AIM OF DEVELOPMENT


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Vehicle Outline


Exterior design

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Interior design

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Engine

•  SKYACTIV-G 2.5T, SKYACTIV-G 2.0 (without cylinder deactivation), SKYACTIV-G 2.5 (without cylinder deactivation), SKYACTIV-G 2.0 (with cylinder deactivation), SKYACTIV-G 2.5 (with cylinder deactivation) and SKYACTIV-D 2.2 have been adopted.
Engine mechanical (SKYACTIV-G 2.5T)
•  For SKYACTIV-G 2.5T, the following has been implemented to lower fuel consumption.
―  Sliding resistance reduction
•  Rocker arm (with built-in needle roller bearing) adopted for cam-contact area
•  Reduced valve spring load
•  Narrowed down crankshaft journal
•  Optimized piston skirt shape
•  Lowered piston ring tension
•  Lowered drive belt tension
•  Suppressed chain tensioner load by stabilized timing chain behavior
•  Oil shower pipe adopted
―  Mechanical resistance loss reduction
•  Optimized oil passage
•  Optimized oil pump shape
•  Engine oil variable control adopted
―  Pumping loss reduction
•  Variable valve timing mechanism adopted on both intake and exhaust sides for fine control of exhaust amount and internal EGR volume
―  Weight reductions
•  Hard-plastic intake manifold adopted
•  Exhaust manifold integrated cylinder head adopted
―  Heat loss reduction
•  Water jacket spacer adopted
―  Cooling loss reduction in early stage of combustion
•  Piston cavity adopted
―  Cooling efficiency improvement
•  Air seal cowl adopted
•  Optimized cooling fan shape
•  Optimized engine coolant passage
•  Optimized water pump impeller shape
―  Combustion efficiency improvement
•  Multiple hole-type fuel injectors adopted
•  High-pressure fuel pump adopted
―  The HLA has been adopted to achieve the maintenance-free valve clearance.
―  4-3-1 type exhaust passages have been adopted to improve the acceleration/environmental performance.
―  An ejector which can recirculate the evaporative gas in all engine ranges (boost range from non-boost range) has been adopted to improve the emission performance.
―  An exhaust gas recirculation (EGR) system has been adopted to achieve cleaner exhaust emissions and improve fuel economy.
Engine mechanical (WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))
•  For SKYACTIV-G 2.0 and SKYACTIV-G 2.5 (without cylinder deactivation), the following is performed to lower fuel consumption.
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―  Improvement of mechanical resistance loss
•  Narrowed down crankshaft journal
•  Optimized piston skirt shape
•  Lowered piston ring tension
•  Roller follower adopted
•  Reduction of valve spring load
•  Stabilization of timing chain behavior
•  Optimized engine coolant passage
•  Optimized water pump impeller shape
•  Lowered drive belt tension
•  Optimized oil passage
•  Optimized oil pump shape
•  Oil pump discharging pressure control has been adopted.
―  Improvement of pumping loss
•  Variable valve timing mechanism has been adopted on both sides of intake and exhaust.
―  Cooling loss improvement (with coolant control valve)
•  Coolant control valve adopted
•  Optimized engine coolant passage
Engine mechanical (WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))
•  For SKYACTIV-G 2.0, 2.5 (with cylinder deactivation), the following is performed to lower fuel consumption.
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―  Improvement of pumping loss
•  Cylinder deactivation control adopted
―  Cooling loss improvement
•  Coolant control valve adopted
•  Optimized engine coolant passage
Engine mechanical (SKYACTIV-D 2.2)
•  For SKYACTIV-D 2.2, the following is performed to lower fuel consumption.
―  Low compression ratio
•  Combustion efficiency by lower compression ratio (14.4)
―  Weight reductions
•  Aluminum alloy cylinder block adopted
•  Exhaust manifold integrated cylinder heads adopted
―  Weight reduction and mechanical resistance loss improvements
•  Piston shape optimized
•  Narrowed down crankshaft journal
•  Two-step boost control has been adopted, realizing low emission, low fuel consumption, high torque, and high response.
―  Variable geometry turbocharger adopted
―  Regulating valve actuator adopted
―  Variable turbine geometry turbocharger actuator adopted
