Ford will unveil at the Geneva Motor Show the 2009 Fiesta, a model based on the Verve Concept. The new Fiesta will be available in Europe stating fall 2008 and later in Asia, South Africa and Australia. Starting 2010 it will also come to North America.
New to the Fiesta range for European markets is the popular Ford Duratec 1.6-litre Ti-VCT engine. The 115 PS engine with variable intake cam timing, provides a well-balanced blend of performance and economy. It brings a 15 PS performance improvement over the outgoing Fiesta without a fuel consumption penalty.
Another engines found in the 2009 Fiesta are: 1.25-litre (60 and 80 PS) and 1.4-litre (91 PS) Duratec petrol engines; the 1.4-litre (68 PS) and the 1.6-litre (90 PS) diesel engines.
Fiesta will be offered with Ford Durashift 5-speed manual transmission or the Durashift 4-speed automatic transmission (available with 1.4-litre (91 PS) Duratec engine).
The new Ford Fiesta brings the radical Verve Concept exterior and interior styling to production reality and incorporates features and technologies normally found in larger, more expensive vehicles. It rejects the notion that an affordable small car has to be basic or boring.
The highlight of the Verve Concept interior – the futuristic, mobile phone-inspired, human-machine interface technology of the instrument panel centre stack – will be a core feature of the new Ford Fiesta when it hits the road.
Building on the exciting momentum of Ford’s distinctive iosis and iosis X concept cars and the premium feel of latest-generation production models like the new Mondeo and Focus, the all-new Ford Fiesta is the latest application of the company’s kinetic design philosophy, bringing the modern Ford of Europe family style to the small car segment.
Since the iosis concept vehicle introduced kinetic design in 2005, each new Ford has been created in a new interpretation of this form language, translating the trademark bold graphic elements and proportions to create a family of distinctive models.
Ford of Europe’s Executive Director of Design, Martin Smith, uses expressions like ‘precision sculpted’, ‘agile muscularity’ and ‘toned athleticism’ to describe the Ford design philosophy that has now created new Fiesta.
However, this does not mean a ‘one size fits all’ approach. Martin Smith explains: “Kinetic design is not just a matter of ‘cut and paste’ from one vehicle to the next; each is a new interpretation of the fundamental design elements. A kinetic small car can emphasise different elements of the form language to a larger car, and to different degrees.”
The result is a new Fiesta that joins a family of vehicles immediately identifiable as new generation Fords, yet with distinctive character to appeal to their target audiences. New Fiesta asserts its own air of confidence, stylishness and individuality.
“We have a kinetic family look now – each individual, yet instantly identifiable as part of the new generation of Ford vehicles,” explains Smith.
From Concept to Reality
For new Fiesta, the challenge for Smith and his team was to reflect the acknowledged character and driving dynamics that this popular small car has always represented, while reinvigorating the Fiesta brand to attract a whole new generation of customers, many of them new to Ford and new to Fiesta. Along with this, the team had to ensure that new Fiesta was undeniably a modern Ford.
The predominately young target audience was defined early on by the design team as ‘Design Progressives’ – a group that immediately identified with the kinetic design philosophy of ‘energy in motion’.
Early in the design process, the design team showed different design concepts to groups of these customers, translating the favoured treatment into the original Verve Concept, later revealed at auto shows around the world.
From the outset, the Verve Concept was created with an eye toward production. Through this process, new Fiesta customers are clearly able to see the strong visual relationship between the concept car that excited them and the production car created from it.
A Small Ford for a New Generation
From front to rear, the all-new Fiesta exudes presence and individuality.
It wears the distinctive, bold Ford ‘face’. Most noticeably, it uses the signature, large, inverted trapezoidal lower grille and large, centred Ford oval badge that characterises both the Verve Concept and other modern Ford family vehicles.
Chrome and brightwork are used selectively, like jewellery accents, to convey elegance and sophistication. The lower grille features this effect with its clean, precise chrome surround.
The grille is finished with a bisecting, horizontal number plate bar and framed by a dynamic-looking front structure, sculpted as if a pair of ‘toned muscles’ were located on either side of the bonnet.
The application of such a strong face creates recognition and communicates an attitude that is bold and sporty, yet friendly and engaging.
