used in this area, which tend to reflect internal noise back into the cabin. For Mazda5’s diesel versions, this new acoustic material is more robust for optimal sound insulation. The noise levels of Mazda5’s diesel engines are reduced to near-petrol like levels by common-rail turbo diesel technology and a dual-mass flywheel that keeps engine noise and vibration to a minimum. Mazda5’s suspension system and rigid body are optimized to suppress vibration and noise from the road, including specially selected tyres and front suspension lower arms with liquid-filled rear bushings. Wind noise is kept to a minimum by the car’s aerodynamic shape, by making the A-pillars as flush as possible and by optimizing the shape and positioning of exterior features. Ample sound insulation throughout the body shell and a single piece rubber seal for the front and double sliding doors help reduce road and wind noise.

 

Convenience

Mazda5 is very easy to use, with standard convenience features like a retractable key and remote central locking, double sliding doors and automatic power windows front and rear (depending on grade). To this it adds optional features like Xenon headlights, cruise control for both diesel engines and an Advanced Keyless Entry and Start System (depending on market and grade). This system uses a card-type key that does away with having to find the car key with bags in your arms. Once the owner of the Mazda5 comes within 80 cm of the car, the card sends an identification code by radio signal to an onboard unit that then releases the car for unlocking by pressing one of three buttons (on the front doors and the liftgate).

 

Mazda5 also has a DVD satellite navigation system available with a pop-up monitor in the dashboard. For cars with this option, a new driver support system is available (depending on market) with a rear-mounted video camera that shows the view behind the vehicle, computes and displays the line the vehicle will take if the steering wheel angle at that moment is maintained. The system starts when the shift lever is in reverse and enables easier backward driving and parking. An Intelligent Auto Light System is also available that constantly monitors the light around the vehicle using upward and front-facing sensors. This system comes with Full Auto Wiping, which controls wiper on/off status and wiper speed via a sensor on the windshield that monitors the glass’s infrared reflectivity, and then automatically adjusts the wipers to the right speed for optimal visibility.

 

Mazda5 also offers enhanced theft protection with advanced security technologies offering peace of mind with high levels of convenience. These include an immobilizer system that prevents engine start up without the correct Mazda key. The key transmits an identification code to an antenna in the ignition key cylinder. If the codes do not match, the control unit disables the starter and the fuel and ignition systems. For even more theft protection, a Thatcham Category-1 burglar alarm system is available (depending on market). This system has an intrusion sensor arrangement that detects break-in through the windows and/or other body openings and has a back up battery that runs the alarm, even if Mazda5’s main battery has been disconnected. The alarm system can be activated or de-activated using the keyless entry transmitter, which employs a rolling code function, making it impossible for a thief to use the code even if it is intercepted.

 

Onboard Entertainment

Mazda5’s standard audio system features a single 2DIN audio unit with an AM/FM radio and room for a CD player, if ordered, along with four full-range speakers and two smaller tweeters. In markets where available, a newly-developed 20 gigabyte Hard Disk Drive audio system can be ordered that does away with loose CDs cluttering up the car. The system can store about 3,000 songs so that, after storage, the CD can be returned home where it belongs. The recorded songs can also be categorized into four separate modes (Playback All, Genre, Artist and Favourite) which allow you to record and store songs according to type or who is going to be listening to them.

 

A rear entertainment system is also available that includes a seven-inch LCD and DVD player unit mounted on the ceiling in front of the second row. By pushing lightly on this unit, the DVD display screen drops down and the DVD unit pops out above it. The display screen can be set in three tilt positions to get the best picture quality for whatever the light conditions might be at the time and the system comes with a remote control unit. The DVD system is also MP3 compatible. This is an especially convenient feature as it offers two distinct audio systems for passengers to

listen to their favourite music. The car’s audio system can be played and, at the same time, passengers wishing to listen to MP3 files can do so with available infrared headphones if they choose. There is also an auxiliary jack mounted in the trim next to the third row seats, making it possible to use a game console, a video camera and other devices for playback.

Design – Stylish and Clean

 

• Two appearance packages

• Segment-first double sliding doors

• Dual-stage liftgate

 

The Mazda5 was designed with external dimensions chosen to yield room for up to seven and easy ingress and egress. Its design is fresh and well balanced with an appealing Zoom-Zoom personality that is familiar but never boring.

