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Fiesta - A Fresh New Approach

Staff, Friday February 20, 2004.

Fiesta ? A Fresh New ApproachFiesta ? A Fresh New ApproachFiesta ? A Fresh New ApproachFiesta ? A Fresh New ApproachFiesta ? A Fresh New ApproachFiesta ? A Fresh New ApproachFiesta ? A Fresh New ApproachFiesta ? A Fresh New Approach

With an outstanding combination of style, driving dynamics, performance and safety features, Fiesta will bring German engineering at its finest to Australia when it goes on sale in April 2004.

The Fiesta range will include two body styles and three series variants ? a three or five door Fiesta LX, the three-door Fiesta Zetec, and the five-door Fiesta Ghia.

All models will come standard with a 1.6 litre Duratec all-alloy engine, featuring double overhead camshafts, 4 valves per cylinder, sequential fuel injection and drive by wire technology.

Fiesta will develop 74 kW at 6000 rpm and peak torque of 146 Nm at 4000 rpm.

Teamed with either a slick shifting 5-speed manual or an electronically controlled 4-speed automatic, the engine will provide responsive performance to match the vehicle’s superb steering and handling.

“Fiesta represents all that is best in contemporary German small car design and engineering,” said Ford Australia President, Geoff Polites.

“Ford’s reputation for outstanding driving dynamics is proved by Falcon and Focus in Australia. Fiesta’s ultra strong and stylish body, an advanced chassis and finely tuned suspension and steering will bring these benefits to buyers in the small car class.

“Customers looking for a small car are just as selective as those wanting a larger car. They prefer a small car because it’s the vehicle that best suits their needs. The days of having to sacrifice driving dynamics, performance and safety features along with size will be gone with the all-new Fiesta.”

Fiesta LX will be available with a choice of either three or five doors, and will include remote central locking, power steering, power front windows, power adjustable mirrors, a single slot CD player, dual stage driver and front passenger airbags, body colour front and rear bumpers, and 15 inch steel wheels as standard. Recommended retail pricing (RRP) for Fiesta LX will be $14,490 for the three-door manual and $15,990 for the five-door manual.

Fiesta Zetec will be offered as a three-door vehicle only and will attract customers who are seeking extra features along with sporty cues. It includes all LX features and adds air-conditioning, steering column-mounted audio controls, front fog lamps, ABS brakes, and 15-inch alloy wheels. Recommended retail pricing for the manual Fiesta Zetec is $18,990.

The most prestigious Fiesta, Ghia delivers extra features in a solid and clean European style. It will be offered as a five-door only and will incorporate the best features of the LX and Zetec and add front map lights and a 6-disc in-dash CD player as standard. Fiesta Ghia will also offer optional side thorax airbags and side curtain airbags. Recommended retail pricing for the manual Fiesta Ghia is $21,490.

Fiesta will be available in a range of exciting colours with unique trim combinations. The colour range includes Moondust Silver, Colorado Red, Panther Black, Vitro (tinted silver with a touch of blue/green), Ink Blue¹, Flare² (burnt orange), Aquarius² (bright chromatic blue), and Diamond White.

Interior colours include Ebony and Stone³ with interior trims unique to each model.

¹ ? Not available on Zetec
² ? Only available on Zetec
³ ? Only available on Ghia
 
 
 
 

PRICING SUMMARY

LX 3 Dr 1.6L manual RRP $14,490 LX 5 Dr 1.6L manual RRP $15,990 Zetec 3 Dr 1.6L manual RRP $18,990 Ghia 5 Dr 1.6L manual RRP $21,490 MAJOR OPTIONS&nbsp Airconditioning (LX only) RRP $2,000 Automatic transmission, Including ABS (LX only) &nbspRRP $3,000 Automatic transmission (Zetec and Ghia) RRP $2,300 Side thorax and curtain airbags (Ghia only) RRP $900 16” alloy wheels (Zetec only) RRP $900 Metallic paint RRP $240

European Styling

Fiesta’s driving credentials and package efficiency are reflected in the simple harmonious design that has created a distinctive small car with solidity and roominess.

“Fiesta has a dynamic visual appeal that creates a sense of movement and emotion,” said Ford Australia Launch Strategy Manager, Tom Rivers.

“Most importantly, the design is one that will look just as good on Australian roads as it does on European roads.”

EXTERIOR DESIGN

The exterior design is characterised by well-balanced proportions that retain subtle links with Fiesta’s heritage while also showing close family links with other Ford cars at the front end and in the defined wheel arches.

