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THE ALL-NEW FORD MONDEO

INDEX

Foreword by John Fleming, President and CEO – Ford of Europe Page 3

The All-New Ford Mondeo in Brief Page 5

The All-New Ford Mondeo – an Introduction Page 7

The All-New Ford Mondeo in Detail Page 8

1. Mondeo Design Page 8 1.1: Exterior Design Page 8 1.2: Interior Styling Page 13

2. Mondeo Interior Environment Page 14 2.1: Cockpit Feel Page 14 2.2: Interior Lighting Page 16 2.3: Supportive and Comfortable Seating Page 16 2.4: Improved Second Row Comfort Page 16 2.5: Advanced Ventilation and Air Conditioning Page 17 2.6: Interior Versatility Page 17 2.7: Stowage and Connectivity for Life's Necessities Page 18 2.8: Allergy-Friendly Interior Page 19

3. New Driver Assistance Technologies Page 20

3.1: Human Machine Interface Page 20 3.2: Navigation, Audio and Communication Systems Page 23 3.3: Keyless Entry Page 25 3.4: Keyless Start Page 26 3.5: Ford Easyfuel Capless Refuelling Page 27 3.6: Driver's Seat Memory Function Page 28 3.7: Mirror Memory Function Page 29 3.8: Hill Launch Assist Page 30

4. Mondeo Series Choice Page 31

4.1: Mondeo Edge Page 31 4.2: Mondeo Zetec Page 32 4.3: Mondeo Ghia and Mondeo Titanium X Page 32

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5. Mondeo Driving Quality Page 34

5.1: New Mondeo Driving Dynamics Page 34 5.2: The Evolution of a Ford Tradition: Refined Suspension System Page 37 5.3: Ford Interactive Vehicle Dynamics Control with Continuously Controlled Damping Page 38 5.4: Reduced Noise, Vibration and Harshness; and Improved Sound Quality Page 39

6. Mondeo Powertrains Page 44 6.1: Perfect Choice for Performance and Efficiency Page 44 6.2: Petrol Powertrains in Detail Page 45 6.3: Diesel Powertrains in Detail Page 50

7. Mondeo Safety Systems Page 54 7.1: Systems Overview Page 54 7.2: Active Driver Assistance Page 55 7.3: Passive Safety – Ford's Enhanced Intelligent Protection System Page 59

8. Manufacturing and Environmental Commitment Page 68 8.1: Ford Genk Gears up to Deliver New Mondeo Page 68 8.2: Sustainability as an Integral Part of the Business Page 69

9. New Mondeo: A Car to Change Perceptions Page 73

10. Mondeo Technical Data Page 74

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Foreword

"Welcome to the all-new Ford Mondeo.

Every car we launch is significant to us, but for the Ford business in Europe there is

no product that is more important than Mondeo.

Since the original car was launched in 1993, Mondeo has been a key model in the

Ford range. It has always been a major player in the large car segment, even as the

segment has continued to shrink, and to date we have almost four million Mondeo

customers with a wide range of wants and needs. These customers have significant

expectations because this is a market segment that has to suit many needs. Above

all, they are counting on us to deliver on our promise to make the all-new car better

in every way.

The dramatic new model is also important as the final piece of our new large car

line-up. It represents the completion of a 715 million Euro investment programme

for our Genk production plant in Belgium where all three new Mondeo bodystyles

will be built alongside the Ford S-MAX, Car of the Year 2007 and latest generation

Ford Galaxy. This investment has transformed Genk into one of Ford's most

modern and flexible vehicle production plants.

Because new Mondeo, S-MAX and Galaxy share many common technologies, we

can build them on the same production line, which is good news for efficiency,

quality, and ultimately, our customers. Thanks to Ford Motor Company's shared

technologies approach to vehicle development, we have been able to leverage a

portfolio of components and technologies and adapt these to a group of vehicles

which have individual characters, both visually and in terms of their driving

behaviour. Mondeo is significant too in that it has been designed from the outset

with sustainability in mind. New Mondeo has been developed around Ford's

Product Sustainability Index initiative, which takes into account the entire product

cycle, from materials to the ecology of our manufacturing sites, the vehicle itself

including emissions and safety, the cost of ownership and end-of-life equations.

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The new Mondeo is the most technologically-advanced car we have ever launched.

It features a host of new affordable features – many of them new to Ford and many

new to the market segment. These include a new generation of Ford's HMI cluster,

a capless refuelling system and Adaptive Cruise Control – all of which will place the

new car in a different league to its predecessors. We are also launching all three

bodystyles simultaneously, because we understand how different our customers'

needs are throughout Europe.

New Mondeo is very stylish, thanks to the evolution of our 'kinetic design' form

language to create three dynamic and clearly differentiated bodystyles. We're also

stepping up our game on quality, both in terms of perception and dependability.

Although Ford has a history of changing the names of its cars when we launch a new

model, we decided early in the car's development to keep Mondeo. That is because

we are proud of what Mondeo has achieved over the last thirteen years, and because

the new car has kept and enhanced all of the strengths of its predecessors,

particularly its driving dynamics and safety features. Mondeo has always

represented value too, and the new car will be no exception.

I am very proud of what the team has achieved in creating the new Mondeo. I'm also

convinced that, like Ford S-MAX, Car of the Year 2007, the new Mondeo will not

only bring new buyers to Ford showrooms but also delight our loyal customer base

across Europe."

John Fleming President & CEO, Ford of Europe

.

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The All-New Ford Mondeo in Brief

• Daring to be different: New Ford Mondeo marks a step change for Ford

in terms of design and technology

• Striking and individual: Dynamic and eye-catching styling embodies

Ford's 'kinetic design' form language, expressing energy in motion

• Premium quality: New model builds on traditional Mondeo strengths and

adds premium car features, including limousine-like comfort and NVH

characteristics, ambient interior lighting, and soft-touch materials

• Transformed: New driver-focused technologies available include keyless

entry and keyless start with 'Ford Power' start button, new Ford Convers+

Human Machine Interface (HMI) instrument display, Adaptive Cruise

Control with Forward Alert, Interactive Vehicle Dynamics Control and

Hill Launch Assist, and Tyre Pressure Monitoring System

• Impressive: List of standard equipment for the range includes Electronic

Stability Programme (ESP), Ford Easyfuel capless refuelling with fuel

inhibitor to prevent misfuelling, 'follow-me-home' lights, trip computer,

air conditioning, and an auxiliary audio input socket located in the glove

box for external audio device connection

• Great to drive: New model delivers real driving quality as a core attribute

and builds on Mondeo's acclaimed driving dynamics

• No-compromise safety: Enhanced Intelligent Protection System provides

latest driver assistance and occupant protection technologies, including a

driver’s knee airbag, horizontal stroking steering column and full length

side curtain airbags

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• Powertrain choice: Range of efficient powertrains with four Duratorq

TDCi diesel and five Duratec petrol engines ranging in power output from

100 PS to 220 PS, including a new 2.3-litre, 161 PS Duratec HE unit

coming later in 2007. New Durashift 6-speed automatic transmission

available later in 2007 complements the proven Durashift 5- and 6-speed

manual transmissions

• Distinct series: Available as Edge, Zetec, Ghia and Titanium X – with

with many new modern technology features as standard

• Flexible and Spacious: Intelligent use of space, impressive package and

improved luggage capacity

• Crafted by Ford: New manufacturing technologies include 'laser-brazing'

for higher quality, seam-free join of bodyside to roof panel. The new

Mondeo range was fully developed in-house and is exclusively built at

Ford’s Genk 'flexible manufacturing' plant in Belgium

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The All-New Ford Mondeo – an Introduction

The distinctive, all-new Ford Mondeo introduces new technical features to the Ford

range and combines these with further improved driving dynamics and safety

enhancements.

With three distinctively different bodystyles each demonstrating Ford of Europe's

'kinetic design' form language, plus a broad choice of trim series, technical features

and a wide range of powertrains, the new Mondeo brings new levels of refinement

and comfort to its class, and to the Ford of Europe portfolio.

"The Ford Mondeo has always been acclaimed for its strong attributes, particularly

its driving dynamics, safety performance and interior package," said Steve Adams,

Vehicle Line Director, Large & Luxury Cars, Ford of Europe. "With this remarkable

new model we've taken these qualities a step further and enhanced its performance

in all of these areas as well as dramatically transforming its design and quality."

The new Ford Mondeo benefits from Ford Motor Company's Global Shared

Technologies initiative, sharing many elements of its core architecture with the

Ford S-MAX – Car of the Year 2007 – and the new generation Ford Galaxy. A

major advantage to developing vehicles in this way is that much of the development

and testing techniques are shared with other models.

"This approach to product development significantly reduces costs allowing us to

focus more attention on providing additional customer benefits," Adams said.

While the core architecture and vehicle features also appear in other vehicles in the

Ford of Europe portfolio, the new Mondeo has been designed as a distinctive model

in its own right, and this starts with the unique design.

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The All-New Ford Mondeo in Detail

1 Mondeo Design

1.1: Exterior Design

The design of the new Ford Mondeo has instant visual impact. New Mondeo brings

Ford's 'kinetic design' form language and philosophy to new levels, embodying all of

its key elements. Together, these create a sleek and dynamic profile that represents

'energy in motion', and delivers a design presence that signals power and grace,

setting it apart from other cars in the market segment.

The key Ford 'kinetic design' signatures are evident in each of the distinctively

different bodystyles – the classic four-door limousine, the stylish and flexible

five-door sedan and the smart and spacious estate.

"We wanted to create an emotional connection with the new Mondeo that would

attract people from an aesthetic point of view even before they appreciate its

technology," explained Martin Smith, Executive Director of Design, Ford of Europe.

"Our goal was to make people feel impressed when they see the car, and ultimately

want to own one."

Every detail of Mondeo's design was pored over meticulously to reflect accurately

new Mondeo's positioning that the team defined for the car from the outset. Even the

exterior colour shades were selected carefully to indicate the prestigious nature of

the new Mondeo whilst at the same time clearly making it a car of its day.

In size terms, new Mondeo has grown slightly when compared to the previous

model. For example, the new Mondeo 5-door is 47mm longer and 120mm wider

(with mirrors) than the previous model, confirming its credentials as Ford's flagship

large car range.

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Previous Mondeo* All-new Mondeo*Wheelbase 2754 2850Overall Length 4731 4778Overall Width - with mirrors 1958 2078Overall Height 1429 1500

*Five-door bodystyle

Fresh Face

Immediately obvious when seen from the front is the new Mondeo’s distinctive

‘face’, which is characterised by its trapezoid-shaped lower grille, a 'kinetic design'

element that is increasingly recognised as part of the new Ford identity and which is

already evident on several recent Ford models, including the S-MAX and the

recently redesigned Ford C-MAX.

The large upper grille is flanked by prominent, swept back headlamps. Series

differentiation is evident in the detail of the grilles with the Ghia model recognisable

by the use of three horizontal bars featuring chrome accents in the upper grille, and

the Titanium X models featuring a silver-painted 'rectangular grid' design in the

upper and lower grilles. Both high series have chrome surrounds on the upper and

lower grilles. Edge and Zetec models feature a 'rectangular grid' design in black for

both grilles, with the upper grille surrounded by a bright chrome finisher.

Due to the location of the sensor, vehicles fitted with Adaptive Cruise Control

(ACC) exhibit the grille combinations as used on the Titanium X model.

The headlamps comprise the largest surface area ever used on a Ford passenger car

and feature distinctive styling cues of their own; special blue filters on the optional

Halogen and Bi-Xenon Adaptive Front lighting System (AFS) headlamps give

gem-like qualities even when the headlamps are on the lowest sidelight illumination.

The bonnet includes two shaped grooves in the surface which, in effect, create a

‘power bulge’, hinting at the dynamic qualities of the car. The additional bonnet

height was viewed by the design team as a positive addition to the exterior design

and adds to the car's muscular proportions in all three bodystyles.

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Viewed from above, the Mondeo's front three-plane-plan view is immediately

evident, providing a clear link between the production vehicle and the definitive

expression of 'kinetic design' – the Ford iosis concept car – first revealed at the

Frankfurt Motor Show in 2005.

The smooth swept-back 'chamfered' lines of the front bumper give the car a sense of

presence, reduce the visual impact of the front overhang and serve to assist the

driver when parking.

The front fog lamps are situated low down in the front bumper from Zetec series

upwards and mirror the line of the headlamps, which adds to the emotional

experience of the new Mondeo adding a touch of jewellery to the dramatic front end

appearance.

Unique Profile

The profile of the new Mondeo gives observers the most comprehensive view of the

three bodystyles; a stylish and flexible five-door sedan, the classic four-door

limousine and a spacious estate all feature a strong silhouette with the A-pillar angle

blending through to each of the three bodystyles. The raised shoulder line gives a

muscular feel to the car and improves the visual stance.

Another Ford exterior design signature is the use of pronounced wheel 'lips' or

arches. This design element signifies the strong driving dynamics the Ford brand

represents.

• Each of the three bodysides feature their own unique character which build

on key elements of kinetic design; an undercut or 'swage' line running

alongside the car's shoulder that extends from the stylish turn indicator

incorporated in the front wing, along the car's length before diminishing on

the rear quarter panels.

• Strength in the lower body is highlighted by a strong lower cut line that runs

from behind the front wheel 'lip' through both doors and into the rear wheel

arch.

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Visual impact in the quarter panels is maintained by a distinctive kick-up in the

lower angle of the quarter light glass at the rear of the 'daylight opening' area.

For the first time on the new Mondeo Ford of Europe is utilising an innovative

manufacturing technique known as laser-brazing. This provides a way of joining the

side and roof panels together in a more aesthetically pleasing way, thereby providing

a higher quality finish

"We have introduced this new technology because it supports the styling positioning

of the car and gives a very good quality impression," explained Dr Jens Ludmann,

Mondeo Chief Programme Engineer. "Laser-brazing is one of many 'first to Ford' or

'first to segment' applications in this car."

The Mondeo's profile view most embodies the 'kinetic design' language recently

seen in both the acclaimed S-MAX and the new Galaxy and gives the impression

that the car is moving even when stationary. The kicker in the daylight opening, the

robust shoulders and rocker panels, pronounced wheel arches and strong undercut

through the length of the car all add to the feeling of 'energy in motion', whilst

providing a fluid silhouette and muscular lines to the profile.

Dynamic Rear Styling

The new Mondeo design team made a particular effort to incorporate the

three-plane-plan view and other 'kinetic design' characteristics into the rear-end

design of each bodystyle, while maintaining a low load height allowing for luggage

to be loaded and unloaded with ease.

All bodystyles feature two-piece rear lamps with honeycomb-shaped filters while

the high mounted stop lamp is situated on the middle portion of the liftgate and

decklid for four and five-door respectively, while on the estate it is placed high in

the sheet metal above the rear screen.

All models are fitted with what Martin Smith calls a "sacrifice panel" – a

body-coloured plastic cover on the lower portion of the tailgate or bootlid on all

three bodystyles. Testing has proven this to be successful as a cost-effective and

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relatively simple-to-repair solution in the event of both a light rear end collision or

of the driver reversing into an obstacle. The avoidance of expensive sheet metal

repairs assists the new Mondeo in achieving the desired low insurance ratings.

This also allowed the design team to reduce the depth of the rear bumpers. When

viewed in profile, the rear bumper is close to the body, further enhancing the

premium feel of the rear end design.

Tinted and Coloured Glass

As the high-mounted stop lamp for all three bodystyles is not situated behind any

glass, the design team were able to specify the use of a darker shade of grey for the

available privacy glass. Privacy glass can be used on all glass areas, with the

exception of the front screen and front side windows.

A further innovation for new Mondeo is the use of green or new blue tinted glass to

enhance the overall elegance of the premium exterior. Blue glass is traditionally the

domain of premium class vehicles and this is the first time it has been used on the

Mondeo. Blue glass is standard on the Titanium X series in support of the 'modern

techno' contemporary look for this series.

Green tinted glass is fitted to Edge, Zetec, and Ghia series. Where privacy glass is

specified the same darker shade of grey is used is used on all models for rear doors

and rear windows, while blue or green remains on the front screen and front door

areas of glass.

All Mondeos will be available with an optional solar reflect front windscreen. This

provides a cooling effect to the interior in comparison to non-infra-red glass. Tests

show that reflected energy performance of the solar reflect glass is up to four times

better when compared to standard glass.

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1.2: Interior Styling

New Mondeo's 'kinetic design' exterior language has also been carried through to the

spacious interior which has been fashioned to carry a similar sense of style and

premium levels of quality.

It is not a case of style over function though, as all details of the interior have been

designed specifically to combine their individual elements of quality and refinement

to enhance the overall sense of comfort when travelling in the new Mondeo.

"For the new Mondeo we have improved the overall quality of the interior. The

proportions are more sympathetic and it is more inviting," said Nikolaus Vidakovic,

Chief Interior Designer. "When you open the door you see a flow, an elegance. This

is much more welcoming and harmonious than using heavy, harsh shapes."