 

Exterior Design

The all-new Mazda5 is 4,505 mm long (4,555 with aerodynamic bumpers) and 1,755 mm wide, with a height of 1,615 mm (with roof rails 1,665 cm) and a good sized wheelbase of 2,750 mm. Its wedge shape is realized by a low nose and strong character lines rising from the outside of the trademark five-point grille to the base of the A-pillars. The grille itself flows seamlessly into the surfaces around it and features a large Mazda emblem in the centre. The bottoms of the headlights are in line with the bottom of the grille and have projector lamps with shiny reflectors, which give the face of the Mazda5 a bold yet refined expression.

 

From the side, the wedge-shape design is most obvious, with a climbing roofline that slants steeply over the front compartment then tapers slightly downwards at the rear of the car. Just below the door handles is a distinct character line that emerges from the top of the front fender, moves across the side doors and fuses with the sliding door’s side rail. A solid and compact look is achieved by tapering the side windows towards the rear end and by forming the side doors to slope inward just above the waistline. When seen from the front or back of the car, this seems to make the upper sections of the Mazda5 lighter and less massive.

 

At the rear of the Mazda5, the D-pillars are comprised of uniquely shaped rear lamps that curve into the sides of the vehicle and the rear end, which help Mazda5 avoid the square look associated with some vehicles in this segment. The rear quarter windows, rear lights and the liftgate window form a wrap around surface that gives the rear end of the Mazda5 a clean, well-toned look.

 

Two Appearance Packages

Two appearances packages are available in Europe (name depending on market) intended to appeal to customers with different tastes. The first emphasizes the stylishness of the Mazda5 design for a refined appearance. It employs character lines on the sides of the front bumper air intake that take up the bonnet’s slanting character lines and the sides of the front grille, to emphasise the compactness of the nose. Chrome-look moulding at the bottom of the front grille, silver-coloured reflectors in the headlights and red lenses on the rear lights, create a bright and refined appearance. Neat contours along the side sills help make the bottom of the body seem lighter for a smart overall look.

 

Mazda5’s second appearance package is meant to appeal to customers who want a more sporty-looking vehicle. It has a “winged” front grille design, front air intake side lines that converge towards the bottom to emphasize the vehicle’s wide stance, and a front bumper shape that makes the vehicle’s nose look longer and lower. It adds side skirts, headlights and rear lights with metallic-look accents and relatively dark colours for a sportier feel, 17-inch, five-spoke alloy wheels, side spoilers, a rear underspoiler and roof spoiler for a look of stability and aerodynamic potential.

 

Mazda5 comes with 15, 16 and 17-inch aluminium alloy wheels and a 15-inch steel wheel (depending on engine and grade) and a choice of 11 body colours, with two completely new colours, all of which contribute to the vehicle’s overall stylish and clean road presence.

 

Double Sliding Doors

Mazda5 is the only car in its segment to have sliding doors. When open, the doors protrude only 159 mm out from the sides, making the Mazda5 more practical and convenient in tight parking spaces than vehicles with hinged rear doors. The sliding door openings were optimized during tests using adults entering the vehicle into both the second and third rows with an average-sized three-year old in their arms. Developers then maximized the slide range of the doors to reach back as far as possible by placing the lower slide rail inside the side sill and minimizing the curvature of the C-pillar. The result is a sliding door opening that is 700 mm wide at beltline height—where the open space is best employed—and 1,083 mm high, making getting in and out of the Mazda5 easy and practical, even when holding a small child in your arms.

 

Mazda5’s sliding doors were also engineered to be easy to open. Developers used three dimensional motion-capture studies to understand the physical processes involved in opening the sliding doors of larger MAVs. From this, a door path for the Mazda5 was realized where the initial action of opening the doors provides enough inertia to make pulling the door sideways easy and with a natural movement of the body. The door itself is lightweight with a centre of gravity as close to the middle of the door as possible and is designed with a lower exterior door handle placement. Both slide rails (lower and centre) have relatively large rollers to minimize roll resistance, which maximize the force applied by the person opening the door. As a result, just about anyone can open Mazda5’s sliding doors easily with one hand.

 

Dual-stage Liftgate

Mazda5’s liftgate is also designed to be convenient and easy to use. It has a two-stage opening mechanism with a first stop at 1,812 mm from the ground, which is low enough for shorter people to reach and use easily. The second stop is at the fully opened position 1,909 mm from the ground, which is just the right height for tall people to use easily. Mazda5’s liftgate also has a large opening and a low load sill that supports easy loading and unloading.