The design visually communicates Fiesta?s dynamic capabilities. With a long wheelbase and wide track, it stands firmly on the road, poised for action.

The rocker panels are low to emphasise their strength, while also enhancing the planted stance. Welded joints at the lower edge of the bodyside are concealed from view and have the added benefit of aiding ingress and egress.

The front of the vehicle is dominated by large, expressive headlamps that signal technical competence by showing every working detail. The headlamps contain all of the primary lighting functions, including the turn indicator lamp and park lamp at the top, inside sculptured composite lenses.

Fiesta?s front design is characterised by the truncated elliptical grille opening that is now characteristic of Ford’s European vehicles. The lower grille features a trapezoid shape that further emphasises Fiesta?s wide track and planted stance and provides a mounting point for integral fog lamps at the very front corners on Zetec and Ghia models.

The distinctive shape of Fiesta?s bonnet design has been specifically profiled to provide a driving aid for short drivers. At least 50 per cent of its width contour can be seen by 95 per cent of the stature range of women, which will aid its manoeuvrability for all customers.

The belt line rises towards the rear of the car, giving a dynamic profile and emphasising the low cowl and exceptional side window vision.

“Fiesta’s designers achieved this by blacking out or covering the B- and C-pillars with semi-flush side glass. The top edge of the doorframe closes at the roofline, effectively eliminating the visible shut lines and adding to the impression of a simple, clean and elegant design,” said Rivers.

A body-colour D-pillar has been wrapped around the side of the vehicle, which in conjunction with the high wrapped tail lights, makes the car visually compact and dynamic. Ergonomically inspired full grip door pulls and lower bodyside mouldings complete the door skin graphics.

The rear end view evolves the Ford high tail lamp look and emphasises the practical value of a wide, deep tailgate. High-mounted tail lamp clusters contain all lamp functions. The centre, high mounted stop lamp on the top of the tailgate provides additional clear, safe indication for following drivers.

INTERIOR DESIGN

Fiesta’s light and roomy interior design creates a feeling of spaciousness with key design elements complementing the car’s generous interior package.

“The interior design elements were crafted to take full advantage of the package efficiency of the vehicle’s design,” said Rivers.

“The designers not only aimed to make the most inside from the shape outside, but wanted Fiesta drivers and their passengers to get more enjoyment from the overall interior ambience.”

Large, circular air vents that add an element of visual fun and friendliness to the design punctuate the dash, while the fascia has been designed with a well-defined instrument binnacle. It is fully integrated with the centre console in an inverted L-shape, to provide a control cockpit arrangement for the driver.

The new instrument cluster design is inset directly in front of the driver for optimised centreline visibility. The electronic analogue speedometer and tachometer have supplementary LCD displays for fuel level and engine temperature inset in the speedometer dial with telltales for 18 warning lights. The dials have clear white graphics on dark faces with LCD displays for trip and total distance as well as the clock.

The total and trip distance odometers are incorporated at the base of the speedometer dial in a tamper-resistant LCD panel.

A large rotary switch on the dash falls easily to hand for all main lighting functions. Similarly, the hazard warning switch is mounted centrally on the dash panel for ease of use by both front-seat occupants.

Fiesta features a unique ‘stack style’ audio system that allows a high degree of flexibility. Incorporated in the fascia, the design has been developed to allow easy operation and to deter thieves. Located in the centre stack linking the centre console with the main fascia rail, the audio system sits above the rotary ventilation system controls.

Two types of audio units are specified for Fiesta in Australia:

Fiesta LX and Zetec feature a high series CD stereo featuring AM/FM radio with 24 presets, single-slot CD player, and 4×15W peak power output.
Fiesta Ghia features a premium series six CD stereo with AM/FM radio with 36 presets, AM/FM autostore, six stack CD player with shuffle and compression and 4×40W peak power output with digital signal processing.

The door panels provide improved functionality, including integrated armrests with full-grip door pulls and large audio speakers with integrated covers inserted into the front upper corner of each trim panel to avoid sound masking.

The front-door stowage bin can hold a map book or drink can.

Fiesta’s seats are geometrically designed with deadpan foam cushions, steel-framed, sprung-wire backrests, and cut-and-sew covers. The front seats are adjustable fore and aft, while the driver?s seat has an additional height adjustment. All seats combine dual trim materials and patterns for a harmonious feel.