Vidakovic and his team worked closely with Ford's interior craftsmanship specialists

on the fit and finish of all interior components. The results can be seen throughout,

and is exemplified by a reduced gap on the steering wheel boss.

"Usually, when you open a car door to get in, one of the first things you see is a gap

underneath the airbag housing," said Nikolaus Vidakovic. "We have removed this

gap on the new Mondeo. We felt it wouldn’t be doing the new car justice in terms of

craftsmanship if this detail wasn't addressed."

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2 Mondeo Interior Environment

2.1: Cockpit Feel

Drivers of the new Mondeo will find themselves in a lower and sportier 'cockpit'

driving position as opposed to the high 'command bridge' feel used in taller vehicles

like the Ford Galaxy.

The rake of the A-pillar and front screen lends itself to the cockpit design by

enveloping and involving the driver. The higher beltline and a flow-through centre

console combine to enhance the cosseted feeling for front seat passengers. Front seat

legroom and shoulder room have been increased by 24mm and 52mm respectively.

The raised gear shifter position – coupled with additional adjustment capability for

the steering wheel and front seats – ensures that the driver can choose the most

comfortable driving position and have the best possible visibility with minimum

obscuration by structural or interior package elements of the car.

Wide door opening angles facilitate easy entrance and exit for passengers.

Demographic research and analysis ensure that all of Ford's latest models are

tailored to the modern society for which they are designed, with the interior package

team incorporating any necessary changes thrown up by detailed research. One of

the interior design changes to the new Mondeo implemented through this work is the

integration of longer seat cushions to better suit taller passengers.

Interior Package

In order to optimise the interior package and visibility, Ford's engineers developed

and first used on the new Mondeo a new Computer Aided Virtual Engineering

(CAVE) system.

CAVE uses a combination of computers and projectors to create a virtual life-sized

interior of a car. Using a specially designed rig, a real car seat is fixed into the

appropriate position for the 'driver' who can then evaluate all-round visibility as well

as comfort levels for reaching the steering wheel and operating major controls.

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This system proved invaluable in early customer clinics to gauge reaction to the new

model and as a platform for existing Mondeo drivers to voice their opinions as the

new model advanced. It also enabled the team to make fast and cost-effective

changes to a virtual representation of their designs. The CAVE system is a good

example of the many cost-effective measures that were introduced to key areas of

the car's development – with added benefits for the finished product and ultimately

for customer satisfaction.

Craftsmanship

New and premium levels of craftsmanship are evident throughout the new Mondeo.

On Ghia and Titanium X models a new woven headlining is used that, in a design

choice to reflect the flow-through console, continues down the A-pillars to frame the

front screen.

The careful use of 'piano black' interior styling accents also adds to the ensemble and

creates additional interest and a high quality tactile feel to key touch areas. The

flow-through centre console is finished in a variety of contrasting finishes depending

on series and soft-touch material is used extensively throughout the cabin to

emphasise the quality and refinement of the interior.

The primary shade of the instrument panel on Edge models is black, while on the

other series customers can choose from either black, blue or biscuit colourways,

complementing seat and trim options. Both instrument panel and doors feature

additional trim accents according to series level, ranging from a dark shade of wood

effect veneer on Ghia models to brushed chrome on Titanium X models.

2.2: Interior Lighting

Ambient lighting, usually seen only in premium class vehicles, is included in all new

Mondeo models. A soft amber light illuminates the area from the gear shifter to the

coinbox in the centre console and is generated by two LEDs situated in the overhead

courtesy lamp housing. Ambient lighting adds a touch of class to the new Mondeo

and provides a soft illumination at night to help passengers operate switches or

search for items in the centre console.

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Additional clear lighting is used in the front footwell areas. This ambient lighting

adds warmth to the feel of the car in dark conditions and also provides better

visibility when getting into and out of the car.

2.3: Supportive and Comfortable Seating

The new Mondeo offers 8-way power adjustable comfort seats that provide separate

adjustments for fore/aft, seating height, cushion angle and backrest recline on all

high series models.

All seat specifications, whether standard or optional, have been designed to provide

maximum comfort through extensive amounts of seat travel and ensure that, almost

without exception, everyone will find a comfortable seating position.

The seat foam used is designed to offer optimum comfort and ergonomic

performance and this is complemented by the choice of finishing fabrics and the

pattern of the visible and contrasting stitching.

2.4: Improved Second Row Comfort

Second row Mondeo passengers benefit from heightened levels of comfort and

features which contribute to the limousine-like qualities of the new Mondeo.

Wind, road and powertrain noise has been specifically addressed with the result that

front and rear passengers can now enjoy a conversation more easily across the

cabin's length without the need to raise their voices.

A 12 volt powerpoint, positioned at the rear of the flow-through centre console,

allows rear passengers to use or charge additional electrical devices whilst on the

move.

Second row passengers also benefit from optional seat heating elements and

dedicated reading lamps that are standard on all high-series models.

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2.5: Advanced Ventilation and Air Conditioning

A more powerful ventilation system has been adopted, which features more and

larger ventilation openings. For the first time, the new Mondeo Ghia and Titanium X

models are fitted with additional B-pillar ventilation openings offering greater

control for rear seat passengers.

Dual zone Electronic Automatic Temperature Control (DEATC) is standard on all

models except Edge series where manual air conditioning is fitted. The DEATC

system features individual temperature controls for the driver and front passenger.

2.6: Interior Versatility

The second row of seats in all three bodystyles features a 60/40 split seat back and

cushion.

The seat backs fold forward to allow larger, more bulky loads to be transported. In

all cases it is not necessary to remove the headrests of the rear seats to fold them

forward.

The estate naturally enjoys the most capacious load area of the three bodystyles – a

maximum of 1745 litres when the car is in two-seat mode. The interior package

engineers worked closely with the exterior design team to reach their target of

improving the estate load capacity over the previous Mondeo and succeeded

by 45 litres.

The five-door model has a luggage capacity of 1448 litres when in two-seat mode,

while the closed luggage compartment of the four-door has a generous capacity of

535 litres.

Four tie-down points are located across the rear floor area in each bodystyle. These

help to reduce noise levels of items moving around when travelling and optimise

safety by offering the facility to tether loose items. On the estate model, these tie-

down points are chrome finished D-rings that sit flush in their floor surrounds.

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Hooks have also been integrated on the inner trim panels of the load area and a third

12 volt powerpoint is standard on the estate bodystyle to charge electrical devices

away from the view of passers-by or to transport larger electrical items such as

powered cool boxes that need a dedicated power supply.

When the second row seats are folded forward to maximise the load area on the

estate and five-door models, they form a flat area without an awkward step to

negotiate luggage over or around.

2.7: Stowage and Connectivity for Life’s Necessities

The new Mondeo provides ideally-proportioned storage spaces for items such as

CDs, keys, sunglasses, sweets and other items often found in a car's interior.

Large pockets run the full length of the front doors and can comfortably hold a

1.5 litre drinks bottle. The glove box has been enlarged by approximately

10 per cent and can easily carry drinks cans.

All new Mondeo models feature a 3.5mm auxiliary connection socket as standard.

This is located within the glove box and allows for the connection of portable audio

devices to the car's entertainment system.

Significant additional stowage is located within the armrest of the flow-through

centre console. This has been moulded and divided into two separate areas: the

substantial lower compartment offers integrated slots for holding up to seven CDs,

while the upper tray is ideal for storing loose change. In addition, a dedicated

stowage area next to the steering wheel is ideally located for storing a mobile phone

handset whilst on the move.

2.8: Allergy-Friendly Interior

Ford leads the industry in providing car interiors that are certified as allergy friendly.

The first cars worldwide to receive the “Allergy-Tested Interior” Seal of Approval

were Ford Focus and C-MAX. The renowned German TÜV Rhineland Group – an

independent testing and assessment organisation – tested and certified both cars in

2005. This certification has been confirmed by the British Allergy Foundation.

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For TÜV certification, production vehicles are subjected to extensive analysis,

including testing of the passenger compartment’s air quality for the concentration of

organic substances such as formaldehyde, phenols, phthalates and solvents. Ford

aims to expand this initiative continuously with new models, and the new Ford

Mondeo will be tested according to stringent TÜV criteria.

Legislation requires plastics and elastomers to be marked and substance restrictions

to be adhered to. The new Mondeo, in addition to the recently launched S-MAX and

the new Galaxy, has been developed from the outset to meet all of these regulatory

requirements.

In 1984 – on a voluntary basis ahead and beyond of any regulatory requirements –

Ford developed and introduced a ‘Restricted Substance Management Standard’ to

determine which substances should be avoided, eliminated or phased out in both its

products and manufacturing plants. This extensive process includes testing cars for

allergy friendliness.

It is anticipated that the new Mondeo will achieve full Allergy Tested certification

later in 2007.

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3 New Driver Assistance Technologies

3.1: Human Machine Interface

The new Mondeo features as standard the next generation of Ford's advanced

Human Machine Interface (HMI) system. Ford's latest HMI system received much

acclaim when first launched in the Ford S-MAX and new Galaxy models. However,

as a result of Ford's policy of continual product development, new Mondeo features

the next generation of Ford HMI systems, in which the functions have been

extended and improved, bringing vehicle interaction and systems control to a new

level.

The new Mondeo HMI system features two main components:

• Toggle Switches: Two toggle switches are prominently placed on the steering

wheel. Both toggle switches are simple to operate with push directions of up,

down, left and right. Each selection is confirmed by pressing 'ok' in the centre

of the toggle switch.

• Instrument Cluster Display: All new Mondeo models are provided with one

of three levels of HMI depending on series and features. Situated in the

centre of the instrument cluster the HMI display screen gives concise and

clear information in the driver's field of vision and can be specified in three

different sizes. The Standard and Enhanced clusters use a monochrome

display with red illumination, a combination usually found only in premium

cars in this class, while a new 15cm Ford Convers+ full-colour premium

cluster display is also available.

Depending on series and options selected, a new colour and configurable multimedia

display unit is integrated into the flow-through centre console. This unit enables

passengers to control the radio, navigation system, mobile phone, CD changer and

audio devices connected through the auxiliary socket.

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Three levels of the HMI are available, depending on series and technical features

specified. Edge, Zetec, and Ghia series benefit from the Standard Cluster Level

which has a monochrome version of the central display in the instrument cluster.

Using a four line display, the Standard Cluster Level gives clear data for the trip

computer, information messages and vehicle setup features. The user can select one

of 11 languages and configure the system to meet their personal taste for key criteria

such as the layout of the clock display.

The Enhanced Cluster Level uses a larger monochrome display which, thanks to an

increase in the quantity of lines of data, has the facility to accommodate graphical

representations for key features such as Adaptive Cruise Control (ACC), Tyre

Pressure Monitoring System (TPMS), Interactive Vehicle Dynamics Control

(IVDC), CD and DVD navigation functions, where specified. The Enhanced Cluster

Level is used when these driver assistance features are fitted.

The ultimate cluster display is the new Ford Convers+ system, comes as standard

equipment on the 'modern techno' Titanium X series and which may be specified as

an option on Ghia series as part of the Technology Pack. This system features a

15cm colour display screen positioned between a specially designed speedometer

and rev counter, and provides the same information and functions as the Standard

and Enhanced clusters but in addition gives the driver visual control of the

multimedia and audio functions, including auxiliary input and phone control.

Being simple and intuitive to operate, all levels of Ford's new HMI system follow

strict, straightforward and logical rules and combine critical areas of ergonomic

development to optimise the interaction of the driver with the vehicle features,

comfort and entertainment systems.

- 22 -

Series LevelStandard Cluster

LevelEnhanced

Cluster Level*FordConvers+ Cluster Level

Edge Standard OptionalZetec Standard OptionalGhia Standard Optional Optional**Titanium X Standard

** Included as part of the Technology Pack (Keyless entry, TPMS, and Ford Convers+)* Fitted as standard on vehicles with ACC, TPMS, IVDC, CD Navigation and DVD Navigation

FunctionStandard

Cluster LevelEnhanced

Cluster LevelFordConvers+ Cluster Level

Trip Computer X X XInformation Messages X X XVehicle Display Settings X X XNavigation Repeater - X XACC Display - X XTPMS Display - X XCD Control - - XCD Changer Control - - XRadio Control - - XPhone Control - - XAuxiliary Input Control - - X

"Ford's latest generation HMI system is unique and the logic behind the system and

the way it operates is very easy," said Dr Jens Ludmann. "Other systems are often

complex and complicated for the user. With the Ford HMI system there is no need to

learn it, study it, or spend time trying to understand it; you can just jump in and use

it."

System Development

The system's simplicity and logic is not only a direct result of its design, but is also

due to the make up of the team that developed it. For example, in addition to

electrical engineers and ergonomists, the Ford HMI team includes website designers,

to ensure that the completed systems exemplify the simple and intuitive functionality

that users expect from interactive systems.

- 23 -

The HMI team also includes dedicated psychologists whose task is to ensure that the

complicated internal processes and techniques needed to run the system can be

controlled by the driver via straightforward and intuitive-to-use operations.

"People intuitively use thousands of what we call 'stereotypes' everyday, often in a

state of being on auto-pilot," explains Dr. Stefan Becker, Supervisor of HMI

Development. "Things such as turning on a tap or using a door handle are basic

stereotypes and everyone is familiar with them. Our guiding principle is that we do

not want to force our customers to learn a new system. By giving our customers

stereotypes they are already familiar with, when using computer systems for

example, we can adapt our very sophisticated system to be incredibly user-friendly."

Beyond standard features such as the common trip computer for fuel consumption

and speed information, the HMI system allows the driver to select individual

settings. The system effectively enables a controlled dialogue between the driver and

various support systems – radio, navigation system, Adaptive Cruise Control (ACC),

mobile phone, CD changer and auxiliary audio system can all be easily and

confidently controlled. The essential functions are shown in the instrument cluster

display for quick readability and easy operation. Some functions such as clock

setting and language selection for the display and cluster can also be operated from

the steering wheel using the toggle switches.

3.2: Navigation, Audio and Communication Systems

New Mondeo is available with two different navigation systems.

A CD Navigation system offers updated turn-by-turn directions through the

multimedia audio and navigation display. This forms part of the Navigation

Repeater feature where the turn-by-turn directions are mirrored in the Enhanced

Cluster display located in the instrument cluster. This means the driver has two

places to see navigation directions and gives passengers the opportunity to see the

directions via the multimedia unit in the flow-through centre console.

- 24 -

The new DVD Navigation system incorporates a full-colour touch screen display

that enables both driver and passengers to easily set the route. This system is linked

to the instrument panel cluster display function on both enhanced or Ford Convers+

cluster levels.

The two HMI system toggle switches located on the steering wheel provide full

driver control, while the location of an 18cm colour touch screen display in the

centre of the flow-through centre console enables a front passenger to safely help

with route-setting when using the DVD Navigation function. The DVD Navigation

system is a brand new development and is launched by Ford for the first time in the

new Mondeo.

Enhancements for this system over the previous model include extended map

coverage, including Eastern Europe, improved Traffic Message Channel

representation which gives real-time traffic information and an 'optimal route'

setting, allowing for a selectable mix of shortest and fastest destination settings.

Navigation Information is displayed in two areas. The multimedia unit itself, housed

in the flow-through centre console is the primary display for this system, while key

navigation information is also displayed in the instrument cluster display.

The new Ford Mondeo can be specified with a variety of high-quality audio and

communications systems. Depending on series level and optional equipment

specified by the customer, a choice of three stereo radio/CD players is available for

new Mondeo, including two new generation Sony units, one of which has a 6-CD

autochanger. Both of the Sony units have MP3 compatibility and offer 40 radio

station presets. Radio station memory buttons have increased in quantity from six to

twelve, and these now provide the dialling feature when in telephone mode.

An external 6-CD changer located in the rear luggage compartment of the new

Mondeo can be specified as a further option – in combination with a Navigation

system, for example.

- 25 -

For safe and convenient telephone control when on the move, a Bluetooth®

hands-free telephone and voice control system is also available. The Bluetooth®

feature is compatible with all three in-dash stereo radio/CD players and the DVD

Navigation system.

In line with Ford's holistic approach to system integration, all of the audio

equipment is able to communicate with Ford's new HMI system and can also be

operated via voice control when specified.

In keeping with the new Mondeo's premium levels of interior craftsmanship, all

audio units have been designed to support the vehicle's enhanced interior ambience

and quality levels. The smooth integration and positioning of the units within the

flow-through centre console coupled with their high quality red, monochrome or

full-colour readouts, provide evidence of this approach.

All new Mondeo models feature a 3.5mm ‘aux-in’ socket in the glove box for easy

connection of portable audio and MP3 devices.

3.3: Keyless Entry

Two major new technical features available to Mondeo customers for the first time

are the keyless entry and keyless start functions.

Where the option is taken for keyless entry, the driver is equipped with a 'fob' which

takes the form of a rhombus-shaped unit that easily fits in the palm of the hand.