 

Interior Design

The Mazda5 interior design compliments the car’s superior functionality by shapes, materials and colours, and by placing instruments throughout the cabin in such a way to create an atmosphere of comfort, quality and ease of use. The instrument panel design creates a natural and convenient distance between the driver and the instrument panel controls. Developers raised the centre instrument panel so the controls are easy to reach, and placed the shift lever at the bottom of the instrument panel, a position that makes shifting easier, especially during longer trips.

 

Mazda5 comes in two interior trim and material packages (name depending on market) that match the two exterior appearance packages. The first interior package has a light beige colour, which contrasts the aluminium-look finishes on the centre stack and door switch bezels, and fabric and trim that feel soft to the touch, which make travelling in the Mazda5 warm and relaxing. The second interior package combines a black keynote colour with metallic accents on the centre instrument panel for a contemporary feel. The two-tone fabric employed is slightly stiffer and woven with a geometric pattern that matches the grain of the instrument panel, which gives a sense of balance and quality.

 

Exterior and Interior Craftsmanship

Mazda vehicles are known for delivering high levels of craftsmanship and quality. Mazda5’s build quality is immediately obvious via minimal gaps between body panels and precise exterior fittings. It is also obvious in Mazda5’s exterior details, like the inner surface of the B-pillar—visible when the sliding door is open—where spot welding marks and roughness were eliminated for a high quality look.

 

On the inside, Mazda5’s trim, materials and colours are made with high levels of craftsmanship that focuses on customer delight and functional beauty. Its interior is aesthetically pleasing with all visible parts communicating a sense of refinement for a strong feeling of quality. Those parts touched by customers have a high degree of softness, including trim made of relatively thick cushioning materials. All dials and switches are optimized for a smooth and positive operating feel. User-friendly ergonomics are applied everywhere to achieve ease of use in the cabin. The centre instrument panel is organized in a way that ensures the driver can pay full attention to traffic and driving.

Powertrains – A Complete Line Up

 

The Mazda5 engine line up features two MZR-CD common-rail diesel derivatives with a maintenance-free diesel particulate filter system standard, coupled to a new six-speed manual transmission, along with two spirited MZR petrols. These powertrains are tuned to take full advantage of the car’s aerodynamic form and compact dimensions to deliver Zoom-Zoom driving fun for up to seven people.

 

Diesel Powertrains

 

• Two derivatives of the MZR-CD 2.0-litre common-rail turbo diesel

• Maintenance-free diesel particulate filter standard

• Power, robust torque and low consumption and emissions

• New six-speed manual transmission

 

With two derivatives of Mazda’s improved MZR-CD 2.0-litre turbocharged common-rail diesel engine, Mazda continues to deliver everything the growing number of diesel customers in Europe demand: solid performance, smooth petrol-like operation and outstanding fuel economy; with a catalyzed diesel particulate filter system standard for Euro Stage IV emissions on both derivates. The MZR-CD 2.0-litre Standard Power version is designed for good power and torque with low fuel consumption, while the High Power version is designed for those looking for even more performance.

 

Mazda5 diesel engines employ a variable-geometry turbocharger, which maximizes torque across a wide range of engine speeds. It has an optimized design that makes it smaller, with a turbine that has a lower inertia moment. This gives the engine a smooth, linear acceleration and high maximum output. It also makes 300 Nm of torque available as low as 1,500 rpm for excellent engine response across the speed range. The Standard Power version of the MZR-CD 2.0-litre engine produces 81 kW/110 PS of power at 3,500 rpm and a maximum torque of 310 Nm at just 2,000 rpm with a top speed of 179 km/h. The High Power version produces a maximum 105 kW/143 PS of power at 3,500 rpm and robust maximum torque of 360 Nm at 2,000 rpm with a top speed of 197 km/h.

 

NVH and Low Fuel Consumption

Employing diesel engines in the new Mazda5 was a special challenge for Mazda engineers, since both derivatives are heavier, have higher torque and could potentially create higher noise levels than a petrol engine. Several technologies are employed to keep noise and vibration to near petrol levels.

 

Reducing diesel engine noise and vibration begins with optimized combustion. Mazda5’s diesel engines employ a common-rail injection system with ultra-high pressure of up to 1800 Bar and multi-stage injection of up to six times per cycle, depending on operating conditions. Multi-stage injection prevents overly rapid pressure increases in the cylinders and suppresses knock and overall combustion noise. The engine uses pilot injection (pre-injection) at low engine speeds. During this process, a small amount of fuel is injected into the cylinder before main injection, which reduces combustion noise considerably.

