Mazda 2: In Depth

New Mazda2

Lightweight with strong character

By Frank
September 25, 2007 3:49 PM
Filed Under: Japanese, Mazda

Press Release

Lightweight with a Strong Character

Mazda’s all-new entry into the European B-segment was reinvented from the ground up and is the first model of a further developed new generation of Mazda automobiles. The Mazda2 sparkles with an outstanding total package that is tailor-made for this popular segment in Europe. It is lighter and more compact than its predecessor, but at the same time offers increased safety, greater driving fun and a more expressive design.

The Zoom-Zoom brand message was first introduced by Mazda with the launch of the Mazda6 in 2002. Zoom-Zoom stands for the joy of motion. Universally understood, ‘zoom- zoom’ is the sound used by children to imitate the noise of an engine. As the first representative of a new generation of automobiles from Hiroshima at that time, the Mazda6 embodied this ideal perfectly. So Zoom-Zoom has always been more than merely a brand claim. It describes the ultimate goal of Mazda designers and engineers to provide customers, who experienced the thrill of motion in childhood, with an exhilarating driving experience once again as adults.

The Mazda2, first presented at this year’s Geneva Motor Show , initiates another new phase in the history of the company. This is not a simple model change, but the first product of a further developed new generation of Mazda automobiles. It not only continues the Zoom-Zoom idea, it stands out in an increasingly competitive environment with clever and fresh technical solutions. To achieve this, Mazda considered customer demands across the entire globe.

The main goal of the Mazda2 development team was a further sharpening of Mazda’s brand values – its distinctive design, exceptional functionality and agile handling . At the same time, the team aimed at a further improvement in ride comfort and operating smoothness , but always bearing in mind the need for safety and environmental friendliness . With this special combination of virtues, the new Mazda2 will strengthen the brand’s DNA and Mazda’s presence in the global B-segment.

Almost 50 Different B-segment Cars to Choose From

Mazda’s clear main focus for the new model is Europe, where this class of vehicle has grown by almost 10 percent during the last six years and has taken more than 25 percent of the new car market . While 19 models featured on consumers’ shopping lists in 1991, by 2006 a total of 49 vehicles were courting the favour of consumers. As the sheer number of products continues to grow, it is becoming more difficult for customers to fully appreciate everything on offer. As a result, emotional factors like an eye-catching exterior design and a fresh brand image are becoming more important as differentiating characteristics – particularly as market observers are predicting further growth of the B-segment of 5 percent during the next 10 years in Europe.

For this reason, Mazda once again closely scrutinised the global sub-compact market during the early phases of new Mazda2 development and during the process filtered out the truly important attributes for a modern global B-segment car. The results: more than anything else customers want low fuel consumption – since this has a decisive influence on operating costs and CO 2 emissions – plus high functionality and ease of use , with dynamic performance that ensures comfortable and fast driving, and an eye-catching design.

Mazda Bucks Trend towards Larger, Heavier sub-compact Automobiles

The new Mazda2 is able to meet all these consumer criteria without following the general trend towards larger and heavier automobiles. On the contrary; while the small cars of other automobile manufacturers have increased in weight and size during the last few years, Mazda has been working to make its new Mazda2 more compact and significantly lighter , while adding safety features at the same time in order to meet the expectations and demands of a wide spectrum of customers.

With its emotionally appealing design, the Mazda2 is styled to have a strong appeal for younger groups of customers – singles and married couples without children – while remaining true to the slogan ‘My first Zoom-Zoom choice‘.

Sports Car Genes

The new Mazda2 looks extremely dynamic despite its compactexteriordimensions.Thenatural-seeminginterplay between soft forms and sharp contours, along with carefully modulated transitions, ensure a controlled variety of reflections across its exterior, which is manufactured with extremely high levels of build quality. Equally eye-catching are its striking wedge shape, its focussed placement of contoured edges and strong sculpturing in the area of the doors and fenders. Yet the Mazda2 not only looks good, it also has aerodynamic virtues: with a drag coefficient (Cd) of 0.31, it is one of the most streamlined models in its class.

The goals set for the Mazda2 designers did not allow for any compromises. No variations of the predecessor model were permitted. A completely new, courageous and trend-setting design was obligatory for the second generation Mazda2. And its design would be executed with a lot of Zoom-Zoom spirit, strong individuality and a more clearly-defined Mazda DNA. Despite the newcomer’s more compact outer dimensions, the designers targeted high dynamism and solidity, a rhythmic interplay between soft surfaces and sharp contours , as well as subtle effects of light and shadow at points of intersection.