“We focused on bringing more emotion and character into Fiesta and to make the car appear larger and more athletic than the previous model, even though it remains the same size,” explains Stefan Lamm, Chief Exterior Designer, Ford of Europe. “The grille is one of the main elements in achieving this, by drawing attention to the front of the car.”
Moving rearwards, sleek, wraparound headlamps sweep back sharply, making both a strong visual statement as well as allowing for a very short shut-line to the sculpted, clamshell bonnet. This treatment gives new Fiesta a friendly, open and inviting personality, and in turn helps fulfil the requirements of pedestrian protection.
Strong brand character elements feature along the side of the vehicle, with bold, pronounced wheel arch lips – now a key feature of the Ford brand DNA and present across the portfolio of models. These communicate tension and muscularity, signature elements of kinetic design.
Above the wheel lips is a rising bodyside beltline, a strong dynamic line sweeping along the side of the car towards the high rear light cluster. This maintains the ‘wedge’ attitude admired on the Verve Concept and communicates robustness. The undercut panel running beneath this line adds strength and tension, while the door handles are carefully integrated, for a tidy, harmonious finish.
A sloping A-pillar extends forward towards the front wheel centre line to shorten visually the overhang, while an A-pillar window adds to the sporty look and aids visibility.
New Fiesta retains the sweeping profile and treatment of the glass area – or Day Light Opening (DLO) – of the Verve Concept. This acts as a visual reinforcement of apparent movement that does much to emphasise the car’s sporty character. Side windows combine neatly to create a unified side window graphic – another kinetic design element that communicates dynamism.
The upper arc of this window shape forms a feature line that incorporates the shapes of the tail lamps and rear spoiler into a coherent signature, while an elegant chrome accent frames the lower edge of the side glass and accentuates the established Ford ‘kick-up’ at the lower rear corner.
At the same time, the sweeping roofline extends back appealingly from the forward-stretching A-pillar, framing the bold graphic of the Fiesta side window profile just as on the Verve Concept.
This design approach is applied to both three-door and five-door models, retaining a dramatic and dynamic profile without sacrificing the true family car package.
“We took the five-door design as seriously as the three-door,” says Stefan Lamm. “Both cars are based on the same body, which makes the five-door particularly sporty and dynamic, almost like a five-door coupé.”
At the rear of the car, many kinetic elements combine, including the chamfered rear glass area, low roofline sweeping into a small spoiler, the distinctive licence plate graphic and dramatic tail lamps with honeycomb detailing, positioned high on Fiesta’s rear corners. Smith believes this combination is “the most distinctive aspect of the vehicle”.
An integrated, dark grey lower diffuser insert accentuates the bumper shape and adds to the athletic stance of new Fiesta. The diffuser lends an air of lightness to the rear shape while its lines stretching outward toward the bumper lip draw the eyes once again to the wheels and Fiesta’s sporty stance.
It would be easy to overlook such subtle elements were they not designed to be enhanced through colour. The unique exterior colour of the European Verve Concept – called Hot Magenta – has been translated to the production car as one of seven new colours developed for new Fiesta – with a total of 15 exterior colours available.
Creating a striking, kinetic exterior shape was just one part of the new Fiesta design story and the Verve Concept that preceded it. New Fiesta is as dramatic on the inside as it is on the outside, with courageous use of dynamic lines, full surfaces and bold graphics.
Boldly shaped surfaces and contrasting colours and materials feature in an enveloping dashboard design that wraps around the driver and passenger and creates individual space. Through the application of carefully developed and matched colours and trims, new Fiesta’s interior meets a full spectrum of customer desires, from a playful sense of fashion to mature sophistication.
“It’s a warm, inviting cabin,” explains Niko Vidakovic, Chief Interior Designer, Ford of Europe. “We’ve taken great care to ensure that this overall feel is maintained across the new Fiesta range, but differentiated by the use of a range of colours and trim materials.”
Designed for the Times
For inspiration, new Fiesta’s Design team studied extensively the styling and use of luxury goods and consumer electronics to create the look and feel for new Fiesta’s cabin and main controls.