For optimal rear visibility, Fiesta?s design incorporates new shingle style rear passenger headrests. These slim headrests can be lowered flush with the seats when there are no rear passengers so they don’t restrict the driver?s view rearward. Conveniently, they don?t have to be removed when the seat is folded down to load cargo items.

The rear seats themselves feature a 60/40 fold down design.

COLOUR AND TRIM

Fiesta features an exciting range of exterior colours that reflect ever-evolving customer tastes. These include Diamond White, Colorado Red, Panther Black, Moondust Silver, Vitro (soft-tinted silver with a touch of blue-green), Ink Blue, Flare (burnt orange), and Aquarius (a bright chromatic blue).

Fiesta’s interior features a choice of either Ebony or Stone colour schemes, depending on series and exterior colour. Ebony provides a dark interior environment that is sophisticated and modern, while Stone becomes the new non-grey neutral with a hint of colour.

Harmonious colour and fabric choices flow through to the trim options available on each model.

Fiesta LX Spectre trim has a spontaneous and lively motif that evokes a sense of fun, while the Kompass trim on the Fiesta Zetec is a sporty fabric with a coloured motif in silver or red that reflects the elements in the interior design. Fiesta Ghia features Bussac and Kent trim, a soft and luxurious velour combination with a simple and elegant motif.

Dynamically Different

Fiesta’s ultra strong and stylish body, an advanced chassis and finely tuned suspension and steering will introduce Ford’s reputation for outstanding driving dynamics to small car buyers in Australia.

Already well proven with both Falcon and Focus, class-leading driving dynamics will be a hallmark of the Fiesta range when it goes on sale in April.

“Fiesta is the product of the same global emphasis on driving dynamics that created the Ford Focus and resulted in the BA Falcon here in Australia. The results will set Fiesta apart in the small car segment,” said Ford Australia Launch Strategy Manager, Tom Rivers.

Extensive engineering was devoted to Fiesta’s body structure, suspension, sound refinement and steering systems. Its strong twist-beam rear suspension was honed for interior package efficiency while also targeting best-in-class handling characteristics, and its front suspension and steering systems were scrutinised for reduced friction and compliance management.

“Fiesta’s engineering team didn’t benchmark another small car,” said Rivers.

“Instead they benchmarked Focus and the engineers strived to achieve the same levels of dynamic capabilities that are inherent in that vehicle, using the processes and expertise that created Focus while they did so.”

Fiesta’s driving attributes reflect the agility, stability and confidence that are the foundation stones of driving enjoyment:
Precise and responsive steering
Robust road-holding capabilities that provide stable and predictable handling
Increased roll stiffness for better cornering stability and handling
Strong braking ability for sure and straight stopping
Responsive and powerful acceleration
Ride plushness and comfort levels found more typically in a large car

The Fiesta development team began with the foundation of a strong body architecture. Despite being larger than its European predecessor, Fiesta’s unibody is 100 per cent stiffer in global bending and 40 per cent stiffer torsionally. These new levels of strength and stiffness contribute significantly to Fiesta’s precise and confident handling, as well as its ride comfort and quiet operation.

The vehicle’s body structure has been computer optimised for strength, making extensive use of high-strength steels. Tailor-welded blanks, manufactured from different gauges of steel using laser-welding processes, are prepared to create individual stampings in the body for optimal strength properties.

FRONT SUSPENSION

Key to this stiff design was the creation of ultra-stiff mounting points for the suspension and steering systems. The MacPherson strut front suspension and steering system is mounted on a rigid front subframe that bolts onto the main body structure. This front subframe installs quickly onto the vehicle during assembly, is easier and less expensive to replace in collision damage and helps to isolate road noise from the body structure.

The struts are designed with offset springs for full lateral compensation, thus reducing suspension friction and improving ride smoothness. Dual-path top mounts separate the forces of the dampers and springs, a technique that helped Ford’s body engineers optimise the structure for reduced vibrations and better sound quality.

Friction reduction techniques have also been used in Fiesta’s rack-and-pinion steering system, resulting in precise steering and a transparent feel, augmented by the refinement and lateral stiffness of Fiesta’s rear suspension.

REAR SUSPENSION

Fiesta’s twist-beam rear suspension offers the stability of optimal toe and camber stiffness for increased steering responsiveness and cornering control. The extremely rigid rear suspension twist-beam system combines strong lateral stiffness for robust handling, with longitudinal compliance for bump isolation and comfort. The forgiving aspect of angled rubber bushings, carefully optimised with directionally located voids, provides enhanced longitudinal compliance, along with high camber-toe stiffness.