At the same time, the new design was styled to appeal not only to European consumers, but to customers around the world. Not an easy task, as B-segment vehicles are very popular among women in Japan, for example, who appreciate a soft, friendly design. In Europe, however – with a much more mixed target group – a significantly sportier and more confident design is preferred by many customers.

An important role in finally defining the new design concept was played by the Mazda Sassou, a design study shown at the 2005 Frankfurt Motor Show. With an eye to the future Mazda2, Mazda incorporated the positive Sassou feedback from motor show visitors during the last phases of work on the new production model. The solution for a dynamic design, with a clear Mazda identity, was the combination of sharply cut contours and soft transitions.

Forms with Subtle Beauty and Dynamism

The principles which directed the work of the new Mazda2 designers were ‘exquisite and dynamic’. Their main goal was to create the impression of athletic movement despite the car’s compact dimensions. ‘Exquisite’ stands for forms with a carefully designed, subtle beauty, as well as dynamism. Also important was the balance between the exterior design, a cabin laid out for maximum spatial functionality and the use of forms that appear especially simple and precise. By using extremely short overhangs and other stylistic details, the designers were also able to emphasise the compactness of the vehicle.

A second design theme for the exterior carried the name of ‘coordinated movements’ . Mazda2’s body lines, and the light effects created by them, combine to produce forms of expression that are many-facetted. As a result, even when parked Mazda’s new sub-compact seems like it might drive off at any moment. This impression of movement is further enhanced by the car’s wedge shape and by the character line that flows from the front fender to the rear of the car. And the swage line in the lower area of the doors that climbs as it moves towards the rear wheels, plus the front wings echoing the style of the Mazda RX-8 , contribute to giving the youngest member of the Mazda family power and dynamism.

A Natural Balance between Organic and Contoured Elements

For the team under Chief Designer Ikuo Maeda, achieving this lively impression despite the car’s limited exterior dimensions was a real challenge. It was achieved by emphasising forms that possess natural-seeming movement, and which also express high levels of build quality. The balance between organic and contoured elements is really only harmonious, because the designers consistently followed the primary objective of ‘coordinated movements’.

Seen as a whole, the Mazda2 looks both dynamic and solid , because it is free from unnecessary ornamentation or decoration. The design becomes a carefully conceived symbiosis between form and function that makes the B-segment car from Hiroshima appear as if it were cast from a single piece of metal.

4 per cent Aerodynamic Improvement over the Outgoing Model

The new Mazda2 not only looks good, its body is also optimally streamlined. Thanks to a generous underbody cover beneath the engine bay, to bumpers with aerodynamically optimised contours and reduced turbulence in the area of the A- pillar and side mirrors, the Mazda2’s Cd value was lowered from 0.32 to 0.31 . Even more significant is the result when multiplying the car’s Cd value by the frontal area, which reveals a 4 per cent aerodynamic improvement over the somewhat larger first generation Mazda2. To increase stability on the motorway, Mazda also reduced lift (inherent to all road car designs) at the front and rear axle. The new model’s front axle lift coefficient (CLF) is only 0.02.

Especially small gaps between body panels and neat rubber seals are details that underscore the very high build quality of the Mazda2. This can be seen, for instance, in the area of the headlamp housings and the rear light clusters. The rear lights have the appearance of LEDs when illuminated at night. To make the body seem as smooth as possible, the washer nozzles are hidden inside the cowl. A micro-switch on the liftgate makes the need for a visually-disruptive handle unnecessary. And last but not least, even the front grille structure is designed in such a way that the components behind it are difficult to see from outside the car. The result: the Mazda2 looks very neat and tidy from every angle.

Double Partitioning Reduces Instrument Panel Heaviness Significantly

In designing the interior, the guideline for the designers was ‘space that communicates movement’ . Well-contoured forms combine a confidence-inspiring solidity with strong visual movement. Despite the finite amount of space available, a cabin with a roomy spatial feel was created by skilful design. Visually, the dashboard panel is divided horizontally in two halves and thanks to this stylistic technique, the dashboard does not dominate the cabin and the interior seems enjoyably light. The upper dashboard is smooth and uncluttered, while the outer edges taper slightly away from occupants, so they do not feel cramped.