•  An exhaust gas recirculation (EGR) system has been adopted for cleaner exhaust emissions and improved fuel efficiency.
•  i-stop control has been adopted for improved fuel efficiency, reduced exhaust gas emissions, and reduced idling noise.
Engine control [SKYACTIV-G 2.5T]
•  L-jetronic and D-jetronic types have been adopted for the intake air amount measurement to realize stable combustion free from abnormal combustion.
―  MAF sensor adopted
―  MAP sensor adopted
―  IAT sensor No.1 and No.2 adopted
―  Boost pressure sensor and boost air temperature sensor adopted
•  To improve the fuel economy and emission performance, an electric variable valve timing control has been adopted for the intake side, and a hydraulic variable valve timing control for the exhaust side. The electric type is adopted for the intake side to achieve expanded valve overlap and delayed closing of the intake valve (enlarged intake valve opening angle).
Intake side: Electric variable valve timing control
―  Intake CMP sensor adopted
―  Electric variable valve timing motor/driver adopted
―  Electric variable valve timing relay adopted
Exhaust side: Hydraulic variable valve timing control
―  Exhaust CMP sensor adopted
•  Engine oil variable control has been adopted to reduce the oil pump operation load on the engine.
―  Engine oil solenoid valve adopted
•  With the adoption of fuel pump control, fuel pump power consumption has been reduced to improve fuel economy.
―  Fuel pump control module adopted
•  Boost control has been adopted to improve fuel economy/environmental performance/low-speed torque.
―  Dynamic pressure turbo adopted
•  Generator output control has been adopted to improve fuel economy/idling stability.
―  A current sensor adopted (With i-stop system)
•  To improve engine reliability, an ion sensor has been adopted which detects pre-ignition.
•  LIN communication has been adopted to the current sensor to realize wiring harness simplification. (With i-stop system)
•  i-stop control has been adopted to improve fuel efficiency, and reduce exhaust gas and idling noise. (With i-stop system)
Engine control (WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))
•  L-jetronic and D-jetronic type detectors have been combined for intake air amount detection, improving the accuracy of the intake air amount measurement.
•  Valve timing control has been adopted on both sides of the intake and exhaust, improving fuel economy and emission performance.
•  The engine coolant control valve adjusts the engine coolant control valve opening angle and supplies engine coolant to the appropriate engine coolant passage according to the changes in the engine coolant temperature.
•  Further engine warming has been promoted by blocking each water passage while the engine is cool.
―  Coolant control valve adopted
•  i-stop control has been adopted for improved fuel efficiency, reduced exhaust gas emissions, and reduced idling noise. (with i-stop control)
Engine control (WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))
•  Engine coolant is supplied to the appropriate engine coolant passage according to the engine load conditions.
•  Further engine warming has been promoted by blocking each water passage while the engine is cool.
―  Coolant control valve adopted
•  Pumping loss due to intake/exhaust stroke is reduced to improve fuel economy during low engine loads.
―  Cylinder deactivation control adopted
Engine control (SKYACTIV-D 2.2)
•  Two-step boost control has been adopted, realizing low emission, low fuel consumption, high torque, and high response.
―  Fuel injector
•  Variable geometry turbocharger adopted
•  Regulating valve actuator adopted
•  Actuator of turbocharger with variable turbine geometry adopted
•  Glow control has been adopted to improve engine startability and diesel particulate filter regeneration performance.
•  An exhaust gas recirculation (EGR) system has been adopted for cleaner exhaust emissions and improved fuel efficiency.
•  i-stop control has been adopted for improved fuel efficiency, reduced exhaust gas emissions, and reduced idling noise.
•  SCR control has been adopted which purifies contaminants in the exhaust gas by utilizing chemical reactions. (with SCR system)
•  i-art (intelligent accuracy refinement technology) has been adopted for improved fuel injection precision.