High lateral stiffness allows the suspension system to resist cornering forces while having the travel and longitudinal compliance to soak up bumps and undulating road surfaces.

A U-shaped profile was adopted for the twist-beam structure itself, which helps to deliver both robust stiffness and a lighter weight.

The diameter of the tubular arms was increased and reinforced gussets added for enhanced camber stiffness and toe stiffness under braking. Longitudinal compliance while braking has increased by nearly 30 per cent over the prior European model.

Monotube dampers for the rear suspension provide further ride plushness. These single-tube dampers have more sophisticated valving that enables them to control high-frequency road inputs and soak up undulating and rough road surfaces.

Low-profile springs are placed effectively in an under-floor configuration. This technique contributes to Fiesta’s generous cargo capacity because the strut towers protruding into the load area (which now contact only the dampers) could be reduced in size.

STEERING

Precise, linear and proportionally responsive to the driver?s inputs, Fiesta’s steering characteristics reflect Ford?s expertise in driving dynamics and incorporate techniques used in Focus that have been widely acknowledged for their dynamic excellence.

Every element of the Fiesta steering system has been optimised for friction, free play and compliance. It is the sum of these efforts that separates Fiesta?s steering precision from the rest of the small car segment.

Fiesta?s strong body structure provides the basic foundation for the steering system?s performance. The steering rack itself is mounted to Fiesta?s new rigid front subframe, which augments the body structure?s stiffness.

A hydraulic power-assist steering system (standard across the range), with a high-pressure/low-flow engine-driven pump, gives Fiesta a superior feel and strong linear response characteristics, plus low parking effort. The steering ratio is 15.5:1 for improved response, and reflects the length of the vehicle’s wheelbase. There are 2.8 turns of the steering wheel from lock to lock, for a turning circle of less than 10 metres.

BRAKES

Fiesta is fitted with powerful large brake discs and pads for strong braking performance across the range. The ventilated front discs measure 22×258 mm and the rear brake drums are 203mm with 36 mm brake shoes.

A stiff pedal box has also been fitted which assures optimal pedal travel and excellent pedal feel, improving the driver’s feeling of confidence and security in difficult conditions. The 229 mm vacuum brake booster is also directly linked to the pedal for performance and feel. The booster is integrated with a new master cylinder and compatible with the anti-lock (ABS) system technology.

Standard on Fiesta Zetec, Ghia, and with the automatic transmission on LX, the highly efficient ABS design incorporates standard electronic brake force distribution (EBD) that comes into effect before the ABS is activated to limit the rear wheel slip, improving stability under severe braking conditions. It eliminates the need for a load-apportioning valve by automatically compensating for all vehicle-loading conditions.

A QUIET COMFORTABLE SPACE

“Fiesta features levels of refinement and quiet operation that are normally specific to larger cars,” said Rivers.

“NVH engineers at Ford of Europe’s acoustic centre in Cologne undertook detailed sound quality tests during Fiesta’s development. Using computers, a composite sound of comfort was developed that balanced road and wind noise with powertrain noise at average cruising speeds.

“They also modified the sound to provide an even sportier noise at higher rpm to give the driver more rewarding feedback.”

Fiesta?s interior is insulated from a variety of sounds and vibrations by a clever insulation package. Everything from the designs of the seats, the headliner, floor coverings and trims was used as a key measure for sound insulation.

The insulation package was developed using statistical energy analysis to determine the paths that sound takes into the Fiesta’s interior. The package was further honed by bombarding the body shell with sounds and vibrations to simulate powertrain, road and wind inputs, and then measuring the resulting sound levels inside the vehicle cabin.

Every small detail that contributes to the impression of sound quality was optimised by Fiesta’s NVH team. For example, new door design and sealing systems were created, characterised by a softer percussion behaviour and robust aerodynamic leak-resistance to fight wind noise. Six separate engineering measures were incorporated into the Fiesta body structure and door latch designs specifically to achieve the desired sound quality.

Fiesta’s body shape and the components that connected to it such as wipers, mirrors, and audio aerial, were also developed to create a minimum of air disturbance and the sounds associated with it.

The body structure also includes the use of expandable foam filling in both the A- and C-pillars to reduce the transmission of noise to the vehicle occupants.

The result is an interior quietness that is normally reserved for much larger cars.

Good Things Come in Small Packages

For a contemporary small car with excellent manoeuvrability and ease of parking, Fiesta’s spaciousness is so generous it seems bigger inside than out.