At the same time, the unique, slightly convex shape of the centre stack provides an interesting contrast to the dashboard. The gear shift lever is integrated here, mounted high and close to the driver’s hand, in front of minor switches and controls, as well as a central display for audio and air-conditioning information, encased in a silver-coloured bezel.

White Speedometer and Silver Accents Create Striking Contrasts

Even though Mazda2 does without flashy colours and strongly luminous surfaces in the interior, a very contemporary ambiance is created by the contrast between silver accents (in the area of the outer air-vents, the steering wheel, the speakers, the gearshift, the cupholder, the stereo, the speedometer and the door panels - depending on grade) and the dark keynote colour of the cockpit. Other fresh accents are created by the white speedometer and a repetition of ‘rounded’ elements. Circular forms are used for the four air-vents, the instruments, centre stack display and the controls for the heating and air- conditioning. These forms have become a true Mazda design signature and are reminiscent of those used in the Mazda3, Mazda6 and the MX-5. The Mazda2’s three-spoke steering wheel, with audio controls in the left spoke (depending on model and grade), also presents visual parallels to the wheel of the famous roadster.

All interior elements communicate high precision and craftsmanship – an example of this is the ‘invisible’ seamless cover of the front passenger airbag mounted in the dash top. Also the seats are slim and, with their vertical fabric bands and discreetly patterned materials, help to give the cabin a general impression of airiness and friendliness.

Final Design Decision on the Streets of Milan

December 2004: After 18 months of intense preliminary work, Mazda designers threw away all the submitted designs made until then by the three design studios in Hiroshima, Yokohama and Oberursel (Germany). According to Chief Designer Ikuo Maeda : “Looking for a significantly more dynamic starting point with an even sharper Mazda identity, we began working again with a blank piece of paper. Our goal was to create the maximum amount of dynamism in a length of 3.88 metres without sacrificing functionality.” In early 2005, two designs were competing to become the final design, when the decision was made in Milan, Italy. “I was there on a business trip and received a telephone call from a senior manager in Japan,” Maeda recalls. “He said ‘You make the choice!’ I spent a week walking around Milan imagining the two cars in the city’s streets and squares. After that, I had my winner. This car would be instantly recognisable as a member of the Mazda family, not only in Italy, but also in Tokyo and in every other city.”

Sports Appearance Package

With an available Sports Appearance Package (depending on market), customers can further enhance the sporty appearance of the Mazda2. Side skirts, a lower front spoiler and a trapezoidal front lower air intake, that is wider at the bottom than at the top, visually lower the vehicle’s centre of gravity. A special upper front grille design and a rear roof spoiler are other details of the Sports Appearance Package. The swage line that gently fades into the body contours of the normal Mazda2 and the length of the front overhang are more boldly defined. By focussing the Sports Appearance Package optics more towards the middle of the front bumper, the pack enhances the impression of speed and agility.

A Friendly, Functional Place to Be

High functionality and user friendliness were at the top of the priority list for the interior designers. Though the Mazda2 might seem compact on the outside, on the inside it seems spacious to its occupants. The relatively long wheelbase (for a B-segment car) of 2,490 mm, placing the wheels as close to the corners as possible and clever packaging, all make the Mazda2 interior a roomy place to be, despite having slightly smaller outer dimensions. As a result, Mazda2’s maximum head room (1,004 mm front, 959 mm rear) is one of the best in its class, as is its shoulder room (1,340 mm front, 1,300 mm rear). Front legroom is 1,068 mm and the 883 mm of legroom in the rear offers lots of space to stretch your legs. And although the new Mazda2’s height is exactly 55 mm less than its predecessor, the car’s slightly thinner roof liner thickness and a lower hip point ensure ample head room.

Whether the driver is 1.85 metres or 1.50 metres – the Mazda2 offers just the right seating position for every stature. The driver’s seat has fore/aft slide adjustability of 250 mm (predecessor 210 mm) and the driver’s seatback can be adjusted to an angle of up to 104° (72° in the rear-most position). This adjustment can be made applying 20 per cent less effort than before.

The driver’s seat is height adjustable over a range of 55 mm, which is 17 mm more than the outgoing model. A ratchet-type lever allows stepless adjustment of the seat, while a steering wheel height adjustment range of 50 mm (standard on all models) makes it easy for drivers to find an ergonomically correct position.