 

Mazda5 employs a dual-mass flywheel that limits engine noise and vibration, along with extensive noise and vibration insulation that prevent noise from reaching the cabin (see Chapter 4).

 

Despite delivering power and high torque, Mazda5’s diesel derivatives use low amounts of fuel. This is accomplished by various engine technologies. The common-rail system, for instance, uses improved six-hole injectors to produce the best possible fuel atomization. Fuel injection volume, frequency and timing are electronically optimized based on accelerator pedal position, engine speed and other variables, to optimize combustion efficiency. Due to the modified pistons of Mazda5’s MZR-CD 2.0-litre, a low compression ratio of 16.7:1 is achieved. This lowers pumping losses, improves thermal efficiency at middle and high engine load and improves fuel consumption. In addition, the low compression ratio reduces the engine’s idling noise significantly. Combined with its new six-speed transmission, these technologies keep fuel consumption down without sacrificing Zoom-Zoom driving enjoyment.

 

Emissions

To achieve Euro Stage IV compliance, Mazda5’s MZR-CD 2.0-litre diesel derivatives employ a combination of modern engine technology and a new diesel particulate filter system. The engine itself is designed to produce as few toxic emissions as possible during combustion, while still ensuring lively, high-torque engine response. The engine’s multi-stage injection minimizes the amount of particulate matter (PM) remaining after combustion. The engines also have an electronically-controlled intake shutter valve and exhaust-gas-recirculation (EGR) valve to suppress the production of NOx.

 

Diesel particulate filter System – Euro Stage IV Compliance

These engine technologies are combined with a new catalyzed diesel particulate filter system that reduces PM emissions to almost zero and ensures Euro Stage IV compliance and lower operating costs in most countries. The system captures PM in a silicon carbide ceramic filter with a honeycomb structure consisting of square channels, arranged in staggered formation and closed off at alternative ends. PM contained in the exhaust gas accumulates at the porous dividing walls, while gases pass through the filter.

 

To prevent the filter from becoming blocked with PM, it must be “regenerated” at certain intervals. With the aid of a pressure-difference sensor located at the bulkhead of the engine compartment which measures the pressure difference in the exhaust gas flow upstream and downstream from the diesel particulate filter, three exhaust gas temperature sensors and an O2 sensor, the powertrain control module (PCM) monitors the PM amount in the filter. When filter capacity is reached, the PCM in conjunction with the common-rail injection system initiates burn-off of the accumulated particulates in the filter by injecting small amounts of fuel during the exhaust cycle and raising exhaust gas temperatures for a short period. Further measures to increase the exhaust gas temperature include closing the EGR valve and the intake shutter valve.

 

The new Mazda5 diesel uses a catalyzed diesel particulate filter with channels in the filter coated with platinum. This coating lowers the light-off temperature of the collected PM and allows filter regeneration at a lower exhaust gas temperature of 350 to 500 C° (depending on engine operating conditions). By using a catalytic diesel particulate filter, Mazda5 does not need a special fuel additive to reduce the light-off temperature, as some cars do, making the filter system maintenance-free.

 

To achieve the exhaust gas temperature required to burn off PM during the regeneration process, the amount of fuel injection is increased. However, the regeneration process of the diesel particulate filter represents a marginal part of total engine operating time, so its impact upon overall fuel consumption is minimal. Mazda5’s diesel derivatives with diesel particulate filter system meet strict Euro Stage IV emission standards while using only 6.3 litres of fuel per 100 km (combined) and producing 173 g/km of CO2.

 

Mazda5’s diesel particulate filter system is able to regenerate itself under normal driving conditions that combine a mixture of urban and extraurban driving. However, in highly unusual conditions (like continuous days of ultra-low speed driving) a diesel particulate filter indicator light on the dashboard will indicate that regeneration is required. The car should then be driven at a normal speed for 10 to 15 minutes (at an engine speed of 2000 rpm or higher and a vehicle speed of 40 km/h or more) to regenerate the filter.