Suspension

Front suspension
•  A strut type front suspension adopted.
•  A fluid-filled type front lower arm bushing has been adopted.
•  For the front / rear crossmembers, the welded flange has been eliminated (flange-less), the cross-section expanded and the connection rigidity of the welded parts improved to achieve both rigidity and light weight.
•  The cross-section on the center member of the front crossmember has been expanded and the longitudinal offset of the front lower arm installation position reduced to realize an optimized framework.
•  By adopting a 6-point rigid mount-type front crossmember, the force generated from the tires is transmitted directly, and an agile vehicle response in low-to-mid speed range has been realized.
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Rear suspension
•  Multi-link rear suspension adopted.
•  For the front /rear crossmembers, the welded flange has been eliminated (flange-less), the cross-section expanded and the connection rigidity of the welded parts improved to achieve both rigidity and light weight.
•  The longitudinal span of the rear crossmember was extended and the longitudinal offset of the rear lateral link attachment position was reduced.
•  By raising the installation position of the rear trailing link, the longitudinal input has been reduced, ride comfort improved, and the sense of safety during braking improved.

2WD

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4WD

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Driveline/Axle

•  Unit-design, double angular ball bearings with low rotational resistance have been adopted for the front and rear axles.
•  Unit bearings that require no preload adjustment have been adopted for the front and rear wheels.
•  The following parts have been adopted to reduce vibration and noise:
―  Bell-shaped constant velocity joint has been adopted for the wheel-side joint of the front drive shaft.
―  A tripod-shaped constant velocity joint has been adopted for the differential-side joint of the front drive shaft.
―  For 4WD vehicles, bell-shaped constant velocity joint has been adopted for the wheel-side joint of the rear drive shaft.
―  For 4WD vehicles, a tripod-shaped joint has been adopted for the differential-side constant velocity joint.
―  For 4WD vehicles, 2-part, 1-joint type propeller shaft with middle shaft bearing has been adopted.
•  For 4WD vehicles, the following parts have been adopted to improve off-road mobility and handling stability:
―  Electronic 4WD control system which automatically and optimally controls drive torque distribution for the front and rear wheels.
―  Rear differential which integrates the coupling component to reduce size and weight.
•  Actual fuel economy similar to the 2WD has been realized by minimizing energy loss for the entire i-ACTIV AWD system.
•  The off-road traction assist has been adopted to achieve the road handling ability if diagonally opposed wheels lose contact with the ground.
•  Ball bearings/tandem ball bearings with low rolling resistance have been adopted for the inside of the rear differential and transfer.


Brakes

Conventional brake system
•  A DSC HU/CM has been adopted in which the hydraulic unit (HU) and control module (CM) are integrated with a built-in brake fluid pressure sensor.
•  Magnetic encoder type ABS sensor rotors have been adopted.
•  Semiconductor element type ABS wheel-speed sensors have been adopted.
•  A vacuum pump has been adopted to compensate for the decrease in intake manifold vacuum applied to the power brake unit caused by the retard intake valve closing.
•  An electric parking brake has been adopted.
•  The following systems, mechanisms, and functions have been adopted to enhance safety.
―  Intrusion-minimizing brake pedal
―  Antilock brake system (ABS)
―  Electronic brake force distribution (EBD) control
―  Traction control system (TCS)
―  Dynamic stability control (DSC)
―  Roll over mitigation (ROM)
―  Electronic control brake assist
―  Vehicle roll prevention function
―  Hill launch assist (HLA)
―  Secondary collision reduction
―  AUTOHOLD

Vehicle front side (L.H.D.)

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Vehicle front side (R.H.D.)

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Vehicle rear side

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Dynamic stability control (DSC)
•  Electrical brake assist control has been adopted, improving safety.
•  The DSC HU/CM, integrating both the Hydraulic Unit (HU) and Control Module (CM), has been adopted, resulting in a size and weight reduction.
•  An enhanced malfunction diagnosis system, used with the Mazda Modular Diagnostic System (M-MDS), improving serviceability.
•  Serviceability improved by the automatic configuration function.
•  Receives the lateral-G, longitudinal-G, and yaw rate signals between the Sophisticated Air bag Sensor (SAS) control module and the DSC HU/CM via Controller Area Network (CAN) lines instead of the conventional combined sensor.
•  The vehicle roll prevention function, hill launch assist (HLA), roll over mitigation (ROM), and secondary collision reduction* have been adopted, improving safety.
•  The Off-Road Traction Assist has been adopted to achieve the road handling ability if diagonally opposed wheels lose contact with the ground. (With Off-road Traction Assist)
*  :Vehicles with smart city brake support (SCBS)

Vehicle front side (L.H.D.)

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Vehicle front side (R.H.D.)