The gear shift lever is centre stack- mounted like the Mazda5 and, thanks to being positioned 38 mm higher than on the previous Mazda2, is especially easy to reach and operate. The parking brake lever is also placed closer to the driver by 43 mm.

Practical Storage Compartments demanded by Young Buyers

Mazda2’s cabin design meets the increasing demands for practical storage compartments, especially from younger customers. Storage includes a glove box with an open magazine rack for storing and easily retrieving frequently used items such as a road atlas during journeys. The 7-litre glove box itself can hold up to six CDs and car documents.

The floor centre console between the front seats has a drink holder and a storage tray behind it for items as large as a handbag. Added to this is a 12-volt socket to power or charge electric devices. Next to the power socket is a separate AUX jack that allows users to connect digital devices like an MP3 player like an iPod® to the onboard audio system. The front door pockets have a design that allows storage of a 0.5-litre bottle and an A4 atlas. Across the dashboard area is a total of three storage pockets for small items like coins, packs of gum or keys. Behind the driver’s sun visor is room for maps or other documents as well.

Class-competitive 250-Litre Boot

Despite its more compact exterior, new Mazda2 still has 250 litres (VDA) of load volume in the boot. Folding the rear seatbacks down increases the load length from 674 mm to 1,321 mm and creates a load volume (to the roof, VDA) of 787 litres .

With the rear seats upright, the load space can hold items as big as a large suitcase or a baby buggy, and it easily takes three cases of water. In comparison to the previous generation, the boot threshold is a bit higher to ensure greater body shell rigidity. The boot opening remains nevertheless very practical for daily usage.

Dual Door Seals and Stiffer Doors Lower Wind Noise

Strikingly low levels of cabin noise contribute to making Mazda2 a comfortable place to travel. At a speed of 60 km/h, for instance, only 71.1 dBA of road noise reaches occupants’ ears, which is amongst the lowest in the B-segment. Cabin noise has been significantly reduced versus the outgoing model – especially at engine speeds above 4000 rpm.

For the new Mazda2, wind noise generated at 128 km/h is just 68.5 dBA, which is also among the lowest in its class. Two technical measures contribute to this result. An unbroken seal around each door opening which, together with all- around seals on the doors themselves, give the Mazda2 a complete dual sealing system. Plus, stiffer door panels that resist the effects of aerodynamic suction that can occur on the motorway due to negative pressure outside the doors. As a result, the outer skins of the door deform 33 percent less than the doors of the previous Mazda2. And last but not least, the transmission of tyre noise has been reduced as well , by 1.4 dB in the front seats and by 1.7 dB in the rear seats.

A Choice of Three Grades

Mazda will offer its new B-segment car in three grades (depending on market). Even the base grade is well- equipped with remote central locking, electric adjustable door mirrors , as well as the glove box with magazine rack and floor centre console . On the safety side there is ABS, electric power assist steering with adjustable steering wheel height, ISOFIX anchors in each rear outer seat, plus driver and passenger airbags . Dynamic stability control (DSC) is also available (depending on market).

Beginning with mid-grade models, side and curtain airbags are fitted, as are electric retractable and heated door mirrors , a 60/40 split rear seat , an MP3-CD/radio and AUX Jack as well as electric front windows . Also available are 15 or 16-inch aluminium wheels (depending on market), cruise control (only for the 1.5-litre engine with on-board computer), manual or automatic air-conditioning , power rear windows, fog lights, rain and light sensor , an MP3/CD changer , front seat heating and leather steering wheel with leather gear shift knob. An adjustable speed warning system is also available, as a function of the trip computer, that triggers an audible alert when the car exceeds the pre- programmed vehicle speed limit.

An Excellent View to All Sides

Two numbers that say it all: the belt line slopes towards the front of the car and is 40 mm lower than the old Mazda2 , and at the base of the A-pillar, the belt line height from the drivers hip point is one of the smallest in the class at only 354 mm. Combining the low belt line with a significantly lower positioning of the door mirrors, means the driver enjoys improved visibility diagonally to the front and downwards . This results in increased safety when driving on narrow roads, turning at junctions and in city traffic driving where pedestrians could cross the road. And it makes parking much easier. The car’s agility in city traffic is enhanced by its small turning circle of only 9.80 metres and its front upward vision angle of 18.9°, which makes it easier to see traffic lights and road signs.