 

Transmissions

Both diesel derivatives are coupled to a newly-developed six-speed manual transmission with a self-adjusting clutch, which are designed to deliver Zoom-Zoom driving fun by accommodating both engines’ high torque of up to 360 Nm. It has a three-shaft design, with a primary shaft and two secondary shafts that make it very compact. First, second and third gears have triple-cone synchronizers and fourth gear has a dual-cone synchronizer, which allow full utilization of the engine’s high torque at low revs, while delivering smooth shifting characteristics and improved durability. The transmission’s sixth gear also functions as an overdrive gear that uses engine output fully and allows high speed cruising.

Petrol Powertrains

 

• Two spirited MZR petrols

• Low fuel consumption and emissions

• Smooth-shifting five-speed transmission

 

Mazda5’s petrol line up includes two MZR engines—a 1.8-litre and a 2.0-litre—both inline four cylinder, 16-valve DOHC engines that deliver linear, spirited power and good torque with low   consumption and Euro Stage IV emissions. Both engines feature an aluminium-alloy cylinder block and lower block, making them lightweight and strong for superior coupling stiffness with the transmission, and have lightweight pistons and connecting rods for low vibration and a linear driving feel.

 

They include high-flow intake ports, a low-flow-resistance air cleaner and an intake manifold with long equal-length runners that help reduce intake resistance for strong engine performance. They have a tumble swirl control valve in the intake manifold, which ensures stable combustion when the engine is cold and minimizes exhaust emissions. Mazda5’s 1.8-litre petrol produces 85kW/115 PS of power at 5,300 rpm and a maximum torque of 165 Nm at 4,000 rpm, using just 7.9 litres of fuel per 100 km (combined).

 

Mazda5’s MZR 2.0-litre petrol engine has a variable induction system for good torque throughout much of the speed range. It produces 107 kW/145 PS of maximum power at 6,000 rpm and 185 Nm of torque at 4,500 rpm, while using 8.2 litres per 100 km (combined). Both engines are coupled to an enhanced five-speed manual transmission with triple-cone synchronizers for first and second gears, and dual-cone synchronizers for third and fourth gears, which lower shift effort in every gear, but especially downshifting from second gear to first, which is handy in high congestion city driving. Both engines are quick off the line with good cruising speeds. The 1.8-litre petrol accelerates from 0 to 100 km/h in 11.4 seconds* with a top speed of 182 km/h, the 2.0-litre petrol in 10.8 seconds* with a top speed of 196 km/h.

 

* Under Mazda test conditions

 

Chassis – Stable, Predictable and Fun

 

• MacPherson front, multi-link rear suspension

• Power assisted steering adapted to engine: Electro-hydraulic power assist for petrols, hydraulic power assist for diesels

• Robust brakes, short stopping distances

 

The chassis systems for the new Mazda5 deliver a balance between handling stability and ride comfort for a relaxing yet invigorating drive that augments the car’s comfortable and communicative interior.

 

Body Shell

By focusing on flexural and torsional rigidity, and by using lightweight, high-tensile steel throughout most of the body, a Mazda5 body structure was realized that effectively resists bending in all driving situations. Large cross-section members are used throughout the body frame, along with straight longitudinal members that run from one end of the vehicle to the other. Three cross members at the bottom of the transmission tunnel minimize deformation. Extra body strength and rear end crash resistance are provided by the outer rear frame members, which overlap with the side sills to create large connecting surfaces. Between these two is a newly-developed reinforcement member that minimizes floor panel vibration, strengthens the overall body shell and increases ride comfort for the third row occupants.

 

The pillars of the new Mazda5 were also reinforced to eliminate traces of response delay during cornering manoeuvres. Further body rigidity is supplied by the lower rails of the sliding doors being located inside the side sills, which give each side sill an open section. The side sills are made out of high-strength steel, each with a large cross-section, and have reinforced joints where they connect to the B and C-pillars. Reinforcement welds are also applied to the corner sections where each pillar meets a slide rail, and are applied around the rails themselves for added rigidity. Mazda5’s large liftgate opening is surrounded by a closed-section structure that is linked by gussets to the rear suspension towers. Gussets are also added at the rear floor area, which is unique to this segment, and which contributes to ride comfort for the third row passengers.

 

Suspension

Mazda5’s suspension system is designed and tuned to resist roll due to its relative tall body and compact overall dimensions. It also provides a balance between rigidity and precise road feedback for good amounts of driving fun, and the stability needed for a comfortable ride for up to seven people. Both the front and rear suspensions are optimized for diesel and petrol to ensure that the new Mazda5 responds smoothly and predictably to driver input and is comfortable and quiet.