“Fiesta’s interior has been optimised to create comfort and space for five occupants and their cargo,” said Ford Australia Launch Strategy Manager, Tom Rivers.

“With most small cars, bulky luggage and passengers don’t mix. Fiesta can accommodate two large suitcases or a baby buggy in its boot without sacrificing any of the rear seating area.”

Despite not being the largest car in its class, it excels in package efficiency, with:

Front seat roominess that is comparable with a vehicle in the next class.
Rear seat roominess that includes excellent rear passenger knee clearance and headroom.
Luggage capacity of 284 litres (5HB), in a shape optimised to provide usable volume to accommodate longer items like foldable baby buggies with generous load width between its wheel arches.

Fiesta?s rear suspension was designed for a low profile, with the springs moved to an underfloor configuration without any detrimental effect on their suspension effectiveness. This design frees up space in the boot for cargo, creating a wide load floor. The fold-flat design of the rear seats extends the length of Fiesta’s luggage compartment even further.

“Optimising Fiesta’s package efficiency was imperative to accommodate all human statures from the tallest male to the shortest female,” said Rivers.

“However, the team also included ethnicity factors, general growth trends in terms of heights and weights and changes in lifestyle that are changing vehicle requirements. Such is the broad customer diversity of the B segment.”

Extensive ergonomics testing determined optimal seat height and the width of the door openings were modified for ease of ingress and egress. A height adjustable steering column was also fitted to aid driver comfort.

Other features resulting from ergonomics testing include:

Ease of access, and controls that are natural and intuitive to use.
The latest Ford-style control stalks (as on Focus), which have improved logic and switch feel.
Hazard-warning switch located high and central on the dash within easy reach of both front seat occupants.
Easy to read speedometer and tachometer graphics.
A pop-out handle to help ease the task of opening the bonnet once it is released.
A high-mounted interior tailgate release control fitted high on the outside of the dash for ease of use by the driver or through the driver’s door when the vehicle is parked.

Fiesta has been carefully designed to provide outstanding outward visibility. Its driver seating position can accommodate a wide variety of statures, providing the majority of drivers with a clear perspective of the vehicle bonnet. This visible reference point is especially important when driving in traffic or making close manoeuvres, such as parking.

The position of the driver?s hip joint is 45 mm higher than in the prior European model, providing the same style of ‘command-post’ driver position that has been popularised by the Ford Focus.

Fiesta?s belt line is low and its window area is long, giving the driver a good angle of visibility on both sides of the vehicle. The rear glass area has also been optimised for all round visibility, aided by the shingle-style rear seat head rests that don?t intrude into view when not in use.

The driver?s seat is adjustable for height, in addition to fore and aft, which helps drivers of varied statures find their optimum driving position to take advantage of the outward visibility and command post driving position.

“Every aspect of Fiesta with which the customer interacts has craftsmanship-inspired attention to detail,” said Rivers.

“The team placed special emphasis on all the touch areas ? the door handle, seat controls, steering wheel, in-car entertainment, heater controls, fold-down rear seat, door trims and the gear lever and its position.

“Everything falls to hand in Fiesta thanks to extensive effort devoted to the positioning of key elements such as the steering wheel and gear lever.”

The gear lever is easy to reach from Fiesta’s high driving position, while the radio controls used most often are positioned above the ventilation and heater controls in a zone within easy reach of the driver. In addition, Ford’s easy to use remote audio control unit is positioned on the steering column (Zetec and Ghia only).

“The expectations of today?s small-car customer have resulted in high levels of visual appearance, tactile feel, operating sound and function, usability, ergonomics and overall interior ambience,” said Rivers.

“The sum of these efforts is Fiesta’s comfortable and spacious interior environment.”

KEY PACKAGE DETAILS

Exterior dimensions (mm) 3dr hatch 5dr hatch Overall length 3917 3917 Overall width 1683 1683 Overall height 1413 1432 Wheelbase 2487 2487 Front track 1474 1474 Rear track 1444 1444 Interior dimensions (mm) Front headroom 995 999 Front legroom 1058 1058 Front shoulder room 1344 1355 Rear headroom 950 959 Rear legroom 885 885 Rear shoulder room 1355 1300 Luggage capacity (seats upright) 261 284

Responsive Performance in a Refined Package

Ford’s new Fiesta small car will provide responsive performance and refined driveability from the new 1.6L Duratec 16V double-overhead cam petrol engine.

Powering the entire Australian Fiesta model range, the 1.6L Duratec 16V has been extensively developed to suit its small car application and is equipped with a precision, drive-by-wire electronic throttle for responsive and economical performance.