The Mazda2 high-grade version has 16-inch aluminium wheels , automatic air conditioning and an audio system upgraded with six speakers . Plus many of the mid-grade options are standard, including: power front and rear windows , front fog lights, trip computer and leather steering wheel with leather gear shift knob . This grade is the only version to come with Mazda’s practical Keyless Entry & Start System (depending on market) as part of a package with auto light and auto wiping system .

Keyless Entry & Start System

Unlike conventional locking systems, Mazda’s keyless system does away with the need of holding a key in your hand. When the user is carrying the key in a jacket or shopping bag, the Mazda2 can be opened by simply pushing a button at the door handle . Starting the car is also done by simply turning an ignition knob on the steering column. This wireless system is especially handy in situations when the user is carrying shopping bags in each hand, an open umbrella or is in a hurry. The new key for the Mazda2 has a fob-type design , which makes it easier to use than the card type key used until now. Mazda is offering its handy ‘open sesame’ system on the high-grade model (depending on market) with a so-called ‘Power Pack’ together with auto light and auto wiper systems.

Modern, Low-Consumption Engines

All new Mazda2 engines combine the low fuel consumption expected of a sub-compact car with the lively Zoom-Zoom characteristics of a genuine Mazda.

When it goes on sale in autumn 2007, the new Mazda2 will initially come with two Mazda MZR petrol engines : a 1.3-litre that produces (depending on market) either 55 kW/ 75 ps or 63 kW/ 86 ps and a 1.5-litre unit that produces 76 kW/ 103 ps . Both petrol engines have sequential valve timing (S-VT) and optimised exhaust-valve timing . The new 1.5-litre adds a variable induction system (VIS) that enhances torque across the entire rev range.

Mazda will follow this duo up some months later with an especially fuel-efficient common rail turbo diesel for the European market, developed from the MZ-CD engine line, with 1.4-litre displacement.

The higher power version of the 1.3-litre engine produces 63 kW/86 ps from a displacement of 1,349 cc and, like the larger engine, is made completely of aluminium. This in-line, four cylinder engine has a double overhead camshaft, four valves per cylinder and develops 122 Nm of maximum torque at 3,500 rpm. The standard power version produces almost as much torque – 121 Nm at 3,500 rpm.

The 76 kW/103 ps, 1.5-litre engine has a displacement of 1,498 cc and produces a maximum of 137 Nm of torque at 4,000 rpm . This is the most powerful Mazda2 and it achieves a top speed of 188 km/h and accelerates from 0 to 100 km/h in only 10.4 seconds (Mazda measurement, depends on car’s grade and test conditions).

Mazda engineers worked especially hard at optimising Mazda2’s petrol engines in terms of reducing internal frictional loss. The measures undertaken include changes to the piston rings and lands, fine-tuning the piston skirts, optimising the piston pin offsets and redesigning the oil passages.

CO 2 Emissions Reduced to 129 g/km for the 1.3-litre Engine

Because Mazda2’s engines are optimised for low friction and have a lower idle speed, the transmissions’ gear ratios are between 3 and 10 per cent higher and the new model boasts excellent aerodynamics , the new small Mazda is one of the most fuel-efficient cars in its class . The base model with 1.3-litre petrol engine uses only 5.4 litres of fuel per 100 km (combined cycle), which results in CO 2 emissions of 129 g/km . The 1.5-litre engine is not much thirstier and uses 5.9 litres per 100 km, for a CO 2 rating of 140 g/km.

All Mazda2 petrol engines are mated to a five-speed manual transmission known for its easy operation and precise shift travel. Double-cone synchronizers are used for first and second gears, which ensure easy shifting during both slow gear shifting and shifting during cold weather with low temperatures.

High-tech Mazda Engines

Both petrol engines of the MZR series operate with sequential valve timing (S-VT) which provides variable valve timing for the intake valves and optimised timing of the exhaust valves. In addition to this, the 1.5-litre adds a variable induction system (VIS) that boosts torque across the entire rev range. The intake manifold is made of plastic and ‘breathes’ through 600 mm long intake runners, making robust torque available at low engine speeds. The intake manifold also has integrated tumble swirl control valves ( TSCV s) that ensure high combustion stability, even during slow driving, and together with the exhaust-gas recirculation, improve fuel consumption and emissions. Both MZR 1.3-litre and 1.5-litre engines have an electronically controlled throttle that translates pedal input quickly and precisely.

