Providing the perfect blend of power, handling and fuel economy

To achieve the dynamic Zoom-Zoom driving performance worthy of Mazda's entry as the new generation pickup, the development team has striven to build a powertrain that delivers greater power, higher efficiency, and a quiet comfortable ride.

Powerful and efficient diesel engines

Newly developed MZR-CD 2.5 and MZR-CD 3.0 direct-injection common-rail turbo diesel engines deliver a fine combination of power, fuel economy, quietness and reliability.

The BT-50 marks the perfect opportunity for Mazda to introduce the 2.5-litre and 3.0-litre versions of its latest common-rail direct-injection diesel engine, tuned to match the performance characteristics and requirements of a pickup truck.

Other than the bore and stroke, thus the total displacement, the two engines share the same components, including the common-rail injection system, the new turbocharger design and other advanced Mazda technologies.

Both displacement versions produce plenty of torque from low speed, and demonstrate a linear curve with high output right to the engine's peak, a tuning consideration made to ensure that drivers enjoy easily controllable torque characteristics.

The 2.5-litre engine produces a maximum power output of 105kW at 3,500rpm and maximum torque output of 330Nm at 1,800rpm.

Fuel consumption is much improved. The Single Cab BT-50 consumes 8.3L/100km compared with 9.7L/100km (a 14.4 per cent improvement) for the equivalent B Series model according to ADR 81/01 fuel tests. Mated to a new five-speed manual gearbox it can accelerate from 0-100kmh in just 10.4 seconds.

The 3.0-litre engine produces a maximum output of 115kW at 3,200rpm and maximum torque output of 380Nm at 1,800rpm, and boasts impressive performance.

The fuel consumption of 4x4 models has been significantly improved with the 3.0-litre five-speed manual variants consuming on average 9.2L/100km, down from 10.1L/100km for the B Series.

In addition to adopting the latest common-rail system with high-pressure fuel injection, both displacement versions feature advanced engine technologies such as a variable geometry turbocharger (VGT), double helical intake port design, and powertrain control module (PCM) with a high-performance 32-bit microcomputer.

The variable geometry turbocharger (VGT) employs a variable nozzle design that controls nozzles mounted on the outside of each blade to adjust the speed and volume of exhaust gas flow, ensuring that it consistently strikes the turbine blades at the optimal speed and in the optimal direction. The result is reduced turbo-lag for quick response and torquey low-end performance combined with consistently efficient boost pressure that delivers the power needed for spirited performance at high engine speeds. The mechanism maintains boost pressure, even at low speeds when relatively small amounts of exhaust gas are produced, by reducing the size of the opening for each nozzle to secure adequate velocity of the gases striking the blades.

Conventional VGT designs use only a single connecting pin to secure one side of each nozzle to the shroud assembly, causing the nozzle to angle on its pin as it receives the flow of exhaust gas and make contact with the shroud, which becomes the source of uneven friction. The new BT-50 is the first pickup truck in the world to adopt a VGT design that secures both sides of the nozzle for improved durability and resistance to friction.

Securing the shroud plates that sandwich the nozzles are clearance control pins mounted in three locations, which maintain the right amount of side clearance required by the nozzles to move, maintaining a high level of flow efficiency while also improving durability and reliability.

Adopting this new low-friction nozzle link mechanism, the compact turbine housing design and turbine with low inertial moment improves VGT control response. These technologies come together to realize driving ease at low speeds, positive response and spirited acceleration, as well as greater engine power and torque output.

The direct-injection diesel engine for the BT-50 also sports a larger new intercooler for the turbocharger system, which greatly improves cooling efficiency from the 60 per cent rate of the MZ-DE 2.5 Turbo to 74 per cent for the new MZR-CD 2.5/3.0 engines.

The newly developed diesel engine features a four-cylinder DOHC (Double Overhead Camshaft) structure with 16 valves, which increases the area of the passageways over the previous SOHC (Single Overhead Camshaft) 12-valve design for greater intake and exhaust efficiency, as well as improved engine power and torque output.

The change to 16 valves also reduces the size and weight of related parts, which allowed a change to a high-lift design that yet further improves the efficiency of intake and exhaust handling. The cam's swing arm followers are also changed to a roller type, reducing resistance where they touch the cam, contributing to a reduction in mechanical loss, and improving fuel economy.

From an eco-friendly perspective, the MZR-CD engine employs an EGR system, which recirculates some of the engine's exhaust gas to lower the temperature of combustion and suppress nitrogen oxide emissions. To achieve yet cleaner emissions with these newly developed engines, the EGR used is matched from one of two types to the body type and destination market, and satisfies the emissions regulations in each country.

The fine control over combustion also suppresses the knocking characteristically associated with diesel engines for quieter operation. Improved combustion tuning combines with the use of dual counter-rotating balance shafts and other mechanical changes to help suppress noise and vibration.