The advanced engine design contributes to Fiesta’s real-world fuel efficiency through a unique combination of advanced combustion technology, minimum weight, low internal friction and new levels of refinement.

The 1.6 litre double-overhead cam engine develops 74 kW at 6,000rpm and reaches peak torque of 146 Nm at 4,000 rpm.

It features a precision, sand-cast, light aluminium alloy block with a closed deck and a deep skirt. Cylinder bore liners of cast iron ensure tightly controlled geometry for less internal friction. The Duratec also delivers maximum bottom-end rigidity through a separate cast aluminium bearing beam bolted inside the lower block skirt.

Combined with a pressure die-cast structural aluminium alloy oil pan, heavily ribbed castings and a low-noise ancillary drive system, the engine operates with an absolute minimum of vibration for a refined, spirited driving experience unique to a car of this size.

“Considerable attention to detail was devoted to ensuring that Fiesta customers received all the benefits of Ford’s global devotion to excellent driving dynamics,” said Ford Australia Launch Strategy Manager, Tom Rivers.

“Part of that was ensuring that the engine delivered a spirited, responsive and fun driving experience without any of the noise or harshness that small car customers have historically endured.”

Easy on the wallet and fun to drive, the Fiesta’s 1.6L Duratec 16V engine has also been painstakingly calibrated to deliver excellent fuel economy with high torque levels at lower speeds, which is where most small car owners drive.

“Fiesta’s powertrain has been calibrated to deliver low fuel consumption not just on an official industry test cycle, but across the wide range of driving conditions encountered by customers in real life,” said Rivers.

Considerable attention to detail was devoted to reducing weight to optimise fuel economy. For example, the engine’s highly durable camshaft sprocket is made of a glass and mineral fibre-filled phneolic synthetic resin plastic and weighs only 167 grams, compared to 400 grams for a similar design in metal.

Similarly, a host of low-noise features contribute to refinement levels for the 1.6L Duratec 16V-equipped Fiesta. These include the oil pump, which is driven by the crankshaft nose. Other measures include a single, service-free poly-V accessory-drive belt made of “smart” composite rubber that adjusts itself in length, a low noise alternator, dual internal cooling fans, and a fully length-symmetrical intake manifold.

POWERTRAIN COMPONENTS IN DETAIL

Powertrain control module

A newly designed Powertrain Control Module (PCM) has been adopted for Fiesta, providing improved refinement, lower fuel consumption and reduced emissions. It was customised for Australia’s specific powertrain application.

PCM software features include:

Electronic throttle control
Advance charging system
Smart starting system
Latest on-board diagnostics
Advanced emission controls

The PCM unit allowed engineers to introduce electronic throttle control for the first time in a Ford small car. It determines the amount of air the throttle requires at any given moment and controls the appropriate amount of fuel required and adjusts the timing to ensure ideal combustion. This not only improves driveability but also provides more efficient fuel injection and reduced emissions.

PCM software includes a smart starting system that detects when an engine turns over much faster than the human ear can. Once this occurs it shuts off the starter motor, which allows for a quicker, quieter start and avoids damage to the starter motor, resulting in improved starter motor durability over the life of the car.

Fitted with the latest onboard diagnostics, including service diagnostics, and better CAN-bus communication, Fiesta’s electronic PCM brain delivers improved driveability, lower fuel consumption and reduced emissions, making it the smart new kid in its class.

Aluminium construction

The aluminium construction of the 1.6L Duratec 16V makes it one of the lightest, most compact and efficient petrol engines produced in Europe. The deep-skirted, closed-deck sand casting of the block features cast-iron bore liners with tightly controlled geometry. An aluminium bearing beam and cast structural aluminium oil pan provide a robustly strong bottom end.

Head detail

The 1.6L Duratec 16V engine features a double overhead cam design, with valves at an included angle of 42 degrees. The spark plugs are nearly centrally mounted in the pentroof combustion chamber, allowing for circular flame propagation and improved fuel economy, especially in part-load conditions.

Piston and rod

The 1.6L Duratec 16V’s lightweight alloy pistons has a low-friction coating. The connecting rods are fracture-split sintered steel. The bore size is 79mm and the stroke 81.4mm.

Crankshaft

Duratec 16V’s cast-iron crankshaft features five main bearings and eight counterweights.

Intake manifold

The 1.6L Duratec 16V’s intake manifold was crafted with extensive attention to detail through the use of Ford’s proprietary computer-aided design resources. It was designed for manufacturing simplicity, consists of only three parts, and is made of friction-welded plastic to be more flow-efficient and stay cooler than ordinary cast metal.