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Vehicle rear side

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Transmission/Transaxle

C66M(X)-R
•  For SKYACTIV-G 2.0 (without cylinder deactivation), SKYACTIV-G 2.5 (without cylinder deactivation), six-speed C66M(X)-R manual transaxle has been adopted.
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D66M(X)-R
•  For SKYACTIV-D 2.2, six-speed D66M(X)-R manual transaxle has been adopted.
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FW6A(X)-EL
•  For SKYACTIV-G 2.0 (without cylinder deactivation), SKYACTIV-G 2.5 (with cylinder deactivation), SKYACTIV-G 2.5 (without cylinder deactivation), six-speed FW6A(X)-EL automatic transaxle has been adopted.
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GW6A(X)-EL
•  For SKYACTIV-G 2.5T and SKYACTIV-D 2.2, six-speed GW6A(X)-EL automatic transaxle has been adopted.
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Steering

•  A column-assist type Electric Power Steering (EPS) has been adopted.
•  The quick steering gear ratio (15.5) enhances the vehicle responsiveness to the driver's steering operations.
•  A steering column with tilt/telescoping mechanism has been adopted, allowing fine adjustment of the driving posture.
•  A steering column and shaft with a shock-absorbing mechanism has been adopted.
•  The EPS Control Module (CM) has been integrated with the EPS motor, resulting in a size and weight reduction.
•  Serviceability has been enhanced by enabling high-function malfunction diagnosis using the Mazda Modular Diagnostic System (M-MDS).

L.H.D.

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R.H.D.

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Heater, ventilation and air conditioning

•  A sub-cooling type condenser with an integrated condenser and receiver/drier have been adopted.
•  A refrigerant pressure sensor adopted in which refrigerant pressure is changed into a linear electric signal and precise information is transmitted.
•  A climate control unit has been adopted with which the airflow temperature setting for the driver and passenger sides can each be adjusted independently. (full-auto air conditioner)
•  A climate control unit with built-in the display panel is adopted. (full-auto air conditioner)
•  HFO-1234yf has been adopted as the new refrigerant. HFO-1234yf refrigerant has little effect on global warming. (With HFO-1234yf)
•  To improve the heating performance temporarily under cold diesel engine conditions, a PTC heater which uses electricity as the heat source as been adopted. (SKYACTIV-D 2.2 (With PTC heater))


Restraints

Standard deployment air bag control system
•   The following have been adopted to the air bag modules and seat belts.

×: Applicable
—: Not applicable

Seat position

Air bag module

Seat belt

Driver-side air bag module

Passenger-side air bag module

Side air bag module

Curtain air bag module

ELR (Emergency Locking Retractor)

Load limiter

Front pre-tensioner seat belt

Driver's seat
×
×
×
×
×
×
Passenger's seat
×
×
×
×
×
×
Rear seat (LH/RH)
×
×
Rear seat (center)
×

Two-step deployment air bag control system
•  The following have been adopted to the air bag modules and seat belts.

×: Applicable
—: Not applicable

Seat position

Air bag module

Seat belt

Driver-side air bag module

Passenger-side air bag module

Side air bag module

Curtain air bag module

ELR (Emergency Locking Retractor)

Load limiter

ALR (Automatic Locking Retractor)

Front pre-tensioner seat belt

Rear pre-tensioner seat belt

Driver's seat
×
×
×
×
×
×
Passenger's seat
×
×
×
×
×
×
Rear seat (LH/RH)
×
×
×
×*
×
Rear seat (center)
×

*  :Australian specs.


i-ACTIVSENSE

Active safety technology
•  The active safety technology is designed to support safe and assured driving, and to prevent accidents.
•  The active safety technology consists of the following systems.

