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2009 Mazda 6 Diesel Arrives, Guilt-Free Performance - (Australia)

December 2nd, 2008
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Mazda has bolstered its performance and environmental credentials with the arrival of a high-performance MZR-CD 2.2-litre turbodiesel engine to the Mazda6 range that will change the way Australians perceive diesel.

The new Mazda6 Diesel wagon and Mazda6 Diesel Sports hatch boast the performance to match expensive European diesel luxury cars at a more affordable price, bringing turbodiesel performance and exemplary environmental credentials within reach of everyone.

The 2.2-litre, common-rail, four-cylinder turbodiesel engine is a new-generation, environmentally friendly Mazda powerplant which employs variable geometry turbocharging and direct-injection to deliver an impressive 136kW of power and 400Nm of torque, up 31kW and 40Nm on the 2.0-litre engine it replaces.

All this extra performance – 30 per cent more power, 10 per cent more torque, 11 per cent quicker acceleration from 0-100km/h – comes at no extra cost to the environment.

The new Mazda6 Diesel delivers a combined-cycle fuel economy of 5.9L/100km in hatch form, exactly the same as the less-powerful 2.0-litre engine it replaces.

Mazda Australia Managing Director Doug Dickson said, "This spirited and economical new-generation engine cements Mazda's leadership as the only Japanese brand offering turbodiesel passenger cars to Australians.

"This new 2.2-litre turbodiesel delivers on the once conflicting attributes of robust and refined, powerful and efficient… from a compelling sub-$40,000 price."

Mr Dickson said the Mazda6's high-tech new engine makes diesel synonymous with exhilaration.

"The new Mazda6 turbodiesel appeals to economy-minded buyers and true driving enthusiasts. With 400Nm on tap from just 1,800rpm, and mated to a sporty six-speed manual transmission, it delivers spirited in-gear acceleration and an exhilarating drive."

The new Mazda6 turbodiesel is the first step towards Mazda's Sustainable Zoom-Zoom commitment to improve fuel efficiency by 30 per cent across its range by 2015.

"The new Mazda6 Diesel wagon and Mazda6 Diesel Sports hatch is proof that environmentally-friendly cars can also be fun to drive," said Mr Dickson.

The Mazda6 Diesel goes on sale December 1, 2008, in hatch and wagon bodystyles. The Mazda6 Diesel wagon has a recommended retail price of $36,690; the Mazda6 Diesel Sports hatch is $43,890.

The Mazda6 turbodiesel is the second turbodiesel passenger car in Mazda's current range alongside the Mazda3 Diesel priced from $29,500.

Mazda6 Diesel available in two flavours
The second-generation Mazda6 Diesel is offered in two equipment grades, each tied to a specific bodystyle and equipped to meet the needs of environmentally-aware Australian new car consumers.

The Mazda6 Diesel wagon is similar to the petrol model’s Classic grade. The Mazda6 Diesel Sports hatch is similar to the Luxury Sports petrol grade minus the sunroof.

Like their petrol siblings, both Mazda6 Diesel models are extremely well-equipped and among the best-in-class on value for money.

All Mazda6 petrol and diesel models come standard with body-coloured power door mirrors, air-conditioning, cruise control, keyless entry, tilt/telescopic steering wheel, CD/MP3 audio system with auxiliary jack, front and rear power windows, six airbags, Dynamic Stability Control (DSC), traction control, brake assist, active front head restraints and intrusion-minimising brake and clutch pedals.

The Mazda6 Diesel wagon comes with 17in alloy wheels, fog lamps, rain-sensing wipers, auto on/off headlamps, dual-zone climate control air-conditioning, leather-wrapped steering wheel, lumbar adjustment for the driver’s seat, trip computer, six-disc in-dash CD/MP3 player with six speakers, steering wheel-mounted audio controls and MP3 player connectivity.

The Mazda6 Diesel Sports hatch adds full leather interior, front and rear parking sensors, blackout instrument cluster, leather-wrapped gear knob, eight-way electrically-adjustable driver’s seat with three-position memory and four-way electric adjustment on the passenger’s seat, and a premium Bose® 240 watt sound system

Its visual performance matches its status as the pinnacle of the Mazda6 range, with a full sports body kit, including , Bi-Xenon headlamps with Adaptive Front Lighting System (AFS), 18in alloy wheels, aero bumpers, side skirts and a rear spoiler.

The new Mazda6 Diesel range goes on sale in Australia December 1, 2008.

Mazda expects to sell 70 Mazda6 Diesels a month, split roughly 50/50 between the two models.