From the driver’s seat, the eye is drawn immediately to new Fiesta’s striking instrument panel centre stack. Designed for a global population familiar with the design language and intuitive operation of mobile phones and personal music players, new Fiesta’s centre stack houses the car’s Human Machine Interface (HMI), linked to a multi-function display screen in a high-mounted binnacle, close to the driver’s field of vision.
Functionally, a key element of the design is the decoupling of the traditional in-car entertainment system elements – screen, controls and electronics – something only made possible by development of underlying technologies. Separating these elements allowed designers to place controls and buttons for optimal ergonomic positioning in a design that resembles the usage logic of a modern mobile phone.
“Cars in the past featured a ‘big brick’ audio head unit, which created vertical surfaces,” explains Vidakovic. “In new Fiesta, the only visible part of the underlying electronics is the CD slot. The buttons and the multi-function displays are separated from the electronic control unit and this is far less constraining on design freedom.”
As a result, every button and switch on the HMI has been crafted with the minute attention to detail that characterises good portable electronic designs. New Fiesta introduces a new approach to form and function and the instrument panel centre stack looks and feels very different to traditional automotive switchgear.
Echoing this theme are the stylish rotary controls for heating and air-conditioning that sit at the base of the centre stack, styled to reflect the look and feel of high-end power shower controls.
“Simple touches can radiate a feeling of quality,” says Vidakovic. “These are critical touch points in the cabin, for both driver and passenger and creating a sensation of class through their styling and movement was essential.”
Precision and Confidence
Surrounding the centre stack are several defining interior elements that tell you immediately this must be a new Ford – with every one of these elements designed to reflect the character of the vehicle.
“Most important is the steering wheel,” highlights Vidakovic. “It’s the core interaction between driver and vehicle and carries a size and feel that communicates new Fiesta’s sportiness and confident driving quality.”
The wheel has a modern, sculpted feel, using bright accents on its spokes to create a futuristic look. This is reinforced by the view through the wheel to the precision primary instruments and controls. The primary display – speedometer and rev counter – are framed by binocular-shaped, short tunnels of brightwork, which complement the centre stack and contrast the interior colours in another example of expressive design.
The attention to detail includes elements such as the new control stalks on the steering column, created to be precise and delightful to use. Again, the design team sought inspiration outside the automotive world and here it was provided by the packaging of luxury cosmetics, which often incorporate sophisticated, quality detailing to convey brand appeal. The column stalks use weight and precise action to communicate quality and responsiveness.
Quality is further evident in many details throughout new Fiesta’s interior, including such touches as the stitching on leather seats, the texture of cloth seats and playful ‘Y’ graphic on the seat facings.
Colours Make the Mood
As with the exterior, colours play as vital a role as shape in defining and establishing the character and attitude of the different new Fiesta models.
The range and breadth of colours, materials and interior trims available is class leading and will address the needs of both traditional customers and the predominately younger buyers who may be new to the Ford brand.
In total, there are five distinct series options – Ambiente, Trend, Ghia, Sport and Titanium – and 11 different colour and trim combinations for the interior.
Each option features a two-colour instrument panel, with differing contrasts toned to match the palette of the exterior – higher in sports models and muted in more traditional Ghia interiors.
The blend of colours is designed to be harmonious and was inspired by the exclusive fabrics and leathers of haute couture, according to Ruth Pauli, Chief Designer, Colours and Trims, Ford of Europe.
“Colour plays an important role in making an emotional contact with customers,” Pauli explains. “With new Fiesta, we have selected expressive colours in the right harmonies and contrasts, together with quality materials like glove-leather that’s beautiful to touch. These details bring a feeling of ‘premium-ness’ into a volume small car.”
The use of colour and kinetic design elements allowed the Design team to create more contemporary interpretations of established models, such as Ghia, and to incorporate new considerations, such as street fashion, into other models in the range. For example:
The Ambiente model offers a warm, inviting cabin, using a light contrast instrument panel
The Trend series takes its inspiration from designer clothing and bespoke suits to emphasise a contemporary feel
The new Sport model offers a neutral or blue theme in higher contrast colours and an inlaid graphic element reflective of those used in snowboard designs
The luxurious Ghia series utilises a champagne gold colour, for a softer, more Italian style. Inspired by luxury brands, Ghia offers soft-touch materials with low-contrast, tonal colour changes
The modern Titanium model employs a Soho Burgundy red colour, with dark gloss, high contrast finishes for a sleek, technical appearance, inspired by premium technology brands
“Each series should look different and have a different feeling,” concludes Pauli. “The same, striking interior form language can create a range of moods through the application of different colour and trim materials, from sporty to sophisticate.”