Drivers familiar with having a 'plipper' unit to operate the locking features of their

car will already be accustomed to the unit's approximate size and shape. This fob

will need to be carried by the driver in order to operate the keyless entry and keyless

start functions.

"When we developed this system we spent a large amount of time considering all the

different scenarios the car and key holder would find themselves in," said Dr Jens

Ludmann. "Vehicle security and passenger safety are important considerations to

our customers and we wanted to bring to market a foolproof system that is easy to

use in everyday life."

- 26 -

Where the option is taken for keyless entry, a conventional mechanical key is no

longer needed to unlock the car. Instead, the car uses three external antennae to

detect the presence of the fob within a small boundary around the car's body. The

keyholder simply pulls a door handle to gain entry to the cabin or the handle on the

bootlid or tailgate to access the rear load area.

No more than 200 milliseconds elapse between the handle being operated and access

being gained. In this period a complex radio frequency dialogue takes place between

the fob, external antennae and electronic modules for the handle to operate and

access to be granted.

On leaving the car a small button on the exterior of either front door handle is

pressed to lock the car. There is an additional button on the rear of the car that forms

part of the release handle.

To supplement the central locking and keyless entry locking systems, all new

Mondeos feature one of four levels of alarm system. The alarms range from a

perimeter alarm to a Thatcham Category one alarm with interior sensors, battery

back-up sounder and tilt sensors.

3.4: Keyless Start

New Mondeo Titanium X models are equipped with keyless start as a standard

feature. As the driver enters the car with the fob about their person, three internal

antennae detect its presence, which is the first part of a simple procedure the driver

uses to start the engine and drive away.

The keyless start feature completely removes the need for a conventional rotary

ignition barrel. The off, accessory, ignition on and engine crank positions have been

incorporated into the single 'Ford Power' button. Ergonomically positioned adjacent

to the steering wheel near the top of the flow-through centre console, the button is a

good example of the high level of craftsmanship and emotional appeal of the new

Mondeo.

Every aspect of the new 'Ford Power' button's design and operation was carefully

considered and revised until the engineers and designers were satisfied that it was

- 27 -

indicative of the car's quality. The amount of pressure the driver uses to activate the

button to start the engine, the 'Ford Power' wording and the shade of red illumination

of the button itself received the same levels of attention as more complex functions

elsewhere in the new Mondeo.

While the engineers were keen to make the 'Ford Power' button a convenient feature

for the driver, safety was also considered to be important.

The electrical protocols of the system have been devised so that when the three

antennae have detected the matching fob unit and the infra-red signals are correct for

the ignition switch to crank, a pedal must be depressed for the engine to start as the

'Ford Power' button is pressed. The clutch pedal must be depressed in cars with

manual transmission, while in cars with automatic transmission the brake pedal must

be depressed as the Ford Power button is activated. The sequence protocol reduces

the risk of a child inadvertently starting the engine.

If on-board functions such as heater controls, wipers and audio functions need to be

used without the engine running, the car can be placed in 'accessory' mode prior to

the clutch or brake pedal being depressed. This corresponds to a conventional rotary

ignition switch being turned to the second position and allows control of the

accessory functions without the engine running.

The 'Ford Power' button is also used to switch off the engine. Once again, the

engineers were keen to build in a more complex sequence to rule out the possibility

of the button being briefly pushed or brushed against inadvertently. The 'Ford

Power' button needs to be pressed and held for two seconds, or to receive three short

presses in a two-second timeframe, in order to stop the engine when the car is

moving. If the car is completely stationary a single brief press of the Ford Power

button is sufficient to stop the engine.

3.5: Ford Easyfuel Capless Refuelling

The new Mondeo is the first Ford production model to feature the company's

award-winning Easyfuel capless refuelling system.

- 28 -

Thousands of drivers every year accidentally misfuel their vehicles. Ford engineers

were determined that owners of the new Mondeo would not suffer the inconvenience

and potential expense of such a mistake.

Benefits to the system are twofold; first, the lack of a conventional cap that needs to

be removed prior to fuelling the car means that drivers have fewer things to touch,

reducing the likelihood of fingers becoming tainted with fuel.

Secondly, a significant breakthrough in the development of this feature has been the

creation of a special fuel inhibitor. This is a 'first' for Ford and a 'first' in the

market segment, and provides major protection against misfuelling at the fuel pump.

The fuel filler neck aperture has been specifically designed around the different sizes

of fuel nozzle, and Ford has engineered the system to allow only a nozzle that

matches the corresponding fuel type of the car to open and enter the filler neck. This

protects against both petrol and diesel misfuelling.

The use of mechanical devices around the nozzle opening and a special flap at the

top of the fuel filler neck operate together to seal the opening and provide the same

assurance that the system is as secure as when a properly fitted separate cap is used

on conventional filling systems.

Initially shown as a concept technology at the Frankfurt Motor Show in 2005, the

Ford Easyfuel system was awarded 'Idea of the Year Award' in the UK's Autocar

Magazine 2005 Awards.

3.6: Driver's Seat Memory Function

The 8-way power adjustable seat can be specified with an optional memory function.

Memory buttons enable up to four different seating positions to be stored and

recalled or to return to the ‘last-used’ position through the use of any remote key that

corresponds to the car.

This personalisation feature is simple and intuitive to use. To store a position a long

push is made on one of the four memory buttons. The selection is then confirmed by

an audible chime. Position recall is simply made by a single push of the memory

- 29 -

button. The memory button switch bank is packaged in a visible location on the

driver's door side of the seat valance.

The memory seat buttons store the following aspects to the seat position:

• Slide Cushion forward / rearward

• Height Cushion up / down

• Tilt Cushion up / down

• Backrest incline / recline

A special anti-pinch feature is incorporated into the programme which works by

measuring the change rate of the motor speed via sensors.

3.7: Door Mirrors

The design of the door mirrors has been improved and the size increased to provide

optimum visibility. New Mondeo door mirrors each have an additional 17cm²

surface area compared to the previous model.

3.8 Hill Launch Assist

Ford's Hill Launch Assist (HLA) system is available on the new Mondeo.

Using the braking system, HLA is engaged when the car is stationary to avoid it

from rolling. While effective on both uphill and downhill gradients, Ford engineers

believe it will give drivers greater control when performing hill starts. HLA provides

a two and a half second delay when the driver moves their foot from the brake pedal

to the accelerator pedal as the system maintains pressure to the braking system.

The HLA feature avoids the need for the driver to go through an awkward sequence

of events involving the handbrake to hold the car momentarily whilst on a hill. Once

sufficient engine torque is reached the HLA feature automatically releases the brake

system in a controlled manner. HLA is normally activated automatically, but the

driver can also select a manual activation mode in the HMI cluster menu.

The HLA feature is available on new Mondeo models equipped with Interactive

- 30 -

Vehicle Dynamics Control (IVDC) or Adaptive Cruise Control (ACC) with Forward

Alert (FA). For non-IVDC suspension systems HLA is available as an option.

4 Mondeo Series Choice

The Ford Mondeo range has always offered a wide choice for customers, and for the

new Mondeo the development team has worked hard to develop a comprehensive

series strategy that meets the segment’s diverse owner expectations.

For each bodystyle, the new Ford Mondeo is available in four distinct series – Edge,

which provides a high level of standard equipment essential for business and family

needs, the contemporary Zetec series, and, at the top of the range, the Ghia and

Titanium X models. A Sport pack can be specified for Zetec, Ghia and Titanium X

series models featuring sports suspension, rear spoiler on five-door and estate

bodystyles and a choice of 17- or 18-inch alloy wheels with 235 tyres depending on

series.

This comprehensive line-up is designed to fit all customer needs.

4.1 Mondeo Edge

The Edge model is the entry-level Mondeo and it offers all the essentials for

business and family, including the new Ford HMI – with Standard Cluster Level

display – and enhanced Intelligent Protection System.

The Mondeo Edge model will appeal to price-sensitive customers, perhaps replacing

their car for the first time in a number of years and wanting to acquire a wide range

of modern safety, convenience and comfort features in the process.

Standard equipment on Mondeo Edge includes:

• Electronic Stability Programme (ESP) with Electronic Brake Assist (EBA)

• Ford Easyfuel capless re-fuelling with misfuel inhibitor

• Emergency hazard warning lights activation

• Power-operated front windows

- 31 -

• Power-operated and heated door mirrors

• Follow-me-home lights

• 'Smart' wipers that automatically switch down one setting at speeds of less

than 2km/h

• Trip computer

• Air-conditioning

• AUX input in glove box

• Intelligent Protection System (IPS) with driver knee and full length side

curtain airbags

• Active headrests on front seats

• Lumbar adjustment on driver’s seat

• Front and rear seat armrest

4.2 Mondeo Zetec

The popular Mondeo Zetec series has been carefully equipped to represent

outstanding value for money and attractive visual detailing.

Standard features like the DEATC air conditioning system, sports seats, a leather

steering wheel, leather gearshift knob and power-operated rear windows combined

with interior detailing bring high levels of comfort and a quality feel to the interior.

Exterior styling features include front fog lamps and body coloured door handles.

4.3 Mondeo Ghia and Mondeo Titanium X

New Mondeo customers have a choice of range-topping models, each offering

individual style and an impressive list of features and equipment.

Characteristic ‘classic luxury’ is represented by the Ghia series. It features extensive

use of chrome and wood ornamentation inside, elegant and unique alloy wheels,

- 32 -

auto lighting and rain sensing wipers. On the inside, the passengers are able to enjoy

the comfort seats including height adjustment on the passenger side. In addition,

Ghia features power-operated and heated door mirrors with puddle lights and cruise

control for a stress-free journey.

The Mondeo Titanium X model will appeal to those customers favouring a more

contemporary ‘techno’ flavour, with an array of standard features, including '3D

metal finish' instrument panel, alloy wheels in distinctive Titanium X style, blue

tinted glass, bright chrome or brushed silver exterior finishing touches,

powered/heated door mirrors with puddle lights, front LED ambient interior lighting

and footwell illumination.

The Titanium X series also features the new Ford Convers+ HMI Cluster as standard

equipment. Customers have an option of CD or DVD navigation multimedia

systems.

The Titanium X represents the ultimate Mondeo and offers additional premium

features, including Alcantara trim, Halogen AFS headlamps, 17-inch alloy wheels

with sporty 235 tyres and the keyless 'Ford Power' button.

Additional design and protection options have been developed exclusively for the

new Mondeo by the Ford Customer Service Division. Items including 17- and 18-

inch alloy wheels, body styling kits and dog guards are available.

- 33 -

5 Mondeo Driving Quality

5.1: New Mondeo Driving Dynamics

The Ford Mondeo has been acclaimed for its driving quality since the launch of the

first generation in 1993. The new Mondeo will extend the model's reputation in this

area and from the outset was developed with superior driving dynamics as a core

attribute. Consequently, the new Mondeo combines sporty driving dynamics with a

refined ride and minimal noise, vibration and harshness. In addition, all new

Mondeos come with Electronic Stability Programme (ESP) as standard.

Whilst sharing much of its core architecture with the Ford S-MAX and Galaxy, the

ride and handling of the new Mondeo has been uniquely tuned to account for its

lower centre of gravity and weight proportions.

The torsional stiffness of the new Mondeo has been analysed and directly compared

by Ford's engineers to the previous model. The figures speak for themselves:

• The four-door exhibits an improvement of 116 per cent

• The five-door exhibits an improvement of 130 per cent

• The estate exhibits an improvement of 159 per cent

Ford's optional new Interactive Vehicle Dynamics Control (IVDC) with

Continuously Controlled Damping (CCD) provides even better handling, comfort

and stability, plus shorter braking distances. The CCD system continuously adjusts

the damper properties to the current road and driving conditions and offers the driver

a choice of three different settings: Comfort, Normal and Sport.

The system is capable of adjusting the dampers to a firmer setting every tenth of a

second, providing responsive and immediate control in dynamic driving situations. It

is closely connected to the Mondeo's standard ESP system.

"Fundamentally we start with a very sound chassis technology in our cars," said

Dr Jens Ludmann. "Our secret is that we simply pay huge attention to detail and that

we spend a lot of time and effort on suspension tuning."

- 34 -

The steering system for all bodystyles and all powertrain options is rack-and-pinion

with hydraulic power assistance. The 2.5-litre 220 PS Duratec engine uses a

hydraulic pump, while all other engine options use a variable-displacement pump,

that creates less heat and contributes to fuel efficiency.

All new Mondeo models have been engineered to provide the best possible steering

feedback for the driver across all road surfaces and at all speeds.

New Mondeo's driving quality attributes will be packaged as Ford Precision Drive to

establish Ford's leadership credentials firmly in customer minds.

Recognising that Ford has a strong heritage of acclaimed driving dynamics to live up

to, the Mondeo development team has paid special attention to the car's suspension

and steering system. The major modifications include:

• Wider track

• Optimised front suspension design

• New rear suspension design

• Isolated rear subframe

• Optimised steering system

Wider Track

Fitted with the entry level 205/55 R 16 tyres, the front track at 1,589mm is 67mm

wider than the previous Mondeo and the rear track at 1,605mm is 68mm wider. This

change supports improved straight-ahead stability, higher cornering grip and better

roll control due to the reduced ratio between the centre of gravity height and track

width.

- 35 -

Optimised Front Suspension Design

When addressing the elementary needs for the new Mondeo's front suspension it was

necessary to achieve high lateral and camber stiffness by improved wheel bearings

as well as stiffer structural suspension components and, at the same time, fine-tuned

longitudinal compliance to absorb bumps. Also required were optimised suspension

kinematic and elasto-kinematic characteristics in order to control intelligently the

wheel position over the entire wheel travel and under longitudinal and lateral forces

for an optimum handling balance.

Ford engineers also took a repeated component-by-component approach to reduce

steering friction and provide compliance for optimal system performance and best

steering and handling control.

The lower control arm uses hydro-bushings at the rear for efficient disturbance

management, resulting in clearly enhanced rolling comfort. The arm allows the

necessary aft movement of the wheels to absorb bumps whilst being extremely stiff

in a lateral direction to enhance handling precision.

New Rear Suspension Design

The new Mondeo uses a new version of a proven multi-link rear suspension design

with a subframe mounting system featuring rubber bushings. This suspension

concept is already familiar in the Ford S-MAX 'Control Blade' system design and

uses four links to control each wheel precisely.

In the new Mondeo, the system is optimised by the application of a new rubber

isolated subframe for low road noise. The design of the linkage ensures that the

lateral stiffness of the original system is retained.

Much like the front suspension, several rear suspension targets were set to achieve a

highly robust chassis for the new Mondeo. The targets included high lateral and

camber stiffness for precise handling quality, and high longitudinal compliance to

absorb road irregularities. Predictable handling was achieved by intensively tuned

elasto-kinematic characteristics of the suspension.

- 36 -

Isolated Rear Subframe

Used for mounting the suspension system, the isolated rear subframe is one of

several measures aimed at isolating noise and vibration from the car's passengers.

Fine attention to detail is in evidence through the fine-tuning that the suspension

bushes received and increased local stiffness of the body at the suspension

attachment points.

Handling Characterteristics

Producing a fun-to-drive large family car requires special attention to the tuning of

the suspension and steering systems in order to achieve enhanced stability. A wider

track and bush attachment base combine to provide resistance to roll movements.

Optimised Steering System

The new Mondeo features a rack-and-pinion steering system with hydraulic power

assistance, which provides the best possible steering feedback. The system was

developed for optimal stiffness and reduced friction. With a new

variable-displacement pump, the system is more fuel-efficient and less complex and

as the system creates less heat, the cooling feature could be deleted.

The result is a steering system that is characterised by its ease and precision – a

major factor contributing to overall driving quality by helping to reduce fatigue and

enhance enjoyment.

5.2: The Evolution of a Ford Tradition: Refined Suspension System

Ford has again opted for the trusted MacPherson front suspension system for the

new Mondeo, focusing on precision and package.

A design honed by Ford since the 1950s, the MacPherson strut system has been

continually improved from generation to generation. The suspension subframe is

extremely rigid and wide, sitting in isolating rubber mounts for enhanced ride

comfort.

The system also incorporates other benefits to enhance driving dynamics for the new

Mondeo:

- 37 -

• Isolated Subframes: Used on both front and rear suspension, these

body-mounted subframes are critical to NVH performance while

enhancing steering and suspension system performance

• Control Arm Hydro Bushings: The control arm’s soft hydro-bushing and

stiff rubber bush are designed in such a way that high lateral stiffness for

steering precision and fine-tuned longitudinal compliance for minimal

impact harshness is achieved

• S-shaped Springs and Dual Path Strut Mounts: The springs enable

complete lateral force compensation in the dampers despite the minimal

package space they require. With this design, ride comfort is clearly

enhanced due to the elimination of friction in the suspension system. The

inclination of the top mount against the damper axis enhances the ride and

handling and supports the side load compensation, thus reducing friction.