New MZR-CD 2.2-litre Diesel Engine

Building on solid foundations
The second-generation Mazda6 was first launched in Europe in November 2007. It represented an evolution of Mazda Zoom-Zoom and set a new standard in the Medium Car segment for its combination of eye-catching stylishness, exclusive driving experience and insightful packaging.

Since launch, the Mazda6 has been a critical success in Europe, Asia and Australia, and has recently gone on sale in North America. Now the Mazda6 is about to become even more popular with the introduction of a new Mazda-developed MZR-CD 2.2-litre turbodiesel engine that is one of the quietest, most powerful and economical in its segment.

Mazda6 has always been a driver’s car and with the launch of the new-generation model locally in February 2008, the fun factor was improved even further. The second-generation Mazda6 is powered by a MZR 2.5-litre S-VT four-cylinder engine which produces 125kW at 6000rpm and 226Nm at 4000rpm (up 3kW and 19Nm on the previous 2.3-litre engine).

Mazda’s New-Generation Powerful and Clean Diesel
Mazda now introduces a new clean turbodiesel that is one of the quietest and most powerful in its class.

Mazda’s new MZR-CD 2.2-litre turbodiesel has a lively yet cultivated character that will offer a truly exclusive driving experience in the second-generation Mazda6.

With a class-leading 136kW of power and 400Nm of torque, and a combined cycle fuel economy figure of 5.9L/100km in hatch form, the new-generation Mazda6 Diesel offers guilt-free performance, unrivalled for the money.

To realise this kind of power and torque with 2.2 litres of displacement, the MZR-CD 2.2-litre employs a highly efficient variable-geometry turbocharger (VGT) with curved (instead of straight) vanes on the turbine (exhaust) side.

This increases maximum available torque at both low and high engine speeds while also increasing all-important low-end response (as low as 1,800rpm with a flat torque curve that continues until 3,000rpm) that contributes to a smooth and powerful driving feel.

When combined with an abradable seal on the compressor side (intake side), which reduces the clearance between the blade and the compressor housing, these attributes deliver superior turbocharger response at just about all engine speeds.

Converting the engine’s combustion energy into this much engine torque meant the pistons had to be designed to take the resulting high combustion pressure and temperatures. As a consequence, the pistons are made of an aluminium alloy with improved high-temperature fatigue strength.

A half-Keystone cross-section top-ring with improved carbon scavenging abilities is used, and the groove for the top ring is made more durable with the adoption of a cooled ring carrier that increases the groove’s cooling capability.

Mazda engineers also increased the fuel injection pressure to 200MPa (by comparison, the previous generation MZR-CD 2.0-litre turbodiesel uses 180MPa). They realised this by making functional improvements to the high-pressure pump, among other improvements, and by new injectors featuring 10 spray holes per injector (instead of the six for the MZR-CD 2.0-litre) that are smaller (reduced from 0.13mm to just 0.119mm).

These changes enable more precise injection timing, and an increase in the number of times of injection and injection amount. And it allowed the fuel injection patterns at transitional states to be more precisely controlled.

As a result, the Mazda6 Diesel 2.2-litre engine provides superior acceleration in those situations you need it most, like entering a highway. It also surpasses its competitors in lower-speed acceleration. Third gear from 50-100km/h, for example, is 1.7 seconds faster than the previous generation Mazda6 MZR-CD 2.0-litre.

Low Fuel Consumption
This new diesel engine meets the requirements of Mazda’s Sustainable Zoom-Zoom plan by being frugal at the pump. It uses 5.9L/100km (hatch) and 6.0L/100km (wagon) on the combined cycle.

It achieves this by employing highly responsive solenoids for the common-rail injection system that achieve a minimum injection interval of just 0.2ms (the MZR-CD 2.0 is 0.3ms), which speeds up the minimum injection interval by about 30 per cent, improves its responsiveness and lowers fuel usage.

Fuel is also saved by lowering the compression ratio to 16.3:1 and utilising the temperature cooling effect this causes, which secures more mixing time until ignition, and allows a more precise fuel-injection pattern. As a result, fuel consumption is a low 5.9L/100km (hatch) with CO2 emissions of just 156g/km (hatch).

In fact, the MZR-CD 2.2-litre offers substantially higher power and torque than the previous-generation MZR-CD 2.0-litre, while delivering equal levels of fuel consumption and CO2 emissions.

Low Emissions – Particulate Filter with World’s First Ceramic Support Matrix Structure
Mazda engineers not only made the new 2.2-litre turbodiesel powerful and lowered fuel consumption, they also lowered the amount of raw emissions and raised the efficiency of its after-treatment technologies.