For the Titanium series, an Aesthetic Lighting Pack enhances the use of colour even further. In this premium, big-car feature a dome light comprising two small LEDs – situated in the overhead courtesy lamp – illuminates the centre console and gearshift area in a soft red glow.
A second ambient LED light source within the dash panel above the glove box emits a complementary soft red light on the passenger side of the car.
When the doors are opened, ambient lights brighten and are matched with footwell courtesy lighting. Even the centre console has an internal red LED illumination when opened that reflects premium electronic devices.
Martin Smith concludes: “This is designed to be the most complete, expressive and exciting Fiesta Ford has ever produced, inside and out. To me, it is a car that evokes an instant emotional response – ‘I want one’ – before you even get near it.”
Buying a Fiesta has always meant owning a great car to drive, with impressive vehicle dynamics in a small car package. The new Ford Fiesta is set to extend that reputation even further, with key changes and a new Sport model.
Being the first product of Ford Motor Company’s new global product development process, this latest generation Fiesta will introduce Europe’s familiar small car to customers around the world. It will also introduce these customers to Ford of Europe’s excellence in chassis development and attention to detail in vehicle handling and drive comfort.
New Fiesta stands on virtually the same footprint as the previous model and has actually lost weight – tipping the scales approximately 40 kilogrammes lighter, depending on engine choice, even after adding 10 kilogrammes in safety features and sound insulation.
The driver can feel the difference of that weight loss in the handling of the vehicle, according to Dieter Schwarz, Vehicle Engineering Manager for global Fiesta development.
“Driving the new Fiesta is going to be a very pleasant surprise,” says Schwarz, whose engineering teams used the Fiesta’s robust structure to deliver an even more engaging driving experience. “It is lighter and you can really feel it. The handling is nimble, yet the car feels solid and reassuring.”
Lean, Green Steering System
A key factor in the light, nimble handling of new Fiesta is a new feature – the first application of full Electric Power Assist Steering (EPAS) on a European Ford.
EPAS replaces the traditional hydraulic power-assist system of the previous-generation Fiesta, which required higher effort in low speed manoeuvres like parking and urban driving.
EPAS also delivers a noticeable reduction in real world fuel consumption by operating only when steering assistance is required and deactivating when not, thereby reducing the power it consumes from the engine and the fuel it requires. This compares favourably to a traditional hydraulic pump, which operates continuously once the car’s ignition is engaged.
Ford’s driving dynamics experts were aware that some EPAS systems compromise steering feel. Consequently, they devoted extensive effort to detailed tuning of new Fiesta’s EPAS system to ensure that it delivers the precise steering feedback expected from a Ford vehicle.
“We had three core objectives in tuning the steering system,” explains Norbert Kessing. “It should improve fuel consumption and CO2 emissions; it should feel as natural as possible and familiar to our customers; and disturbance sensitivity – such as kickback from poor road surfaces – should be improved versus the previous car.”
A key engineering challenge was to develop the new Fiesta EPAS system to reduce fuel consumption and CO2 emissions while maintaining Fiesta’s traditionally excellent feedback to the driver in higher-speed, handling situations. Here, extensive work was undertaken to achieve a fine, almost imperceptible transition between levels of assist and direct feedback from the road.
Much of the development time was dedicated to this intensive fine tuning of the EPAS system, on every type of road, from narrow city streets to twisty country roads. In total, steering development engineers accumulated over 50,000 kilometres of on-road testing. This work was supported by Ford engineers’ experience of the Electric Hydraulic Power Assist Steering (EHPAS) system developed for the Ford C-MAX and Focus.
“Optimisation work for the steering was not isolated to the steering components,” explains Kessing. “The whole vehicle has to be optimised to react correctly to the steering system.”