Particular attention went to greatly improving the performance of the cooling system for the BT-50, as befits the engine of a utility that must perform equally well over a range of severe conditions that includes blazing heat, freezing cold, high altitudes and rough surfaces.

The new MZR-CD 2.5 and MZR-CD 3.0 engines have also reduced engine noise by 1.5dB over the previous B Series, and produce an engine note that is clearly quieter and more pleasing to the ear than many of the competing models.

Transmissions built to handle the long haul

The Mazda BT-50 is offered with a five speed manual or five speed electronically controlled automatic transmission, both tuned to optimally match the high performance of the engines and draw out the full pleasure of Zoom-Zoom driving performance, while also contributing to greater fuel economy.

The BT-50 models are fitted with a new five speed manual transmission that raises torque transmission capacity to support the greater power and torque produced. 1st and 2nd gears use triple-cone synchronizers as part of a multi-syncro package that delivers a pleasing feel to shift operations, while a new device known as a dual-mass flywheel is employed by the clutch system to suppress gear noise for a quieter, more comfortable ride.

The electronically controlled close-ratio five-speed automatic transmission offered on 4x4 Dual Cab SDX models features smooth shifting and outstanding fuel economy at highway speeds.

Advanced four-wheel-drive systems Two types of 4WD system are available -- manual shift or electric shift -- with each offering easy shift operation between 2WD and 4WD modes and go-anywhere performance.

Manual transmission models come with the manual 4WD transfer case shift lever, which allows quick selection from 2WD (2H) to 4WD High (4H), 4WD Low (4L) and neutral (N) drive modes. All manual 4WD models include remote free wheel hub lock mechanisms as standard equipment.

Automatic Dual Cab SDX models come with the electric shift 4WD system, which offers smooth "on-the-fly" shifting out of 2WD mode into either 4WD High or 4WD Low drive modes.

4x4 models employ a Limited-Slip Differential (LSD) at the rear wheels, which automatically adjusts drive power to maintain traction, even when one wheel wants to spin loosely in the mud or on rough surfaces with large potholes. They are also fitted with a large underbody protector and mesh barrier guard to protect the intercooler.

To deliver responsive steering and handling that amplifies the pleasure of driving and supports true Zoom-Zoom driving performance along with sedan-like quietness and ride comfort, the Mazda BT-50 adopts the popular chassis and body from the previous model while adding several new improvements.

Refined suspension system for comfort and a controlled ride

While carrying over the double wishbone front design and rear leaf springs proven tough and reliable on previous Mazda pickup trucks, the system is refined to offer a smoother, more comfortable ride.

Larger shock absorbers on the front and rear with a 32mm shaft diameter greatly improve ride comfort as well as the feel of system rigidity. Extending the rear suspension's leaf springs to 1,320mm not only makes them the longest in the class, but more importantly provides ride comfort with a mild, reassuring feeling.

Smooth, responsive steering

Steering has been optimised and completely retuned to provide predictable control under all load conditions. Mazda BT-50’s steering shaft, links, hydraulic power assist valves and the coupling joint that links the gearbox to the steering shaft are all optimised for better overall steering performance and a larger ball joint introduced for added rigidity. The result is improved road feedback and predictable steering wherever the road may take you.

Braking power that's easy to control

While inheriting the ventilated front disc and leading/trailing rear drum brake layout of the previous model's brake system, improvements made improve the feel of brake pedal operation while fully maintaining the level of brake effectiveness. For instance, the caps for the wheel cylinders were changed to high-efficiency parts employing a tight rubber construction, and which increase their rigidity.

This suppresses unwanted play in the brake pedal, and gives pedal operation a solid feel throughout its stroke and particularly when first starting to press the pedal.

The lever ratio is also reduced, improving brake stroke by roughly 10 per cent over the brake system on the previous B Series.

The fluid passageways for the LSPV were changed and the bypass pipe eliminated, shortening the length and reducing the amount of fluid used to reduce the amount of play in the brake pedal.

Combined, the above changes and revisions give the BT-50 top-class brake feeling with a confident feel from the instant the pedal is pressed and throughout its stroke, and with plenty of braking power.

Body built for toughness and a quiet ride

The Mazda BT-50 inherits the unique overlapped, cross-braced design of Mazda's traditional rugged ladder frame, providing the tough durability to perform well fully laden off the road and under harsh conditions.

Improved performance of window seals and a change to a closed-section design for the weather stripping helps prevent wind noise from entering the cabin when driving at highway speeds.

Aerodynamic performance that denies its utility roots

Despite the larger size of the new body, the BT-50 achieves a low drag coefficient that improves fuel economy and acceleration when passing at highway speeds, while also reducing wind noise.

A new chin spoiler integrated into the front bumper improves front/rear lift balance and the grip of the front tyres for better line-tracing ability at highway speed, improved straight-line stability, and a great reduction in the amount of lateral pull felt when passing large vehicles. In addition, redesigned front pillars and door mirrors contribute to achieving class-leading aerodynamic efficiency.