With the use of dual path strut mounts, spring and damper isolation can be

tuned independently, resulting in optimal absorption of road inputs

5.3: Ford Interactive Vehicle Dynamics Control with Continuously Controlled

Damping

Ford's Interactive Vehicle Dynamics Control (IVDC) active suspension system with

Continuously Controlled Damping (CCD) is available on the new Ford Mondeo.

IVDC also includes Hill Launch Assist (HLA).

CCD is an adaptive damper system that controls the pitch and roll of the car by

continually monitoring and adjusting the damper rate every two tenths of a second.

The system has been extensively tuned to the specific weights and tracking of the

new Mondeo.

Customers can choose their ride quality according to personal preference and current

road conditions from three ride settings – Sport, Normal or Comfort. IVDC monitors

the road and vehicle behaviour and, depending on conditions, will automatically

adjust to Sport mode to control body roll.

It also means that on even road surfaces, the new Mondeo progresses using low

- 38 -

levels of damping force for excellent driving comfort. If, however, the car

encounters a pitching road surface, the system immediately stiffens for optimal body

control. All this happens automatically, and changes are barely noticed by the driver.

This active suspension system makes particular sense for larger cars such as the new

Mondeo, where the relation of payload to maximum kerb weight is relatively high. It

enhances dynamic stability, particularly under critical driving conditions and avoids

excessive ESP system intervention. The system ensures the car avoids excessive

body movement and also reacts well to dramatic lateral movements. Additionally,

the input of road vibrations to the driver is reduced to provide a more comfortable

ride overall.

When IVDC is specified, Hill Launch Assist (HLA) is also provided. This uses the

braking system to prevent the car from rolling when moving off on a gradient.

HLA provides a two and a half second delay when transferring from the brake pedal

to the accelerator pedal through the system maintaining pressure to the brake system.

The HLA feature avoids the need for the driver to engage in an awkward sequence

of events involving the handbrake to hold the car momentarily whilst on a hill.

In summary, IVDC with CCD and HLA enhances comfort and safety through

improved levels of handling and stability, and shorter braking distances.

5.4: Reduced Noise, Vibration and Harshness; and Improved Sound Quality

Significant efforts were made to reduce noise levels and improve the perceived

sound quality inside the car to match increased overall refinement.

- 39 -

The achieved low sound pressure levels and the source harmony for engine, road

and wind contributions support the quality of the interior ambience. The new

Mondeo provides stress-free, relaxed driving through low noise levels which enables

easy communication inside the vehicle and optimum use of the internal audio

equipment up to high speeds. This was achieved by detailed analytical preparation

using state-of-the-art CAE tools, time spent in highly sophisticated noise, vibration

and harshness (NVH) test facilities and a high number of test kilometres on both test

tracks and public roads. Attention to detail was a key enabler for successful NVH

development of the new Mondeo.

Sound Package Development

The basis of the premium NVH behaviour of the new Mondeo is its excellent sound

package execution. The aim was a perfect attenuation of noise radiated from the

powertrain, the tyres and wind in addition to external noise sources.

"Engine noise reduction is an important metric that describes the capability of the

body, the sound package and the sealing to attenuate the airborne noise from the

engine bay," explained Dr. Karl-Heinz Bürger, Manager, Vehicle NVH. "Everything

that we can have an influence on has been optimised on the new Mondeo."

Hardware actions taken include the application of optimised engine bay absorption,

the introduction of lightweight instrument panel sound insulation and the application

of highly absorbing headliner material. Every attention to detail has been given to

providing the new Mondeo with premium NVH qualities, even the design and

sealing of the trim clips has been optimised.

In addition to the engine noise reduction, the NVH engineers have optimised the

criterion used to give a combined measure of the body, sound package and the

sealing to attenuate the noise radiated from the tyres.

The combined effect of all the hardware actions that have been implemented is an

overall improvement in terms of noise reduction within the cabin of more than 3dB

across the whole frequency range in comparison to the previous model.

- 40 -

Minimal Powertrain NVH

Designing a premium powertrain sound quality was a key area of attention in the

development phase of the new Mondeo. One important goal was to achieve a high

level of sound refinement that included low to medium engine speeds and at cruising

conditions. At the same time a positive sound feedback from the engine during

accelerating manoeuvres was achieved.

Features incorporated to meet this objective include:

• Air Intake & Exhaust Tuning: On all engine derivatives the design of the

exhaust and the air intake systems have been optimised on powertrain NVH

test cells to meet the interior noise sound quality targets. Shell surface

stiffnesses have been optimised, internal absorption and resonators have been

developed and introduced

• Engine Mount Isolation: All engine mounts underwent a rigorous

development program to improve the structure borne noise isolation in all

frequency areas under all load conditions

• Improved Body Attachment Stiffness: A major effort was made to improve the

local body attachment stiffness of all powertrain and chassis mounts

significantly, including exhaust hangers and suspension mounts

• Isolated Front Subframe: The isolated front subframe attenuates the

vibrational input of the side shafts and the roll restrictor into the body

structure reducing the perceived powertrain rumble within the passenger

compartment

• State-of- the-art High Pressure Common Rail Duratorq Diesel Engines: A

special focus of the diesel engine NVH development programme was to

reduce the typical diesel knocking noise which is characteristic of all diesel

engines. This has been achieved by optimising the injector hardware and the

continual improvement of the engine calibration, using both powertrain NVH

rigs and test drives. A multipilot injection strategy has been introduced to

smooth the combustion events in the entire engine speed and load area

- 41 -

• Attention to Detail: The level of detail given to improve the NVH

characteristics extends to incorporate the secondary noise paths, such as

cables, hoses and ducts. To give some examples, noise transmission through

the gear shifter cables has been greatly reduced and power assisted steering

and air conditioning lines have been tuned to suppress unwanted noises

• Duratec 5-cylinder Powertrain NVH: The Duratec 5-cylinder exhibits

excellent NVH refinement up to high engine speeds while maintaining the

typical positive 5-cylinder sound character with a sporty note

Road Noise Optimisation

The main focus of road noise development was to achieve a low noise level on all

road surfaces. This includes a smooth noise and vibration behaviour while driving

over smooth or rough roads as well as over impacts. The good balance between high

frequency and low frequency road noise of the new Mondeo contributes to its

excellent driving experience. The development work was conducted over a variety

of critical road surfaces at Ford's Lommel Proving Ground in Belgium, and on

public roads close to the Nürburgring in Germany. The following design features are

key enablers for improved road noise elements of the new Mondeo:

• Front and Rear Isolated Perimeter Subframes: Both front and rear

suspension subframes are isolated from the body structure. In conjunction

with the extremely stiff body attachment points this feature allows a

significant reduction of road vibration input and therefore reduced noise

creation

• Optimised Hydrobush and rear suspension tie blade bush: Large bush

dimensions have been chosen to allow soft mount progression with high

tuning capability for rough roads and impact excitation

Reduced Wind Noise

The sleek exterior shape of all three bodystyles provides a good basis to minimise

the creation of flow noise on the surface of the new Mondeo.

- 42 -

Attention to detail is key in minimising wind noise. New Mondeo's design includes

an optimised A-pillar shape, the door mirror design, the flush execution of the door

seals, the concealed wiper arms and blades and the shape of the door handles.

Another area of reduced wind noise development on the new Mondeo was the task

of minimising the transmission of noise from the car's surface area into the

passenger compartment. In order to achieve this, particular attention was given to

the door design. Improvements included making the door glass thicker and

introducing an additional seal between door and body. Also, the location and design

of the mirror seals have been optimised.

The positive result of such actions is wind noise behaviour comparable to that of a

premium class vehicle. This significantly contributes to new Mondeo driving

comfort even at sustained high speeds. The wind noise levels for the new Mondeo

measured in Ford's state-of-the-art aero-acoustic wind tunnel are the lowest of its

vehicle class.

"Our customers will notice the benefits of our work immediately while driving the

car, although they'll appreciate it most when they're at cruising speed and want to

make a hands-free phone call, listen to the radio or have a conversation," said Dr

Karl-Heinz Bürger. "Whilst cruising we have improved the noise level by 2-4dB at

typical highway speeds. We have a metric that looks explicitly at the ability to

understand spoken language, we call it the Articulation Index. In the new Mondeo

we have achieved the same Articulation Index at 3,000rpm in comparison to what

we had previously at 2,000rpm. In other words, if you're driving at 160km/h

(99mph) it gives the impression, from the noise levels you're experiencing, that

you're driving at 120km/h (75mph)."

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6 Mondeo Powertrains

6.1: Perfect Choice for Performance and Efficiency New Mondeo customers can choose from a wide variety of powertrains including

frugal Duratorq diesels and the range-topping 220 PS 2.5-litre Duratec 5-cylinder

petrol unit as used in the Ford S-MAX and based on the engine of the

high-performance Ford Focus ST.

Key advancements in the powertrain line-up for the new Mondeo include:

• Latest state-of-the-art clutch

• Dual-mass-flywheel matched systems technology

• Upgraded hi-tech electronic engine management systems together with an

electronic throttle for precision torque control every millisecond

• Highly efficient integrated radiator/intercooler/condenser heat exchanger

packages

• Duratorq diesel engines employ sophisticated high pressure multiple injection

techniques to smooth out the combustion process, controlling cylinder

pressure rise rates and providing the ultimate in smooth NVH and clean

emissions performance

Mondeo petrol engine choice includes Ford's light and efficient 1.6-litre Duratec

Ti-VCT technology petrol engine – used in Mondeo for the first time – equipped

with a Ford Durashift iB5 5-speed transmission.

From late 2007, the range will be expanded with a new 2.3-litre Duratec HE 161 PS

4-cylinder petrol unit, coupled to the new Durashift 6-speed automatic transmission

featuring a Sport mode. This changes gear at higher engine revs and also allows the

driver to adjust their individual driving style by changing to manual mode for a more

involved driving experience.

Additional petrol units are the 2.0-litre 145 PS unit mated to the MTX-75 5-speed

- 44 -

manual transmission and the range-topping 2.5-litre 220 PS engine coupled to the

M66 6-speed manual transmission.

The Duratorq diesel line-up starts with a refined 100 PS, 1.8-litre Duratorq TDCi

coupled to Ford's Durashift 5-speed manual transmission. A 125 PS version of the

1.8-litre Duratorq TDCi is also available with a choice of the Durashift 5-speed or

Durashift 6-speed manual transmission. Ford's popular 130 PS 2.0-litre Duratorq

TDCi engine with standard Diesel Particulate Filter (DPF) is also available from late

2007 with the new 6-speed automatic transmission. A high output 140 PS 2.0-litre

Duratorq TDCi engine with standard DPF is also available with Ford's Durashift 6-

speed manual transmission.

6.2: Petrol Powertrains in Detail

1.6-Litre Ti-VCT Duratec: Designed for efficiency and economy this 1.6 petrol

engine is mated to Ford's Durashift 5-speed iB5 manual transmission. This high-tech

engine features map-controlled fully independent variable camshaft timing on intake

and exhaust camshaft.

Originally launched in the second generation Ford Focus this engine has been

further optimised to accommodate the requirements of the new Mondeo. The

specific Mondeo development targets were an improved NVH behaviour and

increased power and torque figures with very good fuel economy.

Both the cylinder head and block materials are aluminium – something that

contributes to new Mondeo models fitted with this engine having the lowest weight

of 2050kg GVM in all three bodystyles.

Two power outputs are available – 110 PS (81 kW) and 125 PS (92 kW), with both

derivatives offering a peak torque of 160Nm at 4,100rpm. A best in class torque

curve delivers 90% of this maximum torque between 2,000rpm and 6,000rpm and

85% of it between 1,500rpm and rated speed.

The 110 PS and 125 PS units when installed in the estate bodystyle reach speeds of

185km/h (115mph) and 190km/h (118mph) respectively. Acceleration figures for

- 45 -

50-100 km/h (31-62mph) in fourth gear for estate bodystyle is 14.9 seconds and

14.7 seconds for four-door and five-door in both 110 PS and 125 PS engine options;

zero to 100km/h (0-62mph) acceleration is between 12.3 and 12.9 seconds.

The availability of high torque figures at low engine speeds contributes to the new

Mondeo's fuel economy. Combined fuel consumption figures are 7.2 litres per 100

kilometres (39.2mpg) in all bodystyles for the 110 PS and 7.4 litres (38.2mpg) in all

bodystyles for the 125 PS.

2.0-Litre 145 PS Duratec HE: Ford's popular 2.0-litre Duratec HE petrol engine

offers 145 PS (107 kW) at 6,000rpm and maximum torque of 185Nm at 4,500rpm.

This efficient, affordable and reliable petrol engine was a mainstay of the previous

Mondeo range, and continues its exceptional driveability and performance in the

new model. It is lightweight and compact, offering a good performance feel and high

levels of driving quality.

The 2.0-litre Duratec HE engine is an integral part of Ford’s powertrain range,

offering an exceptional balance of torque and power combined with a high level of

fuel economy. It offers 90 per cent of peak torque in a broad range between 2,000

and 6,000rpm, while meeting strict European Stage IV emissions standards.

Equipped with this engine the new Mondeo in estate bodystyle reaches a maximum

speed of 205km/h (127mph). Acceleration figures for zero to 100km/h (0-62mph)

are 10.3 seconds for the estate bodystyle and 9.9 seconds for four-door and five-door

bodystyles.

In combined ECE mode, new Mondeo in the heaviest estate bodystyle consumes a

very reasonable 7.9 litres of petrol per 100 kilometres (35.8mpg) when equipped

with this powertrain.

Several features of the engine clearly illustrate why it provides an optimal blend of

performance, fuel economy and emissions and is a perfect choice to join the other

engines in the new Mondeo line-up:

- 46 -

• A fine-tuned metallurgical process of a congruent but inverse amount of wear

in the valve gear and between valve and valve seat helps keep the valve

clearance fully constant over a full engine life cycle of up to 250,000

kilometres

• A lightweight nylon intake manifold with equal length inlet tracts to

maximise combustion efficiency, fuel economy as well as emission and NVH

performance

• An Exhaust-Gas Recirculation (EGR) system which helps to reduce NOx

emissions and improves fuel economy

• An all-aluminium alloy construction for light weight for improved

performance and fuel economy

• The rigidity of the engine block facilitates a stiff mounting of the

transmission, which helps tremendously to minimise vibrations induced into

the body

Ford’s proven Durashift 5-speed MTX-75 manual transmission provides new

Mondeo with an effortless and refined shifting character. It features dual-cone

synchronisation in all ratios – including reverse – a measure that contributes to

reduced shifting forces.

2.3-Litre 161 PS Duratec-HE 4-cylinder: This new engine is launched later in

2007, and offers 161 PS (118 kW) at 6,500rpm and a peak torque of 208Nm at

4,200rpm with torque over 190Nm between 2,000 and 5,800rpm.

Designed for high-performance, this 16-valve, all-aluminium, DOHC design is

mated to Ford's new 6-speed automatic transmission.

Containing an abundance of engineering expertise, attributes of this engine include:

• Light Metal Alloy Cylinder Block: The 2.3-litre light metal alloy cylinder

block is bolted on to a ladder-type, cast-aluminium bedplate to strengthen the

main bearing architecture. This provides the five crankshaft bearings with

- 47 -

solid support, which together balance shafts to give smooth performance at

high revs.

• Chain-driven Overhead Camshafts: The camshafts act directly on tappets

controlling four-valves per cylinder linked to a variable intake valve timing

system. The intake camshaft can be continuously fine-tuned over 30 degrees

to deliver more useable torque and a better 'driveability' throughout the entire

rev range. It also leads to improved fuel consumption and cleaner emissions

over the entire load range across all operating conditions.

• Engine Management System: The Visteon electronic management system

controls intake cam-variation, electronic throttle position, ignition timing and

fuel injection calibration. The end result is better throttle response, improved

engine power development and very smooth and responsive vehicle control

under all conditions.

• Knock Control: The engine knock control system adjusts spark timing and

cylinder pressure to deliver best performance from 95 octane petrol. The

engine has been calibrated to operate with varying fuel octane ratings to

optimise engine power output and protect engine durability.

2.5-Litre 220 PS Duratec 5-cylinder: This engine delivers 220 PS (162 kW) at

5,000rpm and an impressive peak torque of 320Nm from 1,500 all the way through

to 4,800rpm.

This high-performance, 20-valve, all-aluminium, DOHC design is mated to Ford’s

highly successful Durashift M66 6-speed manual transmission, which features

triple-cone synchromesh for the lower gears. It is quick, responsive, and operates

smoothly for driving enjoyment.

Targeted top speed is 240km/h (150mph), and the engine provides powerful

acceleration which enables this Mondeo to compete with more overt performance

models. At 2295kg GVM the heaviest estate bodystyle takes 7.7 seconds to push

- 48 -

from zero to 100km/h (0-62mph). To reach 100km/h from 50 (31-62mph) in fourth

gear takes only 8.1 seconds thanks to the close-ratio gearbox, which complements

the sporty performance of the powertrain.

This impressive performance does not, however, come at the cost of economy.