Lightweight Engineering

The chassis for the second generation of the Mazda2 is based on a newly-developed platform that underscores the company’s long years of experience engineering small vehicles. In contrast to the Mazda2 introduced in 2002 which prioritised practicality, for new Mazda2 interior space became a shared priority along with delivering a more contemporary design and the same Zoom-Zoom driving fun as the other members of the modern Mazda family.

With a new state-of-the-art chassis as a foundation, Mazda engineers sought to provide outstanding handling for a car of this class, combined with high stability even on motorways and a harmonious ride quality. The low weight and high rigidity of the body shell played an important role in optimising handling and comfort. For handling, Mazda focused on manoeuvrability and agility on city streets, on steering that is spontaneous and linear, on achieving high grip on curving country roads and well-tempered reactions during fast lane-changing on the motorway.

An ingenious plan to reduce vehicle weight by around 10 percent compared to the former model was seen as the most efficient way to lower fuel consumption and CO 2 emissions . At a very early stage in development, a special team began looking for the best diet plan using advanced computer aided design or CAD technologies. After that, the engineers tested the ideas in drivable prototypes – initially in the previous Mazda2 – and examined the effects they had on the dynamic qualities of the car.

Their efforts were successful; once again, as it had done with the MX-5 roadster, Mazda was able to resist the spiral of ever increasing weight . An increased use of high-tensile steels led to a weight reduction of nearly 100 kg (depending on model). As a result, the new Mazda2 with the 1.3-litre petrol engine weighs considerably less than a ton – 955 kg. But Mazda2’s trend-bucking character is also evident by its length, which is now 40 mm shorter, at 3885 mm.

Use of High-Tensile Steels Has Several Positive Effects

Thanks to the optimised structure of its body shell and an increased use of new kinds of steel, the new Mazda2 is not only 10 percent lighter, but also improved when it comes to safety, body shell rigidity and NVH performance – all attributes that normally add weight to a car.

Through smaller dimensions alone, the weight of the body shell would have been cut by only 4 kg, to 233 kg. Measures taken to increase rigidity and crash resistance would have quickly raised it again to 244 kg. Thanks to the altered body structure and new materials, the team under the leadership of Program Manager Shigeo Mizuno was able to decrease weight to 215 kg – 22 kg less than the old Mazda2 body shell .

Up to 20 Percent Stiffer for Torsional Rigidity

The use of high- and ultra-high-tensile steels contributed first and foremost to a reduction in body shell weight. For example, the B-pillars are made of 980 MPa-grade steel sheet (MPa = measurement of tensile strength). They act as central support columns and extend in the form of a ‘roll- over bar’ into the roof. Despite stronger joint reinforcements in the area of the door openings and the tailgate, the use of high-tensile steel with reduced thickness resulted in a weight saving of 6 kg. At the same time, torsional rigidity was increased . By employing additional spot welds and adding new weld-bonded joints in the tailgate opening of the new Mazda2, it is 20 percent stiffer than the square-edged hatch opening of the outgoing model.

Mazda weight specialists were able to save an impressive 13 kg using weight optimising measures in the suspension . These included making the rear trailing arms shorter and the front lower arms lighter. This reduction in unsprung weight promotes better handling and ride comfort, as well as enhanced fuel economy. But Mazda engineers did not stop there. They also eliminated the underfloor catalyst and – for the 1.3-litre engine – the presilencer. For the intake system, Mazda engineers modified the intake duct design to the top of the radiator shroud. This new intake system eliminated the resonator and a baffle, which also saved valuable weight, as did fitting a smaller radiator and fan for the cooling system.

Weight-Saving Measures on the new Mazda2

Body Shell

Smaller dimensions alone would have lowered the weight of the body shell by 4 kg, to 233 kg. Measures needed to increase rigidity and crash resistance would have then raised it up to 244 kg. But thanks to an optimised body structure, weight was reduced to 215 kg, 22 kg less than the old Mazda2.

Intake and Cooling Systems

For the intake system, Mazda engineers moved the fresh air inlet from its original position behind the left headlamp to the top of the radiator shroud. This new position removed the need for the resonator and baffle.

Bonnet

With a smaller striker assembly and thinner hinges, the bonnet saved 0.69 kg.