Much of this work was done before prototypes even took to the road. Detailed steering optimisation took place with Computer Aided Engineering (CAE) calculations, simulations, steering rig tests and prototype vehicle tests, months before real world assessment and prove-out. Fine tuning was conducted subjectively in the vehicle, supported by CAE and simulation analysis. Overall, the CAE input to new Fiesta saved 20 per cent in vehicle dynamics development time, compared to previous vehicles.
The result is a unique EPAS system. Sophisticated speed mapping allows light steering at parking speeds and firmer steering at higher speeds, making new Fiesta feel natural, confident and easy to position on the road.
This is applied by using a vehicle speed sensor, which identifies the turning rate and angle of steering to determine the level of assistance offered. This helpful feature has then been tuned further by the engineering team for different powertrain options, due to the different weight loads put on the steering.
New Fiesta’s steering ratio has also improved over the outgoing car from 15:1 to 14.25:1, which creates a more responsive and direct feel and a tight 10.2 metre turning circle, perfect for manoeuvring in tight spaces.
EPAS also features an additional pull-drift compensation, which helps cope with changes in road camber for easier driving. The pull-drift system continuously monitors the steering state and position of front wheels, controlling drift automatically by making continuous, imperceptible adjustments to the force on the steering wheel.
“We wanted new Fiesta to have excellent steering precision,” Dieter Schwarz says. “It took a detailed and uncompromising approach, and I am confident that we have actually exceeded our objectives.”
Global Architecture – Local Understanding
Whether it is a new Fiesta built in Cologne, Germany, Valencia, Spain, or Nanjing, China, it will have the same chassis architecture. However, in Ford’s global engineering approach, new Fiestas around the world will be configured and tuned to suit regional driving conditions and customer preferences.
“For all their similarities in style and design, there remain some fundamental differences in customer tastes around the world – and this is most apparent in vehicle dynamics tuning,” Schwarz explains. “Some markets, such as Europe, have a bias toward handling. Others, like Asia, tend to prioritise ride comfort. Regardless of which continent you drive new Fiesta on, the car will have the right characteristics for its surroundings.”
The key to delivering this was early engagement in research to understand fully the customer priorities and wishes in different markets. The engineering approach was to create a solid, proven base chassis architecture that would be appropriate for a range of different markets, yet readily tuned and adapted for regional differences.
Consequently, new Fiesta features the proven, independent MacPherson front suspension and a twist-beam rear suspension, refined and updated for the new car.
New Fiesta’s rear suspension twist beam diameter has increased by 28 per cent versus the previous-generation Fiesta, while the front suspension anti-roll bar diameter has increased to 22 mm, from 19 mm in the previous model. Ford engineers have also honed bushings, spring and damper rates – with these also set to be tailored for different regions.
European Fiesta models, for example, will feature a thicker diameter, stiffer torsion bar in the rear suspension and designed to deliver that trademark Fiesta handling prowess on twisting roads.
At the same time, impact harshness reductions were a major target for Ford engineers. One significant example is the twist-beam pivot bush, which has been increased in size to soak up impact harshness.
The new twist-beam pivot bush uses a larger, more sophisticated design, with different rubber compounds for optimal performance, not only in static stiffness and comfort, but also dynamic performance such as steering precision and handling. It can also be tuned more readily for different markets, to absorb bumps and road harshness on poor surfaces. While slightly heavier in weight, this was considered an essential addition in a no-compromise global new Fiesta.
Much of the initial regional development work has been done in Europe, by replicating different types of roads and surfaces from around the world. More detailed work is now taking place in each of the regions in which new Fiesta will be sold.
Responsive Handling – Sophisticated Ride
Depending on the road conditions and the mood of the driver, new Fiesta offers a combination of sporty and dynamic handling, a sophisticated and mature cruising ability and an effortless performance in urban driving.
“It was very important that new Fiesta would deliver the superior driving capabilities expected from a Ford vehicle, whether in the city or on twisty country roads and at a range of speeds,” says Norbert Kessing. “Our aim was to create a driving environment where the driver will always feel comfortable and in full control.”
To enhance the controlled driving environment, Ford engineers also refined Ford’s Electronic Stability Programme (ESP) for new Fiesta, which is available as an option across the range.
The Fiesta ESP system has been developed to reinforce new Fiesta’s sporty driving characteristics. It is designed to be non-intrusive during spirited driving but to provide crucial protection should the situation require it, something which required careful, detailed development work.