The manifold possesses precisely designed intake runners with a diameter of 36mm. The runners are fully symmetrical in length from the centre of the throttle plate to the intake valve, a technique that has achieved a larger car sound quality from a small car engine.

The intake system features a solid-state temperature and pressure sensor, which makes more precise air mass measurements. These measurements are constantly relayed to the engine management module for efficient engine production. The design also features a separate air cleaner unit for mechanical package efficiency and enhanced pedestrian protection by providing impact space under the hood.

Electronic throttle

Fiesta’s 1.6L Duratec 16V engine has a highly responsive electronic drive-by-wire throttle. This technology allowed engineers total freedom in calibrating the relationship between the pedal angle and the throttle plate under varied operating conditions. This provides excellent responsiveness and contributes to the vehicle’s class-leading driving dynamics.

Knock sensing technology

The 1.6L Duratec 16V engine has an optimised knock control system, which continuously adapts the engine’s operating parameters in real time to optimise performance and economy for all grades of fuel from 95 RON upwards.

Energy management alternator

Fiesta’s 1.6L Duratec 16V engine features an intelligent energy-management alternator with dual internal cooling fans. The alternator senses the battery’s charging needs as well as load changes on the electrical system and signals the engine management module to adjust idle speeds accordingly. It also senses changes in vehicle operating conditions, taking advantage of ‘free energy’ during vehicle deceleration to increase battery-charging levels.

The alternator is driven by a serpentine poly-V belt made of a new “smart” composite rubber with material characteristics that allow the belt to adjust its own length according to operating conditions. This allowed engineers to do away with the dynamic tensioner and save weight.

Fuel injection system

Fiesta’s 1.6L Duratec 16V engine is fitted with a sequential electronic fuel injection (SEFI) system, which injects precisely measured quantities of fuel into each individual cylinder at the optimum point in each combustion cycle. The SEFI system incorporates injectors with a two-hole design. These deliver a twin-spray pattern directly toward the twin inlet ports of each cylinder for more spray penetration and less wall wetting. This in turn translates to improved driveability and low emissions.

Proven robustness

The development of Fiesta’s 1.6L Duratec 16V engine included a non-stop 1,200-hour heat and humidity test, during which humid 140oC air was blown into the front end of the vehicle while the engine continuously drove through a cycle of several seconds of idle, acceleration to peak power for several seconds, and back to idle.

Transmitting the Power

Fiesta customers in Australia will have the choice of either Ford’s latest IB5 five-speed manual transmission or the new fully automatic four-speed transmission that is only now becoming available in Europe.

“Australia will be one of the first countries to launch Fiesta’s new automatic transmission,” said Ford Australia President, Geoff Polites.

“We timed Fiesta’s launch in Australia to ensure we could offer both the manual and automatic variants. By doing so we’re providing our customers with the choice of three different models in two body styles and with two transmissions.

“Small car customers will find that it has been worth the wait for Fiesta.”

The Durashift automatic transmission, optional across the range, is the latest generation, electronically-controlled four-speed, with exceptionally smooth gear shifting to provide the type of relaxed and fuss-free driving experience that a significant proportion of small car drivers require.

It is mated with Ford’s 1.6 litre Duratec 16V engine, providing Fiesta with exceptional gear shifting quality and responsive driving characteristics more usually associated with sportier vehicles.

?Fiesta’s Durashift automatic will enhance the car?s reputation for driving quality by offering a combination of flexible performance and smooth shifting. It adapts its behaviour to ensure this drivability is maintained across a variety of driving conditions,” said Ford Australia Small Car Planning Manager, Peter Fry.

The automatic transmission was carefully engineered for its application in Fiesta to achieve the best overall performance with all the advantages of a fully automatic powertrain without many of the compromises often found in compact automatic vehicles.

The very latest electronic systems used to control the transmission and their interactions with the Engine Control Module (ECM) were crucial to engineering out these compromises. The transmission uses a dedicated computer controlled system and works in conjunction with the engine’s electronic management system to manage its operation. Both the engine and the transmission settings are constantly adjusted to suit the driver’s requirements and prevailing conditions.

At the heart of the transmission are its Electronic Throttle Control (ETC) and Transmission Control Module (TCM) systems.