Suspension

Mazda weight specialists were able to save an impressive 13 kg using weight optimising measures in the suspension. These included making the trailing arm on the rear axle shorter and giving the front lower arms an open-section structure. This reduction in unsprung weight means both better handling and ride comfort.

Exhaust System

Mazda eliminated the underfoot catalyst, and for the 1.3-litre petrol model, the presilencer used in the Mazda2 until now was also eliminated.

Electrical System

A shorter wiring harness saved a total of 2.86 kg – achieved by an insightful placement of large units and power-supply parts.

Door-Mounted Speakers

Mazda’s weight watchers were also at work with the door-mounted speakers. By changing the magnets from a ferrite type to neodymium, and making the plastic moulding single-piece, a total weight savings of 0.98 kg was achieved.

High-tensile steel

The use of high and ultra-high tensile steel alone saved 22 kg. The 980 MPa- grade steel used in the area of the B-pillar is a kind of central beam for the passenger cell. Strengthened joint reinforcements in the doors and liftgate saved 6 kg, without having to use thicker material.

Shortened Wiring Harness Saved 2.86 kg

The Mazda2 calorie-cutting team even found ways to reduce weight in the vehicle electrical system: a shorter wiring harness saved a total of 2.86 kg. What sounds like sorcery is in fact the result of an insightful placement of large units and power-supply parts. The bonnet also contributed to a weight saving of exactly 0.69 kg, with a smaller striker assembly and slightly thinner hinges. Even the audio speakers mounted in the doors were engineered to be lightweight: by changing the magnets from a ferrite type to neodymium, and making the frame and protective cover a single-piece plastic moulding, a total weight saving of 0.98 kg was achieved.

Acclaimed Suspension Concept Modified and Retuned

The front MacPherson strut suspension and the torsion- beam rear suspension also profited from the use of high- tensile steels in certain areas of the body shell to increase local stiffness and ensure optimal suspension geometry. The suspension system uses the same basic concept as that of the previous model, but the components have been modified in many details and retuned to match the much more agile attributes of the new Mazda2. For example, Mazda made the suspension mounts at the axles 15 per cent stiffer compared to the outgoing model. In the front suspension, new bushes on the A-arms reduce road surface influences on the toe angle, which has a positive effect on ride comfort and improves handling stability and the integrity of steering feel.

The trailing arm bushes of the rear suspension are now less sensitive to side forces. The rear monotube dampers have the same diameter as before, but because of the lower vehicle weight they now are as effective as larger-diameter dampers.

Electric Power Assist Steering Supports Driving Fun

Mazda2’s electric power assist steering system is appealing for its very linear and direct response and supports the Mazda goal of oneness between driver and car – the philosophy of Jinba Ittai so completely embodied by the Mazda MX-5. This new steering system provides very high levels of power assistance when the vehicle is being driven at very low speeds, which is especially handy when manoeuvring in tight spots and parking. With only 2.7 turns lock-to-lock , the steering system is very direct. Together with a small turning circle of only 9.8 metre s, this makes the Mazda2 an ideal urban vehicle.

The brake system of the Mazda2 includes an Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), as well as Emergency Brake Assist (EBA) and ventilated front disc brakes. In order to improve pedal feel, the pedal ratio was lowered from 3.79 to 2.85, which means less play in the pedal stroke and a more defined response. At the same time, Mazda reduced the diameter of the master cylinder from 23.8 mm to 20.6 mm and optimised brake booster characteristics. By improving the brake piston seal structure, the drag that results from friction between the pads and the discs of the front brakes was significantly reduced. Dynamic Stability Control (DSC) and Traction Control System (TCS) are also available (depending on market and model).

Testing in Europe

Engineers from the Mazda’s European development centre in Oberursel near Frankfurt, Germany gave the new Mazda2’s chassis a specifically European assessment on the meandering roads of Germany’s mountain region. Alexander Fritsche, Team Leader Chassis/Suspension in Oberursel, says, “Our testing areas feature all conceivable kinds of curves and surfaces – ideal for us testers and the Autobahns there are ideal too, with relatively little traffic.” Together with suppliers, Mazda engineers conducted extensive tests that not only identified the most harmonious damper settings, but also the ideal characteristics for the electric power assist steering. “This system is speed dependent – a lot of assistance when manoeuvring at parking speeds and driving around town, less when driving fast,” Fritsche says. “For this reason it was important for us to always have sufficient road feedback in the city and to tune the steering to be both sporty and comfortable as speed increases.”