Combined fuel consumption figures show that the new Mondeo consumes just

9.3 litres of petrol per 100 kilometres (30.4mpg) in all bodystyles.

“The Duratec 5-cylinder petrol engine is the perfect choice as the hero engine for

our new Mondeo," says Dr Jens Ludmann. "We have been very encouraged by

feedback gained by its use in the Ford Focus ST and the sporty S-MAX. Drivers

who will get the most from the sporty dynamics of the new Mondeo will find this

engine and gearbox combination to be the perfect partnership."

This exciting performance engine contains a wealth of engineering expertise.

Features that enhance the 5-cylinder engine include:

• Light Metal Alloy Cylinder Block: The 2.5-litre light metal alloy cylinder

block is bolted on to a ladder-type, cast-aluminium bedplate to strengthen the

main bearing architecture. This provides the six crankshaft bearings with

solid support, which is very important because of high operating bearing

loads for turbocharged engines.

• Belt-driven Overhead Camshafts: The camshafts actuate tappets controlling

the four-valves per cylinder linked to a dual independent variable valve

timing system. The camshafts can be continuously fine-tuned (50 degrees

intake, 30 degrees exhaust side) delivering more useable torque and a better

driveability over the whole rev range. It also leads to improved fuel

consumption and cleaner emissions over the entire load range across all

operating conditions.

• Engine Management System: The Bosch ME 9.0 electronic management

system allows independent cam-variation, hydraulic valve operation, turbo

boost, electronic throttle position, ignition timing and fuel injection

calibration. The end result is a better throttle response, improved engine

- 49 -

power development and very smooth and responsive vehicle control under all

conditions.

• Turbocharger: The compact and lightweight turbocharger is designed to be

fully integrated. It is cast in one piece along with the exhaust manifold,

resulting in increased thermodynamic efficiency.

• Knock Sensors: The engine knock sensors adjust spark timing and cylinder

pressure to deliver high-level performance from 95 octane petrol. The engine

has been calibrated to operate with varying fuel octane ratings that optimise

engine power output and protect engine durability. The use of 98 octane

premium quality fuel is rewarded by a higher power output of approximately

12 to 15 PS.

• Intercooler: Placed in front of the radiator, the heat exchanger cools the warm

air exiting from the turbocharger unit, operating with efficiencies up to 77

per cent, reducing engine air inlet temperatures from 150°C to 35°C.

6.3: Diesel Powertrains in Detail

All Ford Duratorq common-rail diesel engines fitted to the new Mondeo minimise

emissions and conform to the European Stage IV emission standards. The

technology deployed to achieve these high standards includes a new combustion

system and new fuel injectors. The 1.8-litre Duratorq diesel engine meets European

Stage IV emission levels without the need for a DPF. For markets where DPF is

required, Ford's 'coated' Diesel Particulate Filter – c-DPF – is fitted to the 2.0-litre

versions of the Duratorq engine. The internal surface of the filter is coated with a

catalyst to enable oxidation of particulates in the filter. This innovation to the

first-generation DPF removes the need for a liquid additive and therefore makes the

c-DPF maintenance-free.

1.8-Litre Duratorq TDCi: The 1.8-litre Duratorq TDCi diesel engine offers a choice

of 125 PS (92 kW) at 3,700rpm and peak torque of 320Nm at 1,800rpm or 100 PS

- 50 -

(74 kW) at 3,850rpm and peak torque of 280Nm at 1,800rpm. Ford's transient

overboost facility boosts that torque to a peak of 340Nm on the 125 PS version and

295Nm on the 100 PS derivative.

This engine offers strong engine torque performance combined with low noise levels

and excellent fuel economy.

The cylinder head and block are made of precision-cast iron. The noise-attenuating

and strength properties of a cast iron design help keep the noise considerably low at

a level that is regarded as excellent among all comparable modern diesel engines and

adds to the limousine-like qualities of the new Mondeo.

Drivers of the 1.8-litre 125 PS TDCi have a choice of two proven transmissions as it

can be mated with either the Durashift 5-speed MTX-75 manual or the Durashift

6-speed MMT6 manual. The MMT6 transmission features new triple cone

synchroniser technology for improved shifting between the lower gears.

When combined with the Durashift MMT6 gearbox, this engine provides new

Mondeo with a top speed of 195km/h (121mph) in estate bodystyle, accelerates from

zero to 100km/h (0-62mph) in 10.8 seconds and consumes 5.9 litres of fuel per 100

kilometres (47.9mpg) in the combined ECE mode. When the Durashift 5-speed

MTX-75 transmission is specified, the new Mondeo reaches a top speed of 195km/h

(121mph) in estate bodystyle, accelerates from zero to 100km/h (0-62mph) in 10.9

seconds and returns a fuel consumption of 5.9 litres per 100 kilometres (47.9mpg) in

the combined ECE mode.

The new Mondeo fitted with the 100 PS (74 kW) version of the 1.8-litre Duratorq

TDCi, boasts a maximum torque of 280Nm at 1,800rpm. Using the Durashift

MTX-75 gearbox, the estate bodystyle achieves a maximum speed of 180km/h

(112mph). Acceleration from zero to 100km/h (0-62mph) takes 12.7 seconds, and

combined fuel consumption is 5.8 litres per 100 kilometres (48.7mpg).

- 51 -

Ford has further improved its TDCi engine line-up to meet higher performance

requirements and European Stage IV emission standards. This extends an impressive

Duratorq TDCi legacy, building on current applications in Focus, C-MAX, S-MAX

and Galaxy with a balance of robust power and first-rate acoustics.

New refinements to the Duratorq TDCi 1.8-litre engine include a new combustion

system and new fuel injectors that feature micro-sac nozzles and piezo actuation

which deliver precise measurements of fuel at high pressure. This ensures efficient

and effective combustion for increased performance and reduced fuel consumption

and emissions.

2.0-Litre Duratorq TDCi: The acclaimed 2.0-litre Ford Duratorq TDCi diesel

engine is available as 130 PS (96 kW) and 140 PS (103 kW) variants, and offers

torque of 320Nm in a range from 1,750rpm to 2,240rpm. Ford’s advanced transient

overboost facility allows even stronger pulling power with a temporary peak torque

of 340Nm.

The 140 PS engine comes with Ford’s Durashift 6-speed MMT6 manual

transmission as standard and the 130 PS is offered in late 2007 with Ford's new

Durashift 6-speed automatic transmission which features a Sport mode for drivers to

change to manual mode for a more involved driving experience.

The car's combined ECE mode fuel consumption is impressively low with all

bodystyles needing just 5.9 litres per 100km (47.9mpg) of petrol in the 140 PS

engine mated to the 6-speed manual transmission.

Top speed of the 140 PS TDCi is 205km/h (127mph) for the estate and is 210km/h

(130mph) for the four- and five-door bodystyles, while zero to 100km/h (0-62mph)

acceleration is achieved in 9.8 seconds and 9.5 seconds respectively.

The cylinder head is made of aluminium, while the block is made of cast iron.

Like the smaller 1.8-litre engine, the 2.0-litre unit uses latest generation

common-rail injection technologies to balance and refine the engine's combustion

acoustic characteristics to new, low levels.

- 52 -

Single and twin pilot injections are used, together with split main injections, to

smooth out the combustion process for more progressive and more complete

combustion. This technology simultaneously optimises emissions and acoustic

behaviour.

"We have optimised and refined the diesel injection combustion process, so we have

five injections that we can give in one combustion stroke," explains Dr Jens

Ludmann. "We can differentiate the time between the injections, depending on the

rpm and load to the engine, the engine temperature and the air intake temperature.

The quantity of injections and the time that elapses between them has been finely

calibrated. To devise this system we have a matrix that is multi-dimensional to take

into account all of the variables. This combustion process gives our customers a

truly refined diesel engine with fantastic NVH levels."

The low level of fuel consumption in real-world driving gives the new Mondeo a

strong and dependable cost-of-ownership equation.

- 53 -

7 Mondeo Safety Systems

7.1: Systems Overview

The new Mondeo features an impressive no-compromise array of active and passive

safety technologies. The basic foundation for these features is the car's ultra-stiff

body structure, which reduces the deformation of the passenger safety cell. The new

Mondeo also features a new airbag for the driver's knee area and a horizontal

stroking steering column which together have further enhanced Ford's acclaimed

Intelligent Protection System (IPS).

Safety is a key focus for Ford engineers when new models are developed. The target

is to achieve optimised protection for all the car's passengers through the use of

active and passive safety systems. Active safety systems are intended to aid the

driver in avoiding a collision, while passive safety systems protect the passengers

and help reduce and avoid injuries.

It is recognised that Ford's models are performing at their best ever level in

independent crash testing in both left and right hand drive versions

"This is a family car and family cars need to have a level of safety that firmly and

safely protects all people that sit in the car," said Gisbert Gäb, Manager, Vehicle

Safety. "We employ a holistic approach and we have integrated safety into nearly

everything in the car. For every detail we have endeavoured to make the safety as

good as possible."

- 54 -

7.2: Active Driver Assistance

A number of significant new safety technologies to provide new levels of driver

control and accident avoidance are available in the new Mondeo.

In addition to the standard Anti-Lock Braking System (ABS) with Electronic

Brakeforce Distribution (EBD) and enhanced Electronic Stability Programme (ESP)

system including Electronic Brake Assist (EBA), Ford is also introducing to

Mondeo a host of available technologies that may significantly improve safety.

These include:

• Optional Adaptive Cruise Control (ACC) with Forward Alert (FA) audio and visual collision warning system and collision mitigation by braking

• Optional Interactive Vehicle Dynamics Control (IVDC) active suspension system with Continuously Controlled Damping (CCD)

• Automatic Hazard Warning Lights Activation

• Optional Tyre Pressure Monitoring System (TPMS) and Run Flat tyres

• Highly developed Advanced Front Lighting Systems (AFS)

• Optional Hill Launch Assist (HLA)

In addition to the driver assistance technologies, the braking components and system

have been carefully matched to the size, weight and performance of all bodystyles

and powertrain options of the new Mondeo. The brake discs at the rear have

increased in diameter to 302mm compared to the previous model of 280mm. Brake

friction material has been selected to provide a positive braking feel to the driver

whilst being effective and providing a good length of service throughout normal

driving conditions.

Adaptive Cruise Control

Adaptive Cruise Control (ACC) is an improved cruise control system that helps to

maintain a pre-set cruising speed. When the system senses a moving vehicle within a

preset distance ahead, ACC automatically decelerates to keep this preset distance,

and then accelerates back to cruising speed once the road is clear again. The driver

has full control of the system at all times and selects the preset distance according to

personal preference, traffic flow and road conditions.

- 55 -

Ford’s new ACC system operates as an advanced driver assistance system with the

following stages of operation:

• Freecruising Mode: A clear road without moving obstacles ahead means no

system interference, no warning signals. ACC keeps the car’s speed constant

as determined by the preset selection of the driver.

• Distance-Keeping Mode: The gap to vehicles ahead becomes shorter, as

detected by the radar sensor. ACC releases the throttle to allow speed

modulation. Then, the ACC controlled car will be following at a constant

time gap (or distance at a specific speed.) This includes the acceleration up to

the set cruise speed and deceleration up to a maximum level of around

2.4m/s ² which is a convoy-typical change of speed. (Note: The highest

possible deceleration as performed by the driver in a panic braking

manoeuvre is about three times higher at the level of approximately 10m/s²).

In developing the two operational steps of the ACC system, Ford's engineers wanted

to provide advanced driver assistance rather than remove responsibility for vehicle

control from the driver. The system is effectively an adaptive cruise control, not an

auto-pilot. Ford engineers point out that the systems are driver aids and in no way

should the driver behave in a way that is less responsible or alert as a consequence

of having these driver assistance features.

The cruise speed range stipulated by the driver is from 30-180km/h (19-112mph).

Five alternative time gap settings range between one to three seconds. The speed and

time gap settings enable the driver to make their selections according to their own

preferences, leaving them fully in control.

Forward Alert and Collision Mitigation

The ACC Forward Alert (FA) system operates within a range of 30-180km/h (19-

112mph) and offers audible and visual warnings in driving situations which may

lead to a collision with a vehicle ahead. The warning levels can be adjusted as three

steps – early, normal and late – by the driver who also has the choice to turn off the

audio and visual warnings.

- 56 -

The Collision Mitigation by Braking function works permanently in the background,

and is independent of any audio or visual warnings set by the driver. The function

prepares the brake system for immediate action when the occurrence of a collision

becomes obvious. Once the risk of imminent collision is detected the brake support

begins to engage. This brake system pre-charge enables quicker response when the

driver presses the brake pedal.

Additionally, the sensitivity of the emergency brake assist is increased which helps

to trigger full braking earlier. It is important for drivers to recognise that, although

this function can alleviate the impact of an accident, it cannot in its own right avoid

a collision.

Interactive Vehicle Dynamics Control with Continuously Controlled Damping

Ford's optional IVDC system improves vehicle stability and handling and reduces

braking distance under all conditions through working with the ABS unit to define

current road conditions and optimise the system accordingly.

CCD improves suspension performance and allows the driver to select a different

suspension character. It offers three modes: Comfort, Normal and Sport.

Additionally, the CCD interacts with the ESP system to improve the dynamic

behaviour of the car and to reduce the stopping distance on rough road surfaces

when ABS braking is applied.

Automatic Hazard Warning Lights Activation

All new Mondeos benefit from this system as standard. It aids the driver in certain

hazardous driving situations, by automatically switching on the hazard warning

lights whenever the brake performance is more than 6-7m/s², which is about 60-70

per cent of possible brake performance (10m/s²). Once switched on the hazard

warning lights can be switched off at any time by pressing the hazard warning light

switch. In addition the Hazard Warning Light Assistant can automatically switch off

the hazard warning lights.

- 57 -

Tyre Pressure Monitoring System and Run Flat Tyres

New Mondeo's optional Tyre Pressure Monitoring System (TPMS) warns the driver

when a tyre becomes deflated so that the tyre pressure or problem can be resolved

before it becomes a safety issue. The system is available with or without optional

run flat tyres enabling the driver to continue a journey even with a puncture.

TPMS has been designed to assist the driver in maintaining the correct tyre pressures

and the system provides two levels of warning. A soft alarm at 25 per cent deflation

uses a chime and a temporary warning signal appearing on the HMI instrument

cluster. At 35 per cent deflation, the warning is stronger with a permanent acoustic

and visual alarm. Tyre valve-mounted wheel sensors respond to four body-mounted

low frequency antennae, sending tyre pressure and tyre temperature signals to the

receiver unit.

The system also adjusts automatically with the change of tyres, for example from

winter to summer specification. It also takes into account any increased pressures for

heavy loads. TPMS is mandatory for run flat tyres but can be ordered as an option

with normal tyres. In the event of a puncture to the tread area, run flat tyres maintain

their structure sufficiently to continue to be used for a distance of up to 80km at

speeds not in excess of 80km/h (50mph) whilst the car is loaded at 80 per cent of its

maximum kerb weight.

Advanced Front Lighting Systems

Auto lighting with automatic windscreen wipers is available as standard on Mondeo

Ghia and Titanium X models. Once enabled, it will automatically turn on front and

tail lamps when a light sensor detects a decrease in daylight. It will also turn the

lights off once there is enough daylight to be driving without lamps. This feature

removes the task of turning the lights on and off by the driver as conditions change.

Auto lighting can be specified with any of the three available lighting systems: a

conventional H7 reflector system is fitted to the Edge series. Adaptive Front Light

System (AFS) or Bi-Xenon Headlamps are the other two systems available.

- 58 -

The new Mondeo Titanium X comes with Ford's Adaptive Front Light System

(AFS) as standard and is optional on Zetec and Ghia series. AFS uses halogen lights

which swivel – with up to fifteen degrees of movement – depending on the steering

input by the driver. This system is proven to provide better visibility when

negotiating bends, particularly on roads where the only light source is the car's

headlamps.

For sharp corners an additional H1 static cornering light source illuminates. The

safety advantage is clear; pedestrians at the roadside, animals or objects on the road

can be seen at an earlier stage when entering the curve or manoeuvring in car parks.

High intensity discharge or Bi-Xenon headlamps produce a much brighter light than

conventional halogen lamps. They offer twice the light density on the road at

one-third of the energy input of conventional lights. For the new Mondeo, the

Bi-Xenon lamps can be specified as part of a Bi-Xenon Adaptive Front Lighting

System, which includes additional static cornering lights, plus automatic headlamp

levelling and washer jets.

Static cornering lights are automatically turned on when the car is travelling below

70km/h (43mph), and the steering wheel turns at an angle of at least 30 degrees. This

helps to avoid accidents in times of reduced visibility and particularly increases the

safety of all other types of road users.

In direct comparison tests on a particular bend between conventional halogen

reflector lamps and AFS lamps, the AFS lamps cast light an additional 20 metres

into the bend. The AFS lamps also have additional blue styling filters that illuminate

when the sidelights are switched on. While they are not designed to cast light, they

contribute a stylish touch and increase the ability of other road users to see the car

whilst driving in reduced visibility.