The engine’s highly responsive fuel-injection technologies have new injectors that yield better atomised spray characteristics. These are combined with an exhaust gas recirculation (EGR) system with a cooler bypass structure – that decreases unburned gases and NOx – and the high-response solenoids described previously, to realise superior emissions performance without sacrificing power.

Emissions are then treated by a diesel particulate filter that uses a unique Mazda-developed, ceramic support matrix structure, which is the first of its kind to go into production in the world.

Previous diesel particulate filters converted particulate matter (PM) into CO2 by reacting the PM with the oxygen in the exhaust gas at the surface of the catalytic particle. This meant that the time needed for filter regeneration was determined by the amount of oxygen on the surface of the catalyst. When the temperature of the exhaust gas is raised to quicken the regeneration time, then technological issues – like higher fuel usage or the ceramics exceeding their thermal resistance limit – can occur.

Mazda solved these issues by using highly thermal resistant material for the ceramic monolith of its new diesel particulate filter, and designing the internal structure of the ceramic support matrix with passages for oxygen to enable a large amount of oxygen to be utilised for PM combustion.

With this, Mazda has succeeded in significantly increasing the PM combustion speed. As a result, the number of times the diesel particulate filter has to regenerate (in combined mode) is cut in half, and the time necessary for each regeneration phase is shortened by one third.

For owners of the new Mazda6 2.2-litre turbodiesel, this means worry-free filter regeneration and, because fewer regeneration phases are required, each takes less time resulting in less fuel consumption overall.

Running Quiet
The new Mazda6 Diesel 2.2-litre common-rail turbodiesel not only offers superior output, fuel economy and emissions performance, it is also one of the quietest engines in its segment with this amount of torque. This ensures a driving experience that is one of the segment’s most exclusive.

To achieve this, the new engine has a lower block with a very rigid aluminium-alloy structure, with the bottom of the cylinder block skirt and the cylinder block’s main bearing caps bolted to the lower block at 18 separate locations. This high structural rigidity is combined with a front chain-driven cassette-type balancer shaft to suppress booming noise and lower radiated noise, and to deliver optimised pedal response and engine sound for a refined acceleration feel.

Packaging and Weight Management
Keeping the new MZR-CD 2.2-litre turbodiesel as close as possible in size and weight to that of the MZR-CD 2.0-litre was a key factor in ensuring exhilarating performance combined with fuel efficiency and low emissions.

Some of the newly adopted technologies, such as the balancer shaft and DOHC, result in increased size and weight. Nonetheless, numerous innovations were added to manage size and weight increases, with the goal of maintaining packaging and keeping the weight increase within just 6.0kg of the previous MZR-CD 2.0-litre turbodiesel.

Due to the increase in displacement, the stroke of the MZR-CD 2.2-litre is 8mm longer compared to the MZR-CD 2.0-litre. At the same time, the overall length of the connecting rod was shortened by optimising their design. As a result, their weight remains at the same level as in the MZR-CD 2.0-litre.

The adoption of a balancer shaft that decreases vibration caused by reciprocating motion made a thinner cylinder block with fewer ribs possible – hypothetically, if the MZR-CD 2.2-litre had no balancer shaft, the cylinder block would have been 1.9kg heavier than that of MZR-CD 2.0-litre, and its crankshaft 1.3kg heavier.

Furthermore, decrease in size and weight was achieved by making the balancer housing, oil pump housing, and the oil suction pipe a single structure. To achieve even more weight reduction, while increasing the cooling capability of the new engine, the oil cooler is made of aluminium (-0.6 kg). The weight of the cam cover is also reduced by making it out of plastic (-1.0 kg).

Styling and comfort – Continued Excellence

Design – Japanese Aesthetics in Two Distinct Body Styles
The Mazda6’s athletic, sophisticated exterior design and high levels of build quality has been turning heads all over Europe since launch last year. Its exquisite sense of form based on Japanese aesthetics gives it a unique road presence that is distinctly Mazda.

The hatch version is 4,735mm long, 1,795mm wide and 1,440mm high and the sportiest-looking of the three versions with a sleek roofline at the C-pillar for a coupe-like image. The wagon is 4,765mm long, 1,795mm wide and 1,490mm high and the longest of the two diesel models, with a distinctive kick-up belt line and sleek windows for a cut through the wind look.

The dynamic and sleek exterior design of the Mazda6 also makes it one of the segment’s most aerodynamic vehicles. All external components were streamlined to produce a coefficient of drag (Cd) of only 0.27 (hatch) and just 0.28 (wagon), which contributes to stability at high speeds and an overall lowering of fuel consumption.