ETC provides a full ?drive-by-wire? cable-free connection between the accelerator pedal and the powertrain. It senses the driver?s demands at the accelerator pedal and communicates these to the TCM and the Engine Control Module (ECM) in the engine. The torque converter provides optimised torque multiplication capability at lower speeds to enhance acceleration and, at other times, mainly above 80 km/h, a mechanical clutch locks up the converter to eliminate slip and provide better fuel economy and throttle response.

The TCM governs gear selection by analysing throttle inputs and vehicle and engine speeds to determine how the vehicle is being used ? for example if it is under heavy acceleration or climbing or descending a hill.

Inbuilt into the gear changing characteristics are a number of ?functional modes?, which make use of this information. These include:

Kickdown: This traditional automatic gearbox mode delays upshifts or instigates down-changes to deliver maximum acceleration if the throttle pedal is pressed past the detent stop near the end of its travel. The transmission returns to normal operating mode once the throttle pedal is released and returns to any position before the detent stop. This feature has been developed to give immediate response to driver’s demands without the need to use buttons to pre-select specific operating modes such as ‘ECO’ or ‘Sport’.

Mountain: By comparing throttle position with engine and vehicle speeds, the TCM can detect uphill gradients and optimise shift quality and shift points. This helps to maintain vehicle speed while avoiding frequent gear changes and hunting between gears. There are two transmission settings in this mode, determined according to the steepness of the slope.

Downhill: Throttle, engine and vehicle speeds are compared and the transmission shifts into a lower gear when the brakes are applied. This provides additional engine braking and greater control when driving down a steep hill.

Hot and cold: The cold mode prevents upshifts to fourth gear until the transmission fluid has warmed up, helping to bring the gearbox to normal operating temperature more quickly. This reduces wear and tear from cold starts and improves gearbox efficiency. The transmission temperature monitor can also initiate the safety-cooling hot mode in the unlikely event of the transmission fluid temperature becoming too high.

Driver over-ride: An ‘overdrive off’ button, ergonomically incorporated into the underside of the transmission selector lever, allows the driver to lock out up-changes to fourth gear, which can help to provide enhanced response and acceleration at higher speeds or in circumstances where frequent shifting between 3rd and 4th gear occurs. The transmission can also be locked into first or second gear with the selector when descending steep slopes or driving on ice or snow.

The Fiesta model range in Australia is also available with the latest Ford IB5 manual transmission. This transmission is derived from the slick-shifting unit offered on Focus.

“Fiesta’s development engineers took the best components of the IB5 transmission and enhanced them for use in Ford’s new small car,” said Ford Australia Small Car Planning Manager, Peter Fry.

The transaxle features a series of enhancements. These include new engagement chamfers for ease of gear selection and gear tooth profiles optimised for low gear noise during idling.

The transaxle and clutch housing have also been revised with additional external ribs. These stiffen the units to aid their NVH performance, contributing to Fiesta?s refined driving quality.

The IB5 unit?s final drive gears and bearings have also been strengthened to further boost durability. Shift quality was also the focus of engineering attention to detail with double-cone synchronisers fitted to the first and second gears to minimise downshifting efforts.

The transaxle delivers power to the wheels via articulated, equal-length half shafts to fight the potential for torque steer when full throttle is applied. The layout also contributes to improved stability under hard acceleration, especially in lane change manoeuvres or turns.

Low-friction constant velocity plunge joints are fitted inboard. Large deflection spherical ball joints, also friction optimised, are fitted outboard.

“Fiesta’s manual transmission also adopts another Focus-style driving quality feature ? a new cable-shift mechanism to replace direct-acting rods,” said Fry.

“This technique, which uses low-friction flexible cables provides a precise, positive shifting feel while isolating powertrain vibrations from the gear lever.”

Fiesta?s clutch mechanism is hydraulically operated for reduced pedal effort, shorter travel, consistent operation over a longer life, low-friction operating efficiency and reduced wear and tear. The hydraulic clutch also contributes to reduced cabin noise levels.

Fiesta’s gearing has been carefully calibrated with the available engine for responsiveness and driveability.

Engine type 1.6L Duratec 16V 1.6L Duratec 16V Max power output (DIN) 74kW @6000rpm 74kW @ 6000rpm Transmission Manual Automatic   Ratios: &nbsp 1st 3.15 2.875 2nd 1.93 1.568 3rd 1.28 1 4th 0.95 0.697 5th 0.76 &nbsp Reverse 3.62 2.3 Final drive 4.25 4.27

For further information, please contact:
Ford Australia Communications
Phone: 03-9359 8491
Fax: 03-9359 8900

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