“It’s easy to make a car safe with ESP, but if you want to make the car engaging and agile as well, then that takes a lot of attention to detail. We’re proud of what we’ve achieved with new Fiesta,” says Kessing.
New Fiesta Sport – Rewarding the Expert
An all-new Fiesta Sport model will be available at launch, bringing sporty performance to the Fiesta range offering driving enthusiasts a new default choice Fiesta.
Kessing explains: “At Ford, excellent driving quality is measured by a car’s fundamental ability to flatter a novice driver, yet reward an expert. With the new Fiesta Sport model, we’ve gone a step further to ensure new Fiesta offers experienced drivers something special.”
New Fiesta Sport uses a new, 1.6-litre Duratec Ti-VCT petrol engine, tuned to 120PS and powerful enough to send new Fiesta Sport from zero to 100 km/h (0-62 mph) in 9.9 seconds and on to a top speed of 193 km/h (120 mph). Lowered, tuned sports suspension helps new Fiesta Sport make the most of its increased power and maintain excellent dynamic response.
“We’ve developed new Fiesta Sport to fulfill all the desires of enthusiastic drivers,” says Kessing.
Significantly Reduced Noise
New Fiesta looks more sophisticated inside and out, and its driving refinement echoes that visual sophistication. It is set to raise the standard for small cars with its improved road, powertrain and wind noise isolation.
Noise, Vibration and Harshness (NVH) is known within Ford as ‘Sound Quality and Vibration’ (SQ&V) and the focus is on improving sound quality and minimising unwanted noise transmission for all vehicle occupants. As Kessing explains: “This is not about numbing the senses, it’s more about creating a pleasurable driving environment.”
New Fiesta’s SQ&V team worked closely with the Design team from the outset, to eliminate any physical aspects that could lead to noise intrusion into the cabin.
One of the key areas of co-operation between the two teams was wind noise. To ensure wind noise was reduced to an absolute minimum inside new Fiesta’s cabin, all potential wind noise sources were assessed at the component level first and then at the vehicle level. This allowed areas of potential weakness to be corrected even before the first prototype was built.
Three-dimensional software tools were used in developing new Fiesta’s body structure. The use of these advanced digital engineering tools allowed SQ&V engineers to evaluate the whole car structure and identify easily and rectify any potential noise, vibration, or harshness transmission. This process also allowed SQ&V engineers to view the latest development levels of components in real time, thereby quickening the pace of overall development and allowing far more time for tuning and optimisation.
This up-front work helped ensure that traditional NVH sound package elements, like seals, fitted correctly from the outset – even on the very first prototypes. Consequently, new Fiesta’s sealing system is improved significantly and is expected to be best-in-class for overall performance.
Key contributors to this quiet and refined performance are double door seals to isolate road noise and fully encapsulated glass.
Transmission of powertrain noise throughout the new Fiesta’s body structure has also been reduced by improved sound absorption, body structure improvements and a secondary bulkhead that reduces noise in the cabin.
Particular attention was paid to refinement of the increasingly popular Duratorq TDCi diesel models. Specific powertrain noise reduction techniques deployed for these models include:
• Special dense cloth insulator under the bonnet to absorb sound
• Plastic under tray to engine bay to reduce noise transmission externally and into the cabin
• Extra sound deadening material on the bulkhead
• Extra sound deadening material within the rear quarter trim and B-pillar
• SQ&V-optimised engine calibration
“We wanted to make sure that driving quality remains at the heart of new Fiesta – we had to ensure that the driving experience delivered on the promise made by its dynamic kinetic design,” comments Schwarz. “I am confident we have met that promise.”
Under the stylish exterior of the new Ford Fiesta is a robust body structure, crafted from high-strength and ultra-high strength steels to protect occupants in the event of a collision.
New Fiesta uses an exceptionally high level of cold-and hot-formed high-strength steels in its body structure for a car in this segment. More than 55 per cent of the body structure is high-strength steel, including grades of very-high-strength, dual-phase steel and ultra-high-strength aluminised Boron steel.
Ingredients like these make new Fiesta stronger and stiffer than ever. New Fiesta’s new shape is approximately 10 per cent stiffer torsionally than its predecessor, providing its occupants with a robust safety cell.