On the inside, Mazda6 was designed to take full advantage of the car’s great looks, high quality and fun-to-drive character by delivering what engineers termed Kizuna, or a strong emotional bond between the car and its owner.

Its wrap-around cockpit allows the driver to feel at one with the car, and to fully enjoy an exquisite driving experience not usually found on cars in this class. The inside is not only attractive and roomy, with a floating-look dashboard that makes the inside seem even larger, it also has the highest levels of interior craftsmanship ever on a Mazda vehicle. This quality is underscored by interior forms that are appealing to look at and use on a daily basis.

Space, Comfort & Equipment – Easy to Use and Practical
Though sporty-looking and sleek on the outside, the Mazda6 provides family-sized space and practicality on the inside, which is especially important to CD segment customers.

Compared to the previous model, the second-generation Mazda6 has 20mm more rear leg room and 9mm more rear shoulder room, which translates into more comfort precisely where it is needed – in the back seats.

Customers also enjoy one of the largest forward-upward views in the segment. When combined with specially designed rear head restraints and door mirrors that give the driver a better view to the rear, the Mazda6 is not only safer to drive, but easier to manoeuvre in tight spaces.
To this it adds high levels of practicality with one of the segment’s widest boot/ tailgate openings, Mazda’s Karakuri rear seat folding system that drops the 60/40 rear seats down by pulling a latch in the boot trim (hatch and wagon), and a Karakuri tonneau cover that automatically lifts when you open and close the liftgate (wagon only).

Mazda6 is also designed with comfort in mind. It has specially formed seat frames for good long-trip comfort that also provide side support during sportier driving. And it makes the ride comfortable whatever the weather might be with a heating, ventilation and air conditioning (HVAC) system that has separate temperature controls for the driver and the passenger.

The cockpit is also easy on the eyes with a blackout instrument cluster (Diesel Sports hatch) with amber-red illumination circled by indirect blue lighting. A new sports car-like steering wheel and gear shift lever positions are closer to the driver for easier control and shifting.

Mazda6 is also easy on the ears with a quiet driving experience, regardless of what engine is under the bonnet. Compared to the first-generation model, the Mazda6 is 2.5dB quieter (from 70dB to 67.5dB) when driving at 60km/h on a coarse road.

The new Mazda6 has plenty of convenient storage compartments that make it practical and easy-to-use on a daily basis. For small item storage there is a large glovebox, and a large centre console box – in dimpled-finished leather with a sliding armrest with leather stitching (Diesel Sports hatch) – that has cupholders in front.

There are cupholders in the fold-out centre arm rest in the rear and front door trim pockets that can hold a 1.5-litre bottle and documents. Practical as well is the car’s action illumination system with light fade up and down, and interactive light reaction when using the CD player and radio.

Mazda Australia is offering the Mazda6 Diesel in two trims: the Mazda6 Diesel wagon is similar to the petrol model’s Classic grade, and the Diesel Sports hatch comes in Luxury Sports trim minus the sunroof.

The steering wheel’s CF-NET (Cross-Functional Network) system allows the driver to control the audio settings, satellite navigation (where fitted), climate control and trip computer. Optional features include a touch-screen satellite navigation system.

Mazda6 Diesel is offered in a range of 11 exterior colours (see colour chart on page 19 of the PDF version of this release).

As with all Mazda models, Mica and Metallic paint is a no cost option.

Chassis – Sporty, Predictable and Safe

The Mazda6 took Mazda’s Zoom-Zoom steering and handling attributes to the next level
when it launched in Australia in February 2008. The Mazda6 is also larger and better equipped than the previous-generation Mazda6, and is the third vehicle – after the third-generation MX-5 and the new Mazda2 – to benefit from Mazda’s Gram Strategy weight management process.

The Mazda6 body shell has seven per cent more high and ultra-high-strength steel than the previous Mazda6, which results in double-digit increases in both flexural and torsional rigidity for all body styles – without a significant gain in weight. This, along with weight savings at other locations, means today’s Mazda6 petrol and diesel variants have better handling and fuel efficiency, and enhanced crash resistance.

The front suspension is a high-mount double wishbone system that uses two additional perimeter frame mounting points (six versus four on the previous Mazda6), with dynamic dampers for the upper arms to absorb noise and vibrations, and stiff damper settings for excellent overall rigidity and ride comfort.

This is combined with a single-pivot type lower arm, which gives more precise steering and predictability. Mazda’s E-type multilink rear suspension is employed at the back axle with large-diameter trailing arm bushes placed 25mm higher than those of the previous model to create a different geometry for improved rear lift control and a more linear toe-angle change during the rebound phase.