Mazda not only made a quantum leap when it comes to steering feel and response compared to the outgoing model, but also for driving comfort and NVH. “We wanted to get away from the typically slightly harsh, B-segment feel and to significantly increase the sense of ride comfort,” says Fritsche in outlining the goal of his team. New pancake-type bushes are introduced for the lower arms of the front suspension, which are better at isolating the steering from exterior influences. The trailing arm bushes of the rear suspension are also better at smoothing out bumps and the geometry is designed to reduce roll and dive. “Europe usually represents the biggest challenge for Mazda’s development engineers when it comes to driving comfort. I’m confident that the new Mazda2 is impressive proof of just how consistently those challenges have been met,” concludes Fritsche.

Three-way Load Path Keeps Body Deformation Away From Occupants

Mazda2’s passive safety package is based on a body shell developed using the highly capable Mazda Advanced Impact Distribution and Absorption System (MAIDAS), which is able to disperse impact energy through the body shell along exactly defined load paths. In order to better absorb the energy from a frontal crash, the front side chassis members are straighter and have a larger cross-section. An ultra-high- strength structure in the front bumper and a straight main underbody load path provide effective occupant protection. During an offset crash, a three-way load path deflects impact energy away from the feet and lower legs of the front occupants. And the brake pedal is designed to collapse down and away from the driver’s feet.

Two Impact Beams in the Front Doors Provide Side Protection

During a side impact , B-pillars made of 980 MPa-grade steel, specially strengthened side sills and floor pan cross members provide effective occupant protection. In the front doors there are two side impact beams, which help protect occupants from injury, while a single beam in each rear door limits intrusion. Additional protection from injury is provided by shock-absorbing pads in the door trims, pillars and roof side rails.

In case of a rear impact , the back seat passengers and the fuel tank (located below the cabin floor and directly in front of the rear axle) are given increased protection by a large rear bumper beam and new side members, which are also straighter than the old model and are made of 590 MPa-grade steel.

This crash-resistant survival cell of the Mazda2 is enhanced by two front airbags and seatbelts with pretensioners and load-limiters. Front side airbags and curtain airbags , for helping protect all occupants sitting in the outer seats, are either standard or optional (depending on grade and market). Pedestrian safety is also optimised by the special design of the bonnet, fenders and windscreen wipers.

High-tensile Steel

The use of high-tensile steel materials provides a solution to the seemingly contradictory goal of providing low weight and high crash resistance . By using higher tensile steel, the thickness of the steel sheeting can be reduced , while still retaining the desired body shell strength and structural characteristics. This saves weight and costs, while simultaneously increasing safety levels for the occupants. For the body shell of the Mazda2, high-tensile and ultra-high-tensile steels with strengths of 440, 590, 780 and 980 MPa (mega-Pascal) are used. Varying degrees of strength are obtained through specific chemical and baking processes. Especially strong kinds of steel are used for the A- and B-pillars and the front door sills. Together with an increased number of spot welds – especially in the door openings and the side walls of the boot – this gives the Mazda2 a survival cell that truly deserves the name.

How resistant are the special steels?

Imagine a metal bar with a 3.5mm diameter, its critical failure point clearly varies depending on its type (high tensile / ultra-high tensile)…

Environmentally Friendly Production Methods

Besides making the interior surfaces nice to touch and providing the best ergonomics, the creators of the new Mazda2 also were keen to make sure the cabin does not release unhealthy substances into the air. The design team’s special focus concerned volatile organic substances (VOCs). An example of their efforts to cut VOCs was the reduction of toluene. For the first time, Mazda used a new substance for waterproof sealing the joints between interior panels, which gives off only one tenth of the emissions previously emitted by conventional sealers. By adopting this new subsance, the total concentration of toluene has been reduced by around 60 percent compared to the outgoing model. And not only that, the amount of xylene, formaldehyde, acetoaldehyde and polyvinyl chloride has been significantly lowered. Lead, cadmium, mercury and chromium were banned completely from the Mazda2.

Mazda2’s environmentally friendly character is also evident by its high recyclability. The new Japanese sub-compact meets the ISO 22628 norm and is more than 95 per cent recyclable . The bumpers, for instance, are made of a material that can be recycled into foot rests and splash shields, or can be recycled into new car bumpers.