 

Front Suspension

Mazda5 features a MacPherson strut front suspension that contributes to a good balance between predictable handling and ride comfort. This is achieved by various special features including rubber mountings introduced at the four points where the cross members attach to the body, which support front suspension rigidity while suppressing road input, noise and vibration. The front suspension lower arms have been specially optimized for the new Mazda5 diesel engines and, like the petrol, have liquid-filled rear bushings that contribute to achieving a balance between handling stability, ride comfort and NVH suppression.

 

Front damping force, coil spring rates and spring brackets are specially tuned to suit the specific configurations for both the diesel and petrol engines. The front dampers themselves have large diameter pistons that deliver superior responsiveness, while built in rebound springs suppress wheel bounce during cornering and contribute to stability and road hold. Damper effectiveness is further optimized by a spring design and layout that minimizes damper friction and by an input-splitting-type upper strut mount. This permits separate tuning of damper and spring haracteristics and superior front damper performance. Bump stoppers are designed to function as auxiliary springs, which optimize the interaction between the dampers and the coil springs, making the entire suspension even suppler. A low placement of the steering gear means the tie rods can be short with high amounts of linear toe control that contributes of overall handling stability. The front hub bearings are designed to be very rigid and the front stabilizers have thick diameters that help resist roll.

 

Rear Suspension

In the rear is a multi-link suspension system that optimizes rear wheel camber and roll-centre height, for superior road hold, straight-line stability and a precise steering response. For the Mazda5 diesel engines, the rear coil springs rates have also been optimized. Rear damper friction is minimized by locating springs and dampers in separate locations, with the springs placed under the floor. This also means more room for third row seats. The entire rear suspension is designed to better accommodate the various weights of passengers and luggage in the Mazda5. And finally, bushing characteristics of the front and rear lateral links are designed to

cause toe-in when force is applied to the rear tyres, which contributes to even more handling stability.

 

Steering

Both Mazda5 diesel derivatives come with hydraulic power assisted steering that is designed to be low friction and to provide superior road feedback and assist for tight steering actions. The system is engine speed sensitive and provides the best possible steering performance characteristics when mated to Mazda5’s Zoom-Zoom diesel powertrains. Mazda5 petrol engines comes with Mazda’s electro-hydraulic power assisted steering (EHPAS), which differs from normal hydraulic-only power assisted systems in that its hydraulic pump is driven electrically rather than by the engine. At higher speeds, EHPAS delivers reduced power assist for a strong on-centre steering feel, and at low speeds it delivers more power assist for easy tight steering actions.

 

Brakes

The Mazda5 has robust ventilated front discs and solid rear discs that deliver high amounts of control and short stopping distances. The vehicle comes with two brake size combinations (depending on wheel size), a 278 mm front/280 mm rear system, or a larger 300 mm front/302 mm rear system. A small-diameter master cylinder and a single vacuum booster with a 254 mm diameter enhance braking force and response, and provide a linear increase in deceleration as brake pedal travel increases. This system forms the basis for a four-wheel, three channel anti-lock braking system (ABS) with electronic brake force distribution (EBD) standard, along with available mechanical brake assist and dynamic stability control (DSC) with traction control (TCS). The result of these braking technologies is a stopping distance of 39 meters from 100 km/h* under cold brake conditions.

Safety – On-Rad Confidence

 

• Strong body shell

• Front, side and three-row curtain airbags standard

• Enhanced pedestrian safety

 

Mazda5 has predictable and stable handling under normal driving conditions then adds a host of active and passive safety technologies for a feeling of on-road confidence.

 

Active Safety

Mazda5 delivers excellent driver visibility in all directions, with large forward vision angles, large corner windows, and combines this with predictable and stable handling for safe driving under normal conditions. To assist the driver in avoiding potentially dangerous situations are a host of active safety systems including an Intelligent Auto Light System with Full Auto Wiping, large ventilated front disc brakes and solid rear disc brakes, four-wheel ABS, EBD standard, with available mechanical brake assist and DSC with TCS.

