Next Generation of Small Mazda Engines

Mazda has developed all-new aluminium 4-cylinder engines with displacements of 1.3 litres and 1.5 litres, both of which will make their first appearance in a new small model car to be launched shortly.

The engines are from the MZR family and are the second in Mazda’s new generation engine series, following the MZR 2.0/2.3 engines for the Atenza and MPV. The completely redeveloped engines are said to truly embody the spirit of the brand message of Mazda known as “Zoom-Zoom” (Mazda says this refers to ‘the thrill of motion that we felt in childhood’).

According to Shigeo Mizuno, Mazda’s Powertrain Deputy Manager in charge of development of the engines, the engineering and production staff were brought together to create the MZR1.3/1.5 engines to fully inject Mazda’s ‘brand DNA’ into engine performance.

“We are confident that these small car engines signal a new benchmark for the class,” he said.

The in-line four-cylinder MZR1.3/1.5 engines have incorporated the four following attributes to deliver Mazda’s DNA characteristic responsive performance and handling:

(1) Linear acceleration
(2) Lively response
(3) Strong torque response
(4) Attention to environmental concerns

While setting the same development goal as the MZR2.0/2.3, there are also significant new technologies suitable for small car engines, including a modular design (IAFEM: Integrated Air Fuel Electrical Module), that combines intake manifold, air cleaner, PCM (Powertrain Control Module), etc.

The goal was to achieve a linear, lively, and stronger torque response to reflect its brand message. Striving for this goal, the engines have employed an equal-length 600-mm long intake manifold, which improves intake efficiency in the low to mid-ranges.

Furthermore, the engines have employed a sequential valve timing mechanism. By continuously varying the timing of the intake valves opening and closing, optimum control of intake valve timing can be achieved at all engine speeds. This feature increases power in the low to mid-ranges and delivers strong mid-range torque with a more linear accelerator feel. The original intake and exhaust layout has also been reversed and this new layout features an exhaust system fitted at the rear, as well as a long-branched 4-1 stainless exhaust manifold. This has improved exhaust flow while lifting power and torque levels.

The MZR1.3/1.5 engines do not merely deliver a fun to drive experience, but enhance that feeling with a free-flowing, sporty engine sound, according to Mazda. Based on a technological concept of using lightweight moving parts and rigid structural parts, Mazda engineers have reduced unwanted engine vibrations by employing lightweight pistons and conrods, reducing clearance of each part, and employing a high rigidity aluminium cylinder block and lower block to improve crankshaft support rigidity and bending/torsional stiffness, to create a smooth and rich engine tone.

In addition, by reducing valve system weight inertia and employing special surface treatment on the cams and tappets, the overall level of engine-generated noise has been minimized. The result is a crisp, clear, sporty engine sound.

There is a newly-designed combustion chamber and a fairly high compression ratio of 10:1, which leads to improved power and fuel consumption. In addition, a Tumble Swirl Control Valve (TSCV) has been fitted inside the long intake manifold, which achieves a more stable combustion process with the best air-fuel mixture. This combustion stability effect has achieved low emissions, while the 4-1 exhaust system is employed to increase power.

Improved exhaust gas purification is achieved by employing a new layout that features an intake system located towards the front of the engine and the exhaust system fitted at the rear. Thus, the engines have achieved an excellent balance between environment and power, receiving a rating of E-LEV (Excellent Low Emission Vehicle).

Since 1996, Mazda R&D has had an integrated CAD/CAM system and a state-of-the-art 3D information system which has totally re-invented the whole development/manufacturing process. The machining areas of the MZR1.3/1.5 engine production line, in particular, was developed with the aid of virtual simulation, employing 3D design data. Such technology has led to far quicker and more accurate manufacturing of engines. Furthermore, rigorous quality control ensures the precision of all engine parts, which are automatically checked at 13 quality gates.

By creating a high precision line based on the latest MDI project, Mazda claims it has achieved stable production quality together with a reduction in the production cost of the MZR1.3/1.5 engines.

As Mazda is part of the Ford Group, it seems likely that these small engines will one day be under the bonnets of small Ford models (the next Lynx, perhaps?). After all, Ford doesn’t have any significant small engines and small car development has been a forte of its Japanese affiliate since the early 1980s when the first generation Ford Laser was co-developed with Mazda.

Engine specifications
Engine codes: MZR1.3 (Type ZJ-VE ); MZR1.5 (Type ZY-VE)
Actual displacements: 1348 cc; 1498 cc
Maximum power: 1.3 – 67kW (91PS)/6000rpm; 1.5 – 83kW (113PS)/6000rpm
Maximum torque: 1.3 – 124Nm/3500rpm; 1.5 – 140Nm/4000rpm