"Internal tests have shown remarkable results between the different lamps we have

available," said Dr Jens Ludmann. "The AFS headlamps have a ten metre gain over

what is currently available on the Mondeo at 155 metres. The Bi-Xenon lamps

achieve an incredible distance of 245 metres."

- 59 -

7.3: Passive Safety – Ford's Enhanced Intelligent Protection System

Drivers of the new Mondeo will benefit from Ford’s commitment to safety with a

host of new features which enhance the car's Intelligent Protection System (IPS).

The IPS includes the latest state-of-the-art front airbags and a new driver's knee

airbag as well as side-mounted thorax airbags for the front seats plus full length

window curtain airbags that protect both front and rear passengers. The new Mondeo

also sees improvements to the neck injury protection system.

Combined with three-point safety belts, optimised pretensioners and load limiters,

anti-submarining seatframes and a horizontal stroking steering system, these features

provide the passengers with a highly comprehensive safety system.

"The combination of our horizontal stroking steering column and driver's knee

airbag are a winning formula for enhanced driver protection that we have recently

added to our vehicles," said Gisbert Gäb. "Combined with our other safety features

in the Mondeo we are effectively offering one of the safest cars on the market."

The following passive safety features come as standard on all series of the new

Mondeo:

• Enhanced Ford Intelligent Protection System (IPS) with new driver's knee airbag

• Ultra-stiff body structure for a rigid safety cell

• Improved driver protection through a horizontally stroking steering column

• Retracting safety pedals

• Optimised airbag deployment

• Enhanced safety belt system with pretensioners for front seat passengers

• Advanced seat design

• Advanced neck injury protection system for front seat passengers

• High-level child protection with ISOFIX

• Designed from the outset with enhanced pedestrian protection as an objective

New Driver's Knee Airbag

A new driver's knee airbag provides several benefits to the Mondeo driver:

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• Reduced driver movement: The pelvis movement of the driver is

limited in a crash, thus increasing the distance between the chest and

steering wheel. This minimises driver impact when the crash occurs

• Reduced crash loads: The knee airbag assists in evenly distributing the

crash loads over the driver’s body to reduce peak loads as well as

injury risks to all body parts. It provides deep airbag cushioning, fast

airbag deployment, earlier driver interaction, and improved load

distribution

• More space: With the addition of the knee airbag, Ford's designers

were able to remove some of the bulk in the driver area freeing up

more space to add to the driver's comfort whilst providing additional

driver protection

• Intelligent sequence: What makes the driver protection system so

effective is that the knee airbag, the front airbag, the pretensioners, and

load limiters all release in an intelligently designed sequence so that all

safety components work in unison. The driver movement is tuned as

both airbags deploy to protect the knee and head areas

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Ultra Stiff Body Structure

The enhanced IPS also includes an ultra-stiff body structure and rigid safety cell as

the passenger compartment's structural integrity of the car is extremely important to

passenger safety during a crash.

Straight rails and a well engineered load path distribution used in the front-end sheet

metal are designed to absorb and transfer high-speed crash energy into the body,

side structure and A-pillar, which reduces the deformation of the passenger safety

cell. Due to the stiff outer waistline the side doors could be integrated into the load

path, energy load during an accident is absorbed and stress is reduced in the

passenger safety cell as forces are distributed rather than forcing the protection zone

to collapse.

The new Ford Mondeo has a door-ring reinforcement and a B-pillar reinforcement

made of ultra-high-strength boron steel to improve crash integrity. The use of

ultra-high-strength steel in the A-pillar, roof side rail and rocker helps to provide a

sleek, lightweight design. The combination of different high-strength steel used in

the B-pillars contributes to balanced side impact behaviour as well.

"In the safety world there is a term that we use to refer to a vehicle's rigidity and its

ability to absorb and deflect impacts," explained Gisbert Gäb. "We call this the

'crash pulse' of the vehicle, meaning the deceleration. With Ford's large cars we have

optimised the crash pulse and adapted the restraint system accordingly. This takes

the occupant protection to new standards in the latest Mondeo."

Internal rear crash tests also include offset tests at speeds of 80km/h (50mph) to 70

per cent of the rear of the car. These tests do not necessarily comprise part of the

independent testing regime of alternative territories in which the new Mondeo is

offered.

Advanced Horizontal Stroking Steering Column

A further enhancement to driver protection on the new Mondeo is the advanced

horizontal stroking steering column. This is an improvement over the previous

model that utilised a stroking steering column.

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This feature adapts the stroke direction to the driver’s impact direction, thus

allowing for more effective energy absorption from the steering column. The

amount of intrusion into the cabin is reduced as the column moves away from the

driver under load instead of stroking down axially. The steering column strokes

away for nearly 90mm in the horizontal direction. Reach and rake comfort

adjustment to enable all drivers to tailor the steering wheel position is not impeded

by this safety feature.

This steering column was an industry first when introduced in the latest Ford Focus

and has gone on to achieve recognition in its further-enhanced version in the Ford

S-MAX and new Galaxy models. This column, also used in the new Mondeo, is a

good example of customer benefits derived from Ford Motor Company’s Global

Shared Technologies initiative.

In combination with the knee airbag, the horizontally stroking steering column

offers a comprehensive safety system for drivers of the new Ford Mondeo. In the

event of a crash the benefits are threefold:

• Increased driver survival space: The comfort adjustment is

directional, decoupled from the crash stroke. During a high-speed

frontal impact, the steering column strokes horizontally and thereby

increases the driver’s remaining survival space

• Advanced energy absorption and stroke length: This leads to improved

management of head and chest load levels during impact

• Steering column load limiting function: The steering column also

offers a load limiting function for the driver’s legs in case of an impact

of the knee to the steering column

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Safety Pedals

Another critical factor in a crash situation is the response of the foot pedals. In the

new Mondeo the pedals have been engineered with a retraction mechanism so that

they give way upon intrusion during a crash.

In case of an intrusion, the lightweight pedals will be pressed against the lower cross

beam and then will fold away from the driver’s feet. A foam pad and a heel catcher

serve a dual purpose: they provide additional protection and a comfortable rest for

the driver’s left foot both in left hand drive and right hand drive versions.

Optimised Airbag Deployment

Much care has been taken to create a state-of-the-art airbag system that offers

protection to the passengers in a wide range of impact scenarios.

Dual front airbags and thorax side airbags for driver and front passenger are standard

on the new Mondeo as are the curtain airbags protecting both seat rows in case of a

side impact. The driver's knee airbag also appears as standard equipment on all

models.

The window curtain airbag system allows the airbag to be positioned between an

intruding obstacle and the passenger’s head and shoulder even if the distance in

between has already become very small in the impact. The addition of the driver's

knee airbag to the new Mondeo raises the total number of airbags to seven.

The onboard computer systems tailor the airbag deployment depending on the

collision. Exhaustive testing means that car speeds are referenced to different

obstacles in order to provide early interaction between the passengers and the airbag

in the event of a collision. Within 30 milliseconds of a fire signal being delivered to

the airbags, they are inflated.

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Safety Belt System

The advanced safety belt system fitted to new Mondeo provides several key safety

features.

Front safety belts have pyrotechnic pretensioners and load limiting retractors that

tighten to reduce body movement in the event of airbag deployment. The retractors

control the force applied to the safety belt wearer's chest upon impact.

Pretensioners have conventionally been positioned on the safety belt buckle. Ford's

safety engineers have analysed this closely and have developed the system further

by placing the pretensioners onto the vertical retractor. The advantage is that when

deployed, any slack in the belt is removed more efficiently with a retractor

pretensioner rather than a buckle pretensioner. This gives enhanced restraint to the

upper torso which is where it is immediately needed. This alteration is also visually

preferable as the pretensioners are hidden in the car's B-pillars and therefore not

visible to the passengers.

The finely tuned interaction of airbags, load limiters, adjustable safety belt anchors,

anti-twist belt material, and optimised belt routing all combine to maximise

passenger protection.

Advanced Seat Design

The new Mondeo seats were designed and built with comfort, safety, ergonomics

and style in mind. While the driver's seat previously had a beltminder, this feature

has been extended to the passenger side to also audibly alert the front seat passenger

when their safety belt is not being worn whilst the car is moving. In addition, the

density and structure of the seat foams guide the passengers in the event of a

collision.

The seats have anti-submarining bases to help prevent passengers sliding beneath the

safety belt in an impact.

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Advanced Neck Injury Protection System

With Mondeo's new Advanced Neck Injury Protection system, the advanced

headrest frontal shape and active mechanism lead to minimal relative movement

between head and upper body during low speed rear impacts. Early guidance keeps

the head and neck free of impulsive movement, resulting in less neck strain. Three

components are critical to the success of the system:

• Headrest designed for optimum protection of all passenger sizes,

including a headrest locking feature

• An active protection system that minimises relative movement

between head and neck by the headrest pushing towards the head

during a rear impact

• Seatback foam which allows controlled guidance of the passenger

The active headrest has been further developed from the system used in the previous

Mondeo model.

Child Protection & ISOFIX

Family car customers – including Ford engineers – take the safety of their children

very seriously. Consequently, the new Mondeo is intended to be one of the safest

cars in which children can travel.

To give customers maximum choice as to where in the car they carry their children,

Ford is offering a Passenger Airbag Deactivation key-switch option for the front

passenger seat. Ford dealers perform the installation of the switch, and this benefits

both dealer and owner in terms of greater individual customer communication and

information.

On second row outboard seats Ford also offers ISOFIX anchors for child seats,

which gives optimum child protection in a collision. Additionally, Ford offers a

range of accessory ISOFIX child seats as part of the company’s co-operation with

Britax-Römer.

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Pedestrian Protection

Ford of Europe's design team has worked closely with the company's safety

engineers to deliver a stylish design that meets all of the latest pedestrian protection

legislation.

Internal tests are used to assess initial designs for pedestrian safety – lower leg to

bumper, upper leg to bonnet edge, child head to bonnet, and head to bonnet top and

windscreen. Six separate features are used by the new Mondeo, all with the objective

of alleviating pedestrian injury:

• The car's body is elongated by the use of additional foam in critical

areas. A foam layer in front of the bumper steel structure absorbs leg

impact energy

• A sloping bonnet line allows for greater space between the bonnet, the

engine block and the engine ancillaries. The bonnet design adds to the

compliance of the requirement for softness. The inner structure is a

highly engineered honeycomb design that adds to the absorbent

properties to reduce energy

• A lower leg stiffener is introduced to the lower part of the Mondeo

bumper system. The plastic element collapses in a specifically

designed manner to reduce the angle of the knee bend during an

impact

• Headlamp design and construction enables the headlamps to break

away easily in the case of impact with a pedestrian

• Special brackets have been developed for the windscreen wiper

spindles. Under moderate loads they retract into their fixings for

further energy absorption thus becoming less of a hazardous point

• The front wings are also held in place by specially designed and

manufactured fixing brackets. These are intended to break away in the

event of a collision

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8 Manufacturing and Environmental Commitment

8.1: Ford Genk Gears Up to Deliver New Mondeo

The assembly plant in the Belgian city of Genk has seen a long line of successful

Ford models over the decades, including the Transit, Sierra and Escort. Genk has

also been the manufacturing home to the Mondeo since its original launch in 1993.

Comprising 345 acres, the site at Genk has been manufacturing vehicles since 1964

and the plant is ideally situated to benefit from the local road and rail infrastructure.

Two supplier parks at the site play a pivotal role in maintaining production

throughput and providing just-in-sequence delivery of parts to the assembly lines.

Before initial steps were taken to build prototypes, Ford’s special C3P Virtual Series

System was used extensively.

The C3P system uses an integrated computer based toolset for modelling and

information management. C3P – now an essential part of Ford’s computer based

product development system – is an integration of design and analysis tools within a

single collaborative environment. The term ‘C3P’ is derived from four key elements:

• CAD - Computer-Aided Design

• CAM - Computer-Aided Manufacturing

• CAE - Computer-Aided Engineering

• PIM - Product Information Management

This bundle of technologies allows engineers to address design and packaging issues

as well as cross-carline interfaces with computer-generated models.

Another enormous benefit from C3P is that by replacing the physical prototypes

with the digital mock-ups, time to market and development costs are significantly

reduced.

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The transition phase in stepping up production of the new Mondeo from the

prototypes and initial build phase has already seen a reduction in assembly time

from the previous Mondeo to the new model. Each car takes approximately

25 per cent less time to build.

"This is an amazing achievement considering the additional electrical complexity in

comparison to the previous Mondeo model," said Dr Jens Ludmann. "To reduce the

build time while maintaining our strict quality standards is the kind of

accomplishment any manufacturing plant would be proud of."

A key development in the technology used to build the new Mondeo is the

utilisation of laser-brazing. Conventionally, the side panels and roof are welded

together, leaving a joint that is traditionally covered with a plastic trim. With laser-

brazing, the roof and bodysides can be joined together more effectively and without

a visible join for a high quality appearance. This technology is new to Ford and was

fundamental in helping to deliver the new Mondeo’s expressive design and high

levels of craftsmanship.

"On the roof you can’t see any joins, it looks like one big panel." Said Dr Jens

Ludmann.

8.2: Sustainability as an Integral Part of the Business

Sustainability plays a key role in Ford Motor Company's policies. The development

and integration of a sustainability management system encompasses the pursuit of

improved air quality and fuel efficiency during the vehicles' life cycles, together

with built in recoverability at the time they have completed their useable life.

Ford Motor Company is committed to socially and environmentally responsible

manufacturing. Each manufacturing plant has a workforce dedicated to the task of

analysing the use of energy and resources to identify and make suggestions that are

adopted as working practice and policy to make improvements.

Ford cars are the first and only vehicles that received the German TÜV

organisation's allergy-tested interior certificate and achieved the British Allergy

Foundation's Seal of Approval.

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Recycling

Ford was the first automotive company to issue worldwide vehicle design recycling

guidelines to engineers and suppliers in 1993. In the meantime, this approach was

broadened towards a design-for-environment to incorporate aspects of sustainability.

One result is that 264 parts in Ford of Europe's vehicles are now made with recycled

non-metallic materials. This helped to divert approximately 16,000 tons of waste

from landfills in 2005 alone. Regarding material from renewable and sustainable

sources, 13,500 tons were used in 205 different Ford vehicle parts in Europe at the

end of 2005.

Ford’s recycling teams have implemented the extensive use of recycled and

renewable materials in the new cars produced at Genk. For instance, door panel

inserts and other insulation materials consist of renewable materials, such as wood,

kenaf and cotton. Recycled plastic is also utilised for insulation and sound

deadening. The materials – predominantly grades of recycled polypropylene and

polyamide – do not compromise vehicle performance or quality.

Weight

An important factor for Ford in material selection is weight as saving weight

improves fuel economy. In parallel to achievements in weight reduction through

integration and design optimisation, improvements have also been achieved through

material and process changes.

Environmentally Sound Production

As an industry leader in its commitment to environmentally sound production, Ford

became the first automotive company to certify all its manufacturing plants

worldwide under ISO 14001.

Since 2000, Ford facilities worldwide, including Genk, have improved energy

efficiency by over 16 per cent. Ford is targeting a further 1 per cent improvement,

year on year.

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Another issue the Ford environmental programme addresses is the reduction of

volatile organic compounds (VOC). These compounds are emitted from

manufacturing facilities, including painting operations.

A significant step towards VOC reduction at Ford Genk was taken with the recent

production start of the S-MAX and the new Galaxy and is being carried forward for

new Mondeo production. By raising the paint shop’s level of automation, Ford has

achieved an increase in efficiency and a decrease in emissions. The use of paint with

a higher portion of solid content (and therefore fewer solvent agents) helps in cutting

VOC emissions further.

Advanced Sustainability Assessment

From the very start of its development, the new Mondeo has been subject of the

Ford Product Sustainability Index (PSI). The PSI is currently applied by engineering

management for internal purposes to track and encourage progress towards

environmental, social and consumer economic objectives as part of the Ford product

development process.

PSI incorporates the whole product life cycle; from raw material construction

through to production, vehicle operation, right through to the end-of-life operations.

The reflected indicators include life cycle global warming, life cycle air quality, use

of sustainable material, restricted substances – including allergy-tested interior – and

drive-by exterior noise as well as social and economic aspects, which include

pedestrian and passenger safety, mobility capability and cost-of-ownership. Using

the PSI, Ford can target continuous improvement from one vehicle generation to the

next.

Ford of Europe's strategy is clearly aligned to the global targets of Ford Motor

Company:

• With the new voluntary Product Sustainability Index (PSI), Ford of

Europe is taking a leading role within the automotive industry in

holistically addressing the environmental, societal and economic

impact of its vehicles from the earliest stages of their development

- 71 -

• PSI is the innovative combination of a comprehensive range of

sustainability criteria and their integration into the product

development process right from the beginning, which makes Ford's

PSI exceptional in the automotive industry – and beyond

• The PSI provides a basis for permanent evaluation and improved

sustainability performance for new generations of vehicles

• The all-new Mondeo follows the acclaimed S-MAX and the new

Galaxy models, which were the first new models developed with PSI

in mind

• PSI demonstrates how Ford of Europe is fundamentally reassessing the

way business is conducted by putting sustainability at the heart of our

business

PSI is part of Ford Motor Company's global commitment to make mobility more

sustainable.