 

Passive Safety

Mazda5 occupants are protected by a body shell that adopts the Mazda Advanced Impact Distribution and Absorption System (MAIDAS) and evolves it to deliver maximized strength and to deflect impact energy away from the cabin for high levels of crash safety. Mazda5’s triple-H structure was strengthened even further by reinforcing the three roof cross members. The front doors have a reinforcing member at beltline height that is fitted to an impact beam. Mazda5’s B-pillars are made of high-tensile steel, both the side sills and B-pillars have large cross-sections for extra strength, and reinforcements are introduced below the B and C-pillars to strengthen their joints to the side sills. The sliding doors and the body have optimally large overlaps, and reinforcement welds at the corner sections where each pillar meets a slide rail and around the rails themselves.

 

Mazda5’s rear end has rear side members that are made of high-tensile steel and that absorb rear impact energy. The rear frame members and the side rails overlap in such a way that create large connection surfaces, which help disperse the force applied to the back of the Mazda5 during rear impact. The liftgate opening is strengthened by a closed-section structure that surrounds the entire opening and is linked by gussets to the rear suspension towers. The fuel tank is located in front of the rear axle, which lowers the risk of the tank being damaged.

 

On the inside, the new Mazda5 has a long list of features to protect occupants in case an accident cannot be avoided. There are three-point seat belts and adjustable headrests at all seats, including the fold out seventh seat. The first row seat belts have pretensioners, load-limiters and seat belt reminders. There are front and side airbags for the driver and front passenger, and large curtain airbags standard that protect all three rows. In case of frontal impact, a horizontally collapsible steering column helps reduce injuries to the driver’s head and chest, and there is a collapsible brake pedal that reduces the risk of injuries to the driver’s legs.

 

Energy-absorbing ribs are incorporated into the trim on the pillars and roof side rails, which can lower the risk of potential secondary-impact head injuries. Each of Mazda5’s four power windows has a safety auto-reverse system that detects an obstruction (like a child’s head or a hand) while the window is closing and immediately lowers the window to prevent injury. And, as befits a family vehicle for up to seven, ISOFIX anchors and top tethers are installed in the outside seats of the second row.

 

Mazda5 is also designed with improved pedestrian protection. The bonnet is designed with ample space (100.7 mm minimum) for energy absorption between the bonnet and the first point of contact. Enhancing this is the introduction of an inclined cowl cross member (conventional cowl cross members are more or less horizontal) that is made of thin material that helps disperse impact energy in the unlikely event that a pedestrian hits the top of the cowl. Ribs located across the width of the front undercover maximize the longitudinal stiffness at this point and help reduce the risk of a person’s legs getting trapped under the vehicle.

 

Environmental – Responsible and Low Impact

 

• Environmentally responsible production

• Mazda5 meets JAMA 90 percent recyclability target

• Low consumption engines for less CO2

• Maintenance-free diesel particulate filter system standard on Mazda5 diesel engines in Europe

 

Mazda5 has been designed to have a minimal impact on the environment—without sacrificing on safety, functionality and Zoom-Zoom driving fun—during production, and during and after its operating life.

 

All of Mazda’s development and production facilities in Hiroshima, Japan were ISO 14001 certified between 1998 and 2000. The new Mazda5 is manufactured in a clean and safe environment and is designed to have a minimal amount of environmentally hazardous materials. For instance, Mazda uses lead-free electro-deposition coatings, lead-free petrol tanks and chromium-free body panels. As a consequence, the new Mazda5 is almost completely free of lead, hexavalent chromium, mercury and cadmium. These steps affect all current production models and have enabled Mazda to comply with EU legislation banning the use of these four substances.

 

The Mazda5 not only has far fewer toxic substances than previously built cars, it is also designed to maximize the recycling capacity of its plastic and metal parts. Polypropylene, which is easily recyclable, is used for Mazda5’s front and rear bumpers, its instrument panel and cabin trim. Adhesives used for the floor mats and felt surfaces are designed to allow easy separation and recovery, and all petrol engines are made with aluminium. Plastic parts have international-standard material markings that allow easy classification after recovery. These measures allow the Mazda5 to meet the 90 percent recyclability target set by the Japanese Automobile Manufacturers Association (JAMA).

 

Mazda5’s petrol engines employ high compression ratios and low-friction components for minimal mechanical losses, which contribute to lower fuel consumption and low overall CO2 emissions. Mazda5’s MZR-CD diesel engines employ common-rail technology for low fuel consumption and low CO2 of 173 g/km for both derivatives. An improved EGR system guarantees reduced NOx production. Mazda5’s diesel engines also have a maintenance-free diesel particulate filter system standard that practically does away with black smoke. All Mazda5 engines realize a Euro Stage IV emissions ranking.