The rear dampers are in an upright layout, which realises linear vehicle movement and a feeling of stability. Rack-drive electric power assist steering delivers a firm steering feel and contributes to lowering overall fuel consumption.

Class-leading safety on all models

A long list of active and passive safety systems complete the outstanding Mazda6 package.
Like their petrol counterparts, all Mazda6 models – petrol and diesel – come standard with
front airbags, front-side airbags and curtain airbags in the front and back seats to fully protect occupants in a crash.

In addition, the Mazda6’s superb dynamic range is enhanced by a Dynamic Stability Control (DSC) system developed specifically for the Mazda6. This DSC system incorporates Traction Control (TCS) and allows the driver to fully exploit the Mazda6’s fluid chassis yet acts quickly to restore order if the limits are breached.

Added to this are large 299mm ventilated front disc brakes and 280mm rear disc brakes for dependable deceleration; backed up by Antilock Braking System (ABS), Electronic Brake-force Distribution (EBD) and Emergency Brake Assist (EBA).

The Mazda6 bodyshell is strong and very crash-resistant. It has a perimeter frame extension at the front of the car, and extended joints between the front side members of the perimeter frame, for a 10 per cent improvement in impact-absorption here compared to the previous model.

On the inside there are 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 child seat 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.

Environmental Initiatives

Recyclability Exceeding 90 percent
A typical end-of-life vehicle is 80 per cent recyclable by weight. Most of the recovered materials are metals, predominantly steel and aluminium. The other 20 per cent of the vehicle, consisting mainly of plastics and glass, is dumped in landfills as shredder dust.

Mazda has achieved recyclability exceeding 90 per cent through the following initiatives:

  • Conducting research into vehicle designs and dismantling technologies that facilitate removal of reusable parts and materials
  • Standardising our use of plastics (the main component by weight of shredder dust) on easy-to-recycle types

Bioplastics Development
In association with businesses, academia, and government agencies in Hiroshima
Prefecture, Mazda has become the first carmaker to develop plant-sourced, extrusion-mouldable bioplastics that have good enough appearance, strength, and heat resistance to be used for cabin parts.

Reduced Use of Environmentally Harmful Chemicals
Mazda takes an aggressive approach to reducing its use of lead, hexavalent chromium, cadmium, mercury, and other chemicals that adversely affect the environment. Mazda has stopped using lead, cadmium, and mercury except for parts that are subject to exemptions until alternative technologies are established. Also, Mazda has stopped using hexavalent chromium for some parts and are developing alternative technologies for safety-critical parts and the nuts and bolts used in their assembly.

Reduced Use of Air-Conditioner Refrigerant
Mazda is working to reduce its use of chlorofluorocarbon substitutes that are recognised as greenhouse gases, and is developing air conditioners that use other refrigerants that have a minimal environmental impact.

Reduced Use of Volatile Organic Compounds in Cabins
Since 1999, we’ve offered our main vehicle models with an aldehyde-odour-removing filter that helps to maintain a comfortable cabin environment by removing odours and aldehydes from the air. In addition, Mazda has revised materials and adhesives for cabin parts in an effort to reduce Volatile Organic Compound (VOC) generation in the cabins of new vehicles.

In 2005, Mazda introduced a low-VOC body sealer and has since been developing
VOC-reduction technologies aimed at compliance with a 2007 target set by the Japan Automobile Manufacturers’ Association.

Reduced Use of VOCs in Painting Processes
In partnership with Nippon Paint, Mazda developed an electrodeposited undercoat that reduces VOC and CO2 emissions. Electrode-position, whereby car bodies are submerged in a coating and have an electric current passed through them to apply the coating to them, is typically used for undercoat application since it applies the undercoat not only to outer surfaces but also to inner surfaces, thereby preventing corrosion from the inside.

The new electrodeposited undercoat has a 50 per cent lower VOC content than earlier types and can be used in smaller volumes, meaning lower VOC emissions.

Smaller volumes also mean lower CO2 emissions during production of the undercoat.
Specific advantages (relative to employment of earlier undercoat types) are as follows:

  • An annual reduction of 32 tons in VOCs emitted during the undercoating process
  • An annual reduction of 8.8 tons in CO2 emitted during undercoat production
  • A reduction of at least 10 percent in the volume of undercoat used
  • Better corrosion resistance owing to uniform undercoat thickness on inner surfaces of car bodies

Also, Mazda led the motor industry by developing a Three Layer Wet Paint System, which combines the primer, base, and clear coats into a single application process. Mazda deployed this system at all plants in Japan, thereby greatly reducing VOC and CO2 emissions.

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