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9 New Mondeo: A Car to Change Perceptions

The all-new Ford Mondeo epitomises Ford’s ‘Feel the Difference’ philosophy and is

a step change for Ford’s large passenger car range with desirability being the

ultimate focus of its development.

“We want the new model to change fundamentally the overall perception of Ford

Mondeo in Europe,” said Joe Bakaj, For of Europe’s Vice President for Product

Development. “New Mondeo has built on all of the strengths of its predecessor but

now has more design emotion, more refinement, more technology and more

presence. We’re proud of it, and we know our customers will be too.”

###

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10 Mondeo Technical Data

ALL-NEW MONDEO TECHNICAL SPECIFICATIONS (Preliminary Data)

Features Structure Computer-optimised, high-efficiency, unitary-welded steel �Safety elements - Body Ford Intelligent Protection System (IPS) with optimised body structure to

achieve moderate deceleration levels whilst minimizing intrusions into the passenger compartment in offset and straight front impacts, side impacts and rear impacts: • Front bumper system, consisting of Boron (Ultra high strength steel)

bumper beam and HSS (High Strength Steel) crash cans, bolted to the front side rails (to minimise repair cost in a low speed impact, also considering slightly angled impacts), optimised for maximum energy absorption in low and high speed crash events, with 70mm foam in front of the beam to minimise effect of an impact to pedestrians

• Rear bumper system, consisting of a Boron bumper beam with welded HSS crash cans, optimised for maximum energy absorption in low speed impact to minimise repair cost, also considering slightly angled impact directions

• Front and rear energy-absorbing crumple zones through well defined deformation patterns of the main structural elements such as bumper systems; front and rear laser welded siderails with optimised panel gauges; optimised front subframe with controlled deformation pattern serving as additional load path and energy absorbing unit

• Stiff occupant protection cell through utilisation of HSS and UHSS materials (Boron steel) in the A and B pillar, roof and sill architecture, supported by lateral structural elements in floor and roof, also delivering excellent side impact protection, cross beam and steering column support to enable well controlled steering column kinematics and ride down during the interaction with a forward moving front occupant in a high speed frontal crash

� �Passive safety and restraint system elements

Ford Intelligent Protection System (IPS) featuring: • Full size driver (~60L tethered volume) and 110L passenger airbags

featuring latest single stage inflator technology • Driver knee airbag with computer optimised trapezoid bag shape, ~22L

volume, two tethers. The knee airbag significantly improves occupant crash kinematics and load distribution resulting in improved leg but also upper body protection.

• High power pyrotechnic belt pretensioners (retractor pretensioner) and belt load limiting for front-seat safety belts

• Standard inflatable side curtains for front, and second row seat occupants

• Standard thorax-protecting side airbags for front occupants • Horizontal stroking steering column for optimised energy absorption

and leg protection • Safety Pedals • Active neck injury protection system on front seats • Three-point safety belts in all positions • Safety belt reminders for driver & front passenger • ISOFIX child seat attachment anchors on outboard seats second row • Approval for universal ISOFIX child seats • Optional passenger airbag deactivation kit (dealer fit). • Optimisation for wide range of human body profiles, from 5

- 74 -

per cent female to 95 per cent male • Frontal crash severity sensing

� Bumper system Damage-resistant, full-depth moulded reinforced polypropylene Security system elements • Perimeter alarm with interior scanning capability (optional)

• Advanced Ford PATS immobiliser • Key fob and manual-key operated central locking • Global closing feature for power windows, sunroof

Corrosion protection 24-stage paint and body protection process, including zinc precoating for all

relevant exterior panels, optimised dip phosphate coat, electrocoat primer, primer/surfacer and basecoat/clearcoat system, plus comprehensive cavity wax injection, PVC underbody coating and stone chip protection. Thick PVC sealing beads for flanges. Front plastic wheel arch liners, rear textile wheel arch liners, anti scuff strips on inner doorsills.

Suspension Front – MacPherson type front suspension with L–shaped lower control

arms, rear bushes with hydraulic damping, isolated perimeter subframe Rear – SLA type multilink rear suspension with isolated subframe

(one longitudinal link, three lateral links) Springs mounted to body

Steering Type – Rack and pinion steering Direct steering gear ratio: 15.1:1 Variable displacement pump (except 2.5L Duratec 220 PS: hydraulic pump) Turning circle (m) – 11.45 (Kerb-to-Kerb) Turns lock-to-lock – 2.71 Brakes Actuation:

8/9" tandem booster, effective ratio 7.5:1 Cylinder diameter 26.99mm, stroke 36mm Pedal ratio: 3.8

� Front –vented discs, 300 x 28mm

Effective radius: 124mm Cylinder diameter: 60mm Friction material: Jurid 220

� � Rear –solid discs, 302 x 11mm

Effective radius: 132mm Cylinder diameter: 38mm

� Modulation:

ABS, Traction Control, ESP, EBD, EBA Optional IVDC (CCD, Hill Launch Assist) Optional ACC (Adaptive Cruise Control, Collision Mitigation by Braking, Forward Alert collision warning)

Wheels and tyres Wheel type Pressed

Steel/Alloy Pressed

Steel/Alloy Alloy Alloy

Wheel size 6.5 x 16" x 50 6.5 x 16" x 50 7.5 x 17" x 55 8.0 x 18" x 55 Tyre size 205/55 R 16 215/55 R 16 235/45 R 17

235/45 RF 17 235/40 R 18

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Spare wheel and tyre Mini-spare wheel

Mini-spare wheel

Mini-spare wheel

Mini-spare wheel

Engine Data Engine Type 1.6L Duratec 16V Ti-VCT 110 PS/81 kW Four cylinders, two

independent fully variable camshafts Displacement (cc) 1596

Bore (mm) 79 Stroke (mm) 81.4 Fuel type, grade 95/98 RON Max power (ISO kW/PS) 81/110 At engine speed (rpm) 6300 Max torque (ISO Nm) 160 Max BMEP (ISO kPA) 12.6 At engine speed (rpm) 4100 Compression ratio 11:1 Cylinders 4 Cylinder head Aluminium Cylinder block Aluminium Crankshaft 4 counterweights Valves per cylinder 4 Valve gear Tappets Included angle between valves 41.75° Valve sizes (mm) Intake 30

Exhaust 24.1 Turbocharger n.a. Camshaft drive Belt Pistons Aluminium Connecting rods Sinter Forged Engine management Siemens ECM EMS2101 16 Bit Fuel injection EFI Ignition Tower Coil Emission controls Hego/CMS (Dual Binary Sensors) Emission level Euro Stage IV TRANSMISSION Transmission type: Manual Ford iB5 manual 5-speed Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

n/a 0.88 1.11 1.41 2.04 3.58 -3.62 4.06

Clutch Conventional Clutch diameter (mm) 220/160 Engine Type 1.6L Duratec 16V Ti-VCT 125 PS/92 kW Four cylinders, two fully

independent variable camshafts Displacement (cc) 1596

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Bore (mm) 79 Stroke (mm) 81.4 Fuel type, grade 95/98 RON Max power (ISO kW/PS) 92/125 At engine speed (rpm) 6300 Max torque (ISO Nm) 160 Max BMEP (ISO kPA) 12.6 At engine speed (rpm) 4100 Compression ratio 11:1 Cylinders 4 Cylinder head Aluminium Cylinder block Aluminium Crankshaft 4 counterweights Valves per cylinder 4 Valve gear Tappets Included angle between valves 41.75° Valve sizes (mm) Intake 30

Exhaust 24.1 Turbocharger n.a. Camshaft drive Belt Pistons Aluminium Connecting rods Sinter Forged Engine management Siemens ECM EMS2101 16 Bit Fuel injection EFI Ignition Tower Coil Emission controls Hego/CMS (Dual Binary Sensors) Emission level Euro Stage IV TRANSMISSION Transmission type: Manual Ford iB5 manual 5-speed Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

n/a 0.88 1.11 1.41 2.04 3.58 -3.62 4.06

Clutch Conventional Clutch diameter (mm) 220/160

- 77 -

Engine Type 2.0L Duratec HE 145 PS/107 kW Four cylinders in line DOHC Displacement (cc) 1999

Bore (mm) 87.5 Stroke (mm) 83.1 Fuel type, grade 95 RON Max power (ISO kW/PS) 145/107 At engine speed (rpm) 6000 Max torque (ISO Nm) 185 Max BMEP (ISO kPA) 11.9 At engine speed (rpm) 4500 Compression ratio 10.8:1 Cylinders 4 Cylinder head DOHC Gravity die cast aluminium alloy with sintered valve guides

and seats Cylinder block High pressure die casting aluminium alloy with bed plate Crankshaft Cast iron with 47mm-diameter crankpins, eight counterweights, five

52mm-diameter main bearings and damped front pulley Valves per cylinder 4 Valve gear Single chain, dock Included angle between valves 29° Valve sizes (mm) Intake 32.5

Exhaust 28.0 Camshaft drive Single chain Pistons Drop forged aluminium Connecting rods Sinter forged steel Engine management Visteon Levanta with Can-Bus and individual cylinder knock control Fuel injection Sequential electronic fuel injection (SEFI) Ignition Coil on plug, distributorless electronic Emission controls Close coupled three way catalyst system with heated oxygen sensors

and catalyst monitor sensors post catalyst Emission level Euro Stage IV TRANSMISSION Transmission type: Manual Ford MTX-75 manual 5-speed with double synchromesh on all ratios

(including reverse) and revised cable-shift mechanism Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

0.85 1.11 1.48 2.14 3.67 n/a

-3.73 4.07

Clutch Self Adjust Clutch diameter (mm) 240/170

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Engine Type 2.3L Duratec-HE 16V 161 PS/118 kW Four cylinders DOHC Displacement (cc) 2261

Bore (mm) 87.5 Stroke (mm) 94 Fuel type, grade 95 RON Max power (ISO kW/PS) 161/118 At engine speed (rpm) 6500 Max torque (ISO Nm) 208 Max BMEP (ISO kPA) 1156 At engine speed (rpm) 4200 Compression ratio 10.6:1 Cylinders 4 Cylinder head Aluminium Cylinder block Aluminium Valves per cylinder 4 Valve gear Direct acting DOHC. Variable intake camshaft timing Included angle between valves 39° Valve sizes (mm) Intake 35

Exhaust 30 Camshaft drive Chain Pistons Aluminium Engine management Visteon ESU-415 Fuel injection PFI (Port Fuel Injection) Ignition Coil on Plug Emission controls Hego/CMS (Dual Binary Sensors) TRANSMISSION Transmission type: Automatic AWF21 automatic 6-speed Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

0.686 0.859 1.155 1.566 2.37

4.148 3.39

3.329

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Engine Type 2.5L Duratec 20V 220 PS/162 kW Five cylinders DOHC Displacement (cc) 2521

Bore (mm) 83.0 Stroke (mm) 93.2 Fuel type, grade 95/98 RON Max power (ISO kW/PS) 162/220 At engine speed (rpm) 5000/min Max torque (ISO Nm) 320 Nm Max BMEP (ISO kPA) 16.0 At engine speed (rpm) 1500-4800/min Compression ratio 9.0 Cylinders 5 in line with exhaust manifold to the back side Cylinder head Gravity die casting aluminium alloy with sintered valve guides and

seats Cylinder block High pressure die casting aluminium alloy with bed plate Crankshaft Forged steel with 50mm diameter crankpins, fully balanced with ten

counterweights, six 65mm diameter main bearings and damped front pulley, overall weight 21.5kg

Valves per cylinder 4 Valve gear DOHC with direct-acting mechanical shimless tappets Included angle between valves 58° Valve sizes (mm) Intake 31.0

Exhaust 27.0 Turbocharger Kuehnle, Kausch & Kopp integrated turbo system, one piece precision

cast thin wall iron housing Camshaft drive Tooth belt with dynamic tensioner, integrated hydraulic cam timing

variation inside the drive wheel (CVVT), timing variation 50° (intake), 30° (exhaust)

Pistons Lightweight short-skirt silicon-aluminium alloy piston with graphited piston sleeves, pure piston weight 290g (with piston pin, piston rings

and clips) 412g Connecting rods Forged steel with fracture-split big ends, 143mm length Engine management Bosch ME 9.0 Motor-Management System for injection and ignition

with 2Mb of Flash capacity, Euro Stage IV/ULEV Emissions, consistent Lambda 1-injection strategy across the full load range

Fuel injection Sequential electronic fuel injection (SEFI) Ignition Coil on plug, electronic distributorless Emission controls Close coupled three way catalyst system with heated oxygen sensors

and catalyst monitor sensors post catalyst Emission level Euro Stage IV with electronic on-board diagnostics (EOBD) TRANSMISSION Transmission type: Manual Ford M66 manual 6-speed Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

0.65 0.78 0.95 1.27 1.91 3.39 -3.23 4.00

Clutch Hydraulically operated self adjust clutch system; dual mass flywheel Clutch diameter (mm) 240

- 80 -

Engine Type 1.8L Duratorq TDCi 100 PS/74 kW Displacement (cc) 1753

Bore (mm) 82.6 Stroke (mm) 82.0 Fuel type, grade Diesel Max power (ISO kW/PS) 74/100 At engine speed (rpm) 3850 Max torque (ISO Nm) 280 (295 transient overboost) Max BMEP (ISO kPA) 17.2 At engine speed (rpm) 1800 Compression ratio 18.5:1 Cylinders 4 in line Cylinder head Cast iron Cylinder block Cast iron Crankshaft Drop forged steel Valves per cylinder 2 Valve gear Chain/tooth belt Included angle between valves 0° Valve sizes (mm) Intake 36.5

Exhaust 32.0 Turbocharger Variable-nozzle Garrett GT with intercooler Camshaft drive SOHC Pistons Forged aluminium, gallery-cooled Connecting rods Drop forged steel, fracture split Engine management Ford second generation common rail diesel engine management

system Fuel injection Delphi common-rail with Pilot injection

- Dual stage fuel pump with inlet metering valve - Spherical high-pressure common-rail with fuel

pressure control valve - Slim profile servo injectors with six-hole spray

pattern - Fuel filter with return control valve - Injector Driver Module (IDM) with individual

injector characterisation, noise reduction technology Emission controls Oxidation catalyst, EGR and EGR cooler Emission level Euro Stage IV TRANSMISSION Transmission type: Manual Ford MTX-75 manual 5-speed Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

n/a 0.67 0.87 1.26 2.05 3.80 3.73 3.56

Clutch Self adjust Clutch diameter (mm) 240/155

- 81 -

Engine Type 1.8L Duratorq TDCi 125 PS/92 kW Displacement (cc) 1753

Bore (mm) 82.5 Stroke (mm) 82.0 Fuel type, grade Diesel Max power (ISO kW/PS) 92/125 At engine speed (rpm) 3700 Max torque (ISO Nm) 320 (340 transient overboost) Max BMEP (ISO kPA) 19.9 (21.65 transient overboost) At engine speed (rpm) 1800 Compression ratio 18.5:1 Cylinders 4 in line Cylinder head Cast iron Cylinder block Cast iron Crankshaft Drop forged steel Valves per cylinder 2 Valve gear Chain/tooth belt Included angle between valves 0° Valve sizes (mm) Intake 36.5

Exhaust 32.0 Turbocharger Variable-nozzle Garrett GT 18 with intercooler Camshaft drive SOHC Pistons Forged aluminium, gallery-cooled Connecting rods Drop forged steel, fracture-split Engine management Ford second generation common rail diesel engine management

system Fuel injection Delphi common-rail with pilot injection

- Dual stage fuel pump with inlet metering valve - Spherical high-pressure common-rail with fuel

pressure control valve - Slim profile servo injectors with six-hole spray

pattern - Fuel injector with return control valve - Injector Driver Module (IDM) with individual

injector characterisation, noise reduction technology Emission controls Oxidation catalyst, EGR and EGR cooler Emission level Euro Stage IV TRANSMISSION Transmission type: Manual Ford MTX-75 manual 5-speed or MMT6 manual 6-speed Gear ratios MTX-75 5-speed MMT6 6-speed

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

n/a 0.79 0.67 0.94 0.87 0.87 1.26 1.24 2.05 1.95 3.80 3.58 3.73 -1.42 3.56 FD1: 3.81 (3/4/5/6)

FD2: 2.77 (Reverse/1/2) Clutch Self-adjust Clutch diameter (mm) 240/155

- 82 -

Engine Type 2.0L Duratorq TCDi 130 PS/96 kW Displacement (cc) 1997

Bore (mm) 85.0 Stroke (mm) 88.0 Fuel type, grade Diesel 49CZ min. / EN590 Max power (ISO kW/PS) 96/130 At engine speed (rpm) 4000 Max torque (ISO Nm) 320 (340 in transient overboost condition) Max BMEP (ISO kPA) 2013 At engine speed (rpm) 1750-2250 Compression ratio 17.9:1 Cylinders 4 in line Cylinder head Cast aluminium Cylinder block Cast iron, closed deck Crankshaft Drop forged steel, 5 main bearings, 8 counterweights Valves per cylinder 4

- Timing Belt (Crankshaft to intake) with dynamic tensioner Valve gear - Intake to exhaust chain with hydraulic tensioner Included angle between valves 0° Valve sizes (mm) Intake 28.0

Exhaust 23.1 Turbocharger Variable Geometry Turbocharger with position sensor Camshaft drive Forged/composite Camshaft Pistons Aluminium-Silicon Alloy with Molybdenum-Coating, three piston rings Connecting rods Steel forged, trapezoid shaped small end, split big end Engine management Ford second generation common rail diesel engine management system

Common Rail Multiple Injection: - Tubular high-pressure common-rail with fuel pressure

1600/1650 bar - Twin control valves (PCV/VCV), three pistons +

internal transfer pump - Centrally located injectors, piezo actuated, with 6-hole

micro sac. - Closed loop 'minimum injection quantity' control

Fuel injection Return control valve Emission controls Coated Diesel Particulate Filter (Ford cDPF)

Oxidation catalyst Emission controls Water cooled EGR Emission level Euro Stage IV TRANSMISSION Transmission type: Ford AWF21 automatic 6-speed Gear ratios AWF21 6-speed

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

0.69 0.86 1.16 1.56 2.37 4.15 3.39 3.33

Clutch Self-adjust n.a. Clutch diameter (mm) 240/155 n.a.