System
Outline
Reference
Mazda radar cruise control (MRCC) system
The Mazda radar cruise control (MRCC) system can perform headway control and maintain a constant speed at a set vehicle speed and distance from a vehicle ahead using a radar unit which detects the vehicle ahead without the driver having to depress the accelerator or brake pedal. Additionally, if the detecting vehicle approaches the vehicle ahead too closely such as when the vehicle ahead is braking suddenly, the system alerts the driver using a warning sound and warning indication.
Mazda radar cruise control with stop & go function (MRCC with stop & go function)
The Mazda Radar Cruise Control with Stop & Go function (MRCC with Stop & Go function) uses a radar unit to detect a vehicle ahead, and performs headway control to maintain a constant distance from a vehicle ahead without the driver having to depress the accelerator or brake pedal. Additionally, if the vehicle ahead stops during headway control, the vehicle automatically stops and maintains a stopped condition. If the vehicle approaches the vehicle ahead too closely such as when the vehicle ahead is braking suddenly, the system alerts the driver using a warning sound and warning indication.
Distance recognition support system (DRSS)
For the distance recognition support system (DRSS), the radar unit calculates the distance between the vehicle and a vehicle ahead, and displays the distance between the vehicle and a vehicle ahead in the multi-information display.
Adaptive LED headlights
The adaptive LED headlights improve visibility by changing the headlight illumination range depending on the vehicle driving conditions and the surrounding conditions without switching the headlights between HI/LO.
High beam control (HBC) system
The high beam control (HBC) system turns the headlights HI off when the forward sensing camera (FSC) installed to the windshield recognizes a vehicle ahead and when traveling through towns and cities while the vehicle is being driven with the headlights HI turned on. Due to this, blinding of other vehicles from headlight glare is prevented and driver visibility is assured.
Adaptive front lighting system (AFS)
The adaptive front lighting system (AFS) is a system which enhances the range of visibility when the headlights are turned on by pointing the optical axis of the headlights in the direction in which the steering wheel is operated according to the steering operation.
Lane-keep assist system
The lane-keep assist system detects the white lines (yellow lines) of the vehicle lane using the Forward Sensing Camera (FSC) installed to the windshield, and alerts the driver that the vehicle may be deviating from its lane and it provides steering assistance to help the driver stay within the vehicle lanes.
Lane departure warning system (LDWS)
The Lane Departure Warning System (LDWS) recognizes vehicle lane lines on a road using the forward sensing camera (FSC) installed to the windshield, and if the vehicle departs from its lane unbeknownst to the driver, the system alerts the driver of the lane departure using a warning indication and warning sound.
Blind spot monitoring (BSM) system
The blind spot monitoring (BSM) system detects a vehicle in the blind-spot area at the rear of the vehicle to alert the driver of the possible collision with a target vehicle using the BSM indicator light on the outer mirror glass, the rear crossing traffic alert (RCTA) indicator light displayed on the rear view monitor screen, and the blind spot monitoring (BSM) warning alarm.
Driver attention alert system
The driver attention alert system warns the driver using the warning display and sound if it detects the driver's lack of attentiveness.
Traffic sign recognition system (TSR)
The traffic sign recognition system (TSR) provides support for safe driving by displaying traffic signs on the active driving display or by notifying the driver of excessive speed.
Adjustable speed limiter
•  For the purpose of safety performance improvement, the adjustable speed limiter restricts unintended excess vehicle speed by allowing the driver to optionally set the maximum vehicle speed.
•  The adjustable speed limiter restricts the engine output so that the vehicle speed does not exceed the set maximum vehicle speed even if the accelerator pedal is being depressed.
•  The adjustable speed limiter does not operate simultaneously with the cruise control system.
360°VIEW MONITOR SYSTEM
The 360° view monitor system is a safety system supporting the driver in all directions to prevent accidents by reducing the driver's blind spots.


Pre-crash safety technology

•  The pre-crash safety technology is designed to assist the driver in averting collisions or reducing their severity in situations where they cannot be avoided.
•  The pre-crash safety technology consists of the following systems.

System
Outline
Reference
Smart Brake Support (SBS)
The Smart Brake Support (SBS) warns the driver using the warning indication in the active driving display or multi-information display and warning alarm sounds when the radar unit, laser sensor and forward sensing camera (FSC) detect an obstruction or vehicle ahead, and if there is the possibility of a collision while the vehicle is driven at 15 km/h {9.3 mph} or more. If the possibility of a collision increases, it operates the brakes automatically to decrease the damage from the possible collision.
Advanced Smart City Brake Support (Advanced SCBS)
With the Advanced Smart City Brake Support (Advanced SCBS) system, if a possible collision with a vehicle ahead or pedestrian is detected while the vehicle is traveling at a low speed, the system applies the brakes automatically to reduce the damage from the collision.
Smart City Brake Support [Forward] (SCBS F)
With the Smart City Brake Support [Forward] (SCBS F) system, if a possible collision with a vehicle ahead or an obstruction is detected while the vehicle is traveling at a low speed, the system applies the brakes automatically to reduce the damage from the collision.
Smart City Brake Support [Reverse] (SCBS R)
With the Smart City Brake Support [Reverse] (SCBS R) system, if a possible collision with vehicles/obstructions while reversing increases due to the driver not confirming the safety, the system applies the brakes automatically to reduce the damage from the collision.