- 83 -

Engine Type 2.0L Duratorq TCDi 140 PS/103 kW Displacement (cc) 1997

Bore (mm) 85.0 Stroke (mm) 88.0 Fuel type, grade Diesel 49CZ min. / EN590 Max power (ISO kW/PS) 103/140 At engine speed (rpm) 4000 Max torque (ISO Nm) 320 (340 in transient overboost condition) Max BMEP (ISO kPA) 2013 At engine speed (rpm) 1750-2240 Compression ratio 17.9:1 Cylinders 4 in line Cylinder head Cast aluminium Cylinder block Cast iron, closed deck Crankshaft Drop forged steel, 5 main bearings, 8 counterweights Valves per cylinder 4

- Timing Belt (Crankshaft to intake) with dynamic tensioner Valve gear - Intake to exhaust chain with hydraulic tensioner Included angle between valves 0° Valve sizes (mm) Intake 28.0

Exhaust 23.1 Turbocharger Variable Geometry Turbocharger with position sensor Camshaft drive Forged/composite Camshaft Pistons Aluminium-Silicon Alloy with Molybdenum-Coating, three piston

rings Connecting rods Steel forged, trapezoid shaped small end, split big end Engine management Ford second generation common rail diesel engine management

system Common Rail Multiple Injection:

- Tubular high-pressure common-rail with fuel pressure 1600/1650 bar

- Twin control valves (PCV/VCV), three pistons + internal transfer pump

- Centrally located injectors, piezo actuated, with 6-hole micro sac.

- Closed loop 'minimum injection quantity' control Fuel injection Return control valve Emission controls Coated Diesel Particulate Filter (Ford cDPF)

Oxidation catalyst Emission level Water cooled EGR TRANSMISSION Transmission type: Manual Ford MMT6 manual 6-speed Gear ratios

6th 5th 4th 3rd 2nd 1st

Reverse Final Drive

0.79 0.94 0.87 1.24 1.95 3.58

-1.423 FD1: 3.81 (3/4/5/6)

FD2: 2.77 (Reverse/1/2) Clutch Self adjust Clutch diameter (mm) 240/155

- 84 -

Dimensions and capacities

Exterior (mm) GCIE Code

Four-door Five-door Estate

Overall length L103 4844 4778 4830 Overall width without mirrors W103 1886 Overall width with mirrors W114 2078 Overall height max (empty vehicle)

H100-B 1500 1500 1512/1548***

Wheelbase L101 2850 Front tread W101-1 1589**** Rear tread W101-2 1605**** Front overhang 921 921 921 Rear overhang L105 1073 1007 1059 Interior (mm) Front (mm) Headroom H61-1 996 Leg room range L51-1 1115-1151 Shoulder room W3-1 1448 Rear (mm) Headroom H61-2 976 965 1004 Leg room (Nominal 95% driver pos)

L51-2 950

Shoulder room W3-2 1433 Luggage area (mm) Maximum cargo height H201 - - 849 Width between wheel arches W202 1135 1130 1141 Length at floor to 2nd row L212-2 - 1171 1183 Length at floor to 1st row L212-1 - 1886 1920 Angle for length at floor 1st A212-1 - 12.7 deg 10.0 deg

Liftover height empty vehicle H196 700 700 579 Luggage Volume (litres) Closed luggage compartment V210 550/535*/493** 540/528*/486** 554/542*/494** Volume to roof behind 2nd row V215 - - 940/928*/976** Volume to belt behind 1st row V212 - 892/880*/838** 872/860*/908** Volume to roof behind 1st row V214 - 1460/1448*/1390** 1745/1733*/1685** *Equipped with mini spare wheel ** Equipped with optional full size spare wheel *** Measured to roof rail **** Equipped with 205/55 R 16 tyres L51-1 in rearmost seating position L51-2 with front seat in 95% seating position

- 85 -

Weights � Minimum

kerbweight (kg) Maximum kerbweight (kg)

Gross Vehicle Mass (kg)

Max. towable mass (kg)

Four-door and Five-door 1.6L Sigma 110 PS & 125 PS iB5

1360 1500 2050 900

2.0L I4 145 PS MTX-75 1402 1541 2090 1500 2.3L I4 161 PS AWF21 1466 1612 2165 1700 2.5L I5 220 PS M66 1492 1631 2185 1800 1.8L Lynx 100 PS & 125 PS MTX-75

1430 1576 2150 1600

1.8L Lynx 125 PS MMT6 1471 1605 2155 1600 2.0L DW10 140 PS MMT6 1481 1615 2170 1800 2.0L DW10 130 PS AWF21 1503 1636 2190 2000 Estate 1.6L Sigma 110 PS & 125 PS iB5

1380 1553 2050 900

2.0L I4 145 PS MTX-75 1421 1595 2200 1500 2.3L I4 161 PS AWF21 1485 1658 2265 1700 2.5L I5 220 PS M66 1511 1685 2295 1800 1.8L Lynx 100 PS & 125 PS MTX-75

1449 1629 2255 1600

1.8L Lynx 125 PS MMT6 1490 1658 2265 1600 2.0L DW10 140 PS MMT6 1501 1668 2275 1800 2.0L DW10 130 PS AWF21 1522 1690 2300 2000 � � � � �Minimum kerbweight represents the lightest kerbweight less driver, full fluid levels and 90% fuel levels, subject to manufacturing tolerances and options, etc. fitted Towing limits quoted represent the maximum towing ability of the vehicle at its Gross Vehicle Mass to restart on a 12 per cent gradient at sea level. The performance and economy of all models will be reduced when used for towing.

- 86 -

Transmission Table � 1.6L Sigma 2.0L I4 Performance (HP) 110 125 145 Transmission type iB5 iB5 MTX-75 Clutch type Conventional Conventional Self adjust Clutch diameter (mm) 220/160 220/160 240/170 1st gear ratio 3.58 3.58 n.a. 2nd gear ratio 2.04 2.04 3.67 3rd gear ratio 1.41 1.41 2.14 4th gear ratio 1.11 1.11 1.48 5th gear ratio 0.88 0.88 1.11 6th gear ratio n.a. n.a. 0.85 Reverse gear -3.62 -3.62 -3.73 Final drive 4.06 4.06 4.07 � 2.3L I4 2.5L I5 Performance (HP) 161 220 Transmission type AWF21 M66 Clutch type n.a. Hydraulically operated

Self Adjust Clutch System;

Dual Mass Flywheel Clutch diameter (mm) n.a. 240 1st gear ratio 4.148 3.39 2nd gear ratio 2.37 1.91 3rd gear ratio 1.566 1.27 4th gear ratio 1.155 0.95 5th gear ratio 0.859 0.78 6th gear ratio 0.686 0.65 Reverse gear 3.39 -3.23 Final drive 3.329 4.00

� 1.8L Lynx Performance (HP) 100 125 Transmission type MTX-75 MTX-75 MMT6

Clutch type Self adjust Self adjust Self adjust Clutch diameter (mm) 240/155 240/155 240/155

1st gear ratio 3.80 3.80 3.58 2nd gear ratio 2.05 2.05 1.95 3rd gear ratio 1.26 1.26 1.24 4th gear ratio 0.87 0.87 0.87 5th gear ratio 0.67 0.67 0.94 6th gear ratio n.a. n.a. 0.79 Reverse gear 3.73 3.73 -1.42 Final drive 3.56 3.56 FD1: 3.81 (3/4/5/6)

FD2: 2.77(Reverse/1/2)

- 87 -

� 2.0L DW10

Performance (HP) 140 130 Transmission type MMT6 AWF21

Clutch type Self adjust n.a. Clutch diameter (mm) 240/155 n.a.

1st gear ratio 3.58 4.15 2nd gear ratio 1.95 2.37 3rd gear ratio 1.24 1.56 4th gear ratio 0.87 1.16 5th gear ratio 0.94 0.86 6th gear ratio 0.79 0.69 Reverse gear -1.42 3.39 Final drive FD1: 3.81 (3/4/5/6)

FD2: 2.77(Reverse/1/2) 3.33

- 88 -

Economy, Performance and Emissions � 1.6L Sigma iB5 Performance (PS) 110 125

Bodystyle Four-door and Five-door Estate Four-door and

Five-door Estate

Euro Emissions Stage Stage IV Stage IV Stage IV Stage IV CO2 Emissions (g/km) 172 172 177 177

Emission data re ECE Cycle (g/km)

HC = 0.095 CO = 0.576

NOx = 0.061

HC = 0.095 CO = 0.576

NOx = 0.061

HC = 0.095 CO = 0.576

NOx = 0.061

HC = 0.095 CO = 0.576

NOx = 0.061 Urban fuel consumption L / 100km (MPG) ����������� ����������� ��������� ���������

Extra Urban fuel consumption L / 100km (MPG) �� ������� �� ������� ������� � ������� �

Combined fuel consumption L / 100km (MPG) �������� �������� �������� ��������

Max Speed KM/H (MPH) 190 (118) 185 (115) 195 (121) 190 (118) 0-100 KM/H (0-62 MPH) in seconds 12.7 12.9 12.3 12.6

50-100 KM/H (31-62 MPH) in seconds* 14.7 14.9 14.7 14.9

* in 4th gear

Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

� 2.0L I4 MTX-75 2.5L I5 M66 Performance (PS) 145 220

Bodystyle Four-door and Five-door Estate Four-door and

Five-door Estate

Euro Emissions Stage Stage IV Stage IV Stage IV Stage IV CO2 Emissions (g/km) 189 189 222 222

Emission data re ECE Cycle (g/km)

HC = 0.064 CO = 0.506

NOx = 0.052

HC = 0.064 CO = 0.506

NOx = 0.052

HC = 0.052 CO = 0.197

NOx = 0.030

HC = 0.052 CO = 0.197

NOx = 0.030 Urban fuel consumption L / 100km (MPG) ����������� ����������� �� ������� �� �������

Extra Urban fuel consumption L / 100km (MPG) �������� �������� ��������� ���������

Combined fuel consumption L / 100km (MPG) �������� �������� �������� ��������

Max Speed KM/H (MPH) 210 (130) 205 (127) 245 (152) 240 (150) 0-100 KM/H (0-62 MPH) in seconds 9.9 10.3 7.5 7.7

50-100 KM/H (31-62 MPH) in seconds* 12.7 12.9 7.9 8.1

* in 4th gear Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

- 89 -

� 1.8L LYNX MTX-75 Performance (PS) 100

Bodystyle Four-door and Five-door Estate

Euro Emissions Stage Stage IV Stage IV CO2 Emissions (g/km) 151 154

Emission data re ECE Cycle (g/km)

HC+NOx = 0.258

CO = 0.275 NOx = 0.235 Particulates =

0.023

HC+NOx = 0.258 CO = 0.275

NOx = 0.235 Particulates =

0.023

Urban fuel consumption L / 100km (MPG) �������� ������

Extra Urban fuel consumption L / 100km (MPG) ���� ���� ����������

Combined fuel consumption L / 100km (MPG) ������� � ���������

Max Speed KM/H (MPH) 185 (115) 180 (112) 0-100 KM/H (0-62 MPH) in seconds 12.3 12.7

50-100 KM/H (31-62 MPH) in seconds* 12.7 12.9

* in 4th gear Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

� 1.8L LYNX Performance (PS) 125 Transmission Type MTX-75 (5-speed) MMT6 (6-speed)

Bodystyle Four-door and Five-door Estate Four-door and

Five-door Estate

Euro Emissions Stage Stage IV Stage IV Stage IV Stage IV CO2 Emissions (g/km) 154 156 154 156

Emission data re ECE Cycle (g/km)

HC+NOx = 0.258

CO = 0.275 NOx = 0.235 Particulates =

0.023

HC+NOx = 0.258 CO = 0.275

NOx = 0.235 Particulates =

0.023

HC+NOx = 0.256

CO = 0.344 NOx = 0.226 Particulates =

0.023

HC+NOx = 0.256

CO = 0.344 NOx = 0.226 Particulates =

0.023 Urban fuel consumption L / 100km (MPG) ������ � ����� ������ � �����

Extra Urban fuel consumption L / 100km (MPG) ���������� ������� � ���������� ������� �

Combined fuel consumption L / 100km (MPG) ��������� ��������� ��������� ���������

Max Speed KM/H (MPH) 200 (124) 195 (121) 200 (124) 195 (121) 0-100 KM/H (0-62 MPH) in seconds 10.7 10.9 10.5 10.8

50-100 KM/H (31-62 MPH) in seconds* 11.6 11.9 9.7 9.9

* in 4th gear Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

- 90 -

� 2.0L DW10 MMT6 Performance (PS) 140

Bodystyle Four-door and Five-door Estate

Euro Emissions Stage Stage IV + cDPF Stage IV + cDPF CO2 Emissions (g/km) 156 156

Emission data re ECE Cycle (g/km)

HC+NOx = 0.267

CO = 0.255 NOx = 0.237 Particulates =

0.0008

HC+NOx = 0.267 CO = 0.255

NOx = 0.237 Particulates =

0.0008

Urban fuel consumption L / 100km (MPG) � ����� � �����

Extra Urban fuel consumption L / 100km (MPG) ������� � ������� �

Combined fuel consumption L / 100km (MPG) ��������� ���������

Max Speed KM/H (MPH) 210 (130) 205 (127) 0-100 KM/H (0-62 MPH) in seconds 9.5 9.8

50-100 KM/H (31-62 MPH) in seconds* 8.7 8.9

* in 4th gear Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

2.0L DW10 AWF21 Performance (PS) 130

Bodystyle Four-door and Five-door Estate

Euro Emissions Stage Stage IV + cDPF Stage IV + cDPF CO2 Emissions (g/km) 189 189

Emission data re ECE Cycle (g/km)

HC+NOx = 0.2211

CO = 0.0253 NOx = 0.2152 Particulates =

0.0003

HC+NOx = 0.2211

CO = 0.0253 NOx = 0.2152 Particulates =

0.0003 Urban fuel consumption L / 100km (MPG) ���������� ����������

Extra Urban fuel consumption L / 100km (MPG) �� ������� �� �������

Combined fuel consumption L / 100km (MPG) �������� ��������

Max Speed KM/H (MPH) 200 (124) 195 (121) 0-100 KM/H (0-62 MPH) in seconds 10.9 11.1

50-100 KM/H (31-62 MPH) in seconds n.a n.a

Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

- 91 -

Fluids Fuel Tank (litres) All engines 70 litres. 60 litre option on Lynx engine�Oil supply and quantity (with filter change)

1.6L Sigma 4.1 2.0L I4 4.3 2.3L I4 4.3 2.5L I5 5.5

1.8L Lynx 5.6 2.0L DW10 5.5

�Oil supply and quantity (without filter change)

1.6L Sigma 3.8 2.0L I4 3.9 2.3L I4 3.9 2.5L I5 5.5

1.8L Lynx 5.0 2.0L DW10 5.0 �

Engine Cooling System Capacity

1.6L Sigma NYA 2.0L I4 6.2 2.3L I4 NYA 2.5L I5 7.1

1.8L Lynx 7.9 2.0L DW10 8.1 �

Oil change: 20,000 km (12,500 miles) / 1 year Note: This information reflects preliminary specifications and was correct at the time of going to print. However, Ford policy is one of continuous product development. The right is reserved to change these details at any time.

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