Yet, despite its advances in strength, new Fiesta’s body structure overall is lighter than before. This means advancements in safety have not been achieved at the expense of key attributes, like fuel economy and CO2 emissions.
“Safety is a very important attribute for the new Fiesta, but achieving real weight reduction was another key objective,” says Liesenfelder. “High-strength steels – cold-and hot-formed – were the key to delivering the lighter weight and higher strength we needed for structural efficiency. We believe that the materials used on the new Fiesta are setting a new benchmark in the small car segment.”
Structural Strength for Safety
Under Ford’s safety strategy, high-strength steels are used in areas of the vehicle where structural strength and reinforcement are essential for crashworthiness. This includes the floor structure, front rails and beams and new Fiesta’s ultra-rigid, integrated bodyside reinforcement ring to protect against side impact.
High strength materials were used to create a very stiff B-pillar section and stiff rocker section fore and aft. Impact loads are also transferred laterally to the opposite side of the car via chassis cross-members, to maximise dissipation of side impact forces.
This integrated bodyside reinforcement ring resists side intrusion in the unlikely event of a collision and helps the body structure manage the energy of other impacts effectively – be they frontal, offset or rear.
“Some people believe that just counting the number of airbags can gauge safety performance,” says Joerg Beyer, Chief Carline Engineer for new Fiesta. “At Ford, we count first on creating a very strong body structure to protect all occupants. With this robust structure as the first point of defence, we can then optimise our Intelligent Protection System to provide a tailored, protective response.”
To create the bodyside reinforcement ring, high-strength-steel elements were welded into an ultra-stiff structure whose crash performance was carefully developed using advanced computer simulation technology, long before its first real crash tests.
Elements of the bodyside reinforcement ring include:
A-Pillar – New Fiesta’s slim A-pillar forms the forward part of the vehicle’s stylish roof arch. It is fashioned from ultra-high-strength aluminised Boron steel. The A-pillar delivers the strength and rigidity required for crashworthiness while remaining fashionably slim, as a key element in Fiesta’s dynamic design, and to minimise its potential to obscure driver visibility
B-Pillar – Another Boron steel component, the Fiesta B-pillar reinforcement is shaped for ultra-high strength. Its job is to resist intrusion and retain its structural rigidity in the case of side impacts, while providing the strength to help the vehicle safety cell retain its shape in other crash modes
Rocker Panels – New Fiesta’s rocker panels, the lower rails to which the B-pillar is fixed, are crafted from very-high-strength, dual-phase steels renowned for their energy absorption properties
Rocker Baffles – To optimise the side-impact performance of the vehicle, uniquely shaped, twin-shear baffles are welded to the inner rocker panel. These stabilise the rocker section to ensure that it performs optimally in the event of a side impact. This is designed to make the rocker panel and B-pillar act as a system, with the B-pillar retaining its shape and its connectivity to the rocker panel in a side impact
Side Roof Arch – Another dual-phase steel component – the side roof arch – joins with the A-Pillar to form new Fiesta’s strong roof profile and provide a robust top attachment point for the B-pillar
Lower A-Pillar – The lower A-pillar is formed of very-high-strength, dual-phase 600-grade steel
These individual, high-strength elements are formed into an integrated subassembly during manufacture before they are joined to the vehicle on the production line. This new process ensures better joint strength and even better precision build for the overall body structure. It is also more weight efficient.
The new bodyside subassembly process required significant investment in the Fiesta body shops in the Cologne and Valencia Assembly Plants, but that investment is paying off in structural efficiency, according to Liesenfelder.
“We’ve discovered the strength benefits of the door rings when conducting both frontal and side impact tests,” Liesenfelder says. “The ring structure helps us to ensure minimal deformation of the door apertures in crash testing and is indicative of the integrity of the safety cell.”
Even More High-Strength Steel
More high-strength steel can be found in other key areas of new Fiesta’s body structure.
The dual-phase steel front frame rails and side rails feature structural actuation points – called trigger points – to initiate predictable collapse in crush zones. This is a key energy absorption feature. Forming the ‘triggers’ hardens the dual-phase material, giving it unique twin characteristics of energy absorption and energy resistance.
“The front of the rail is the crush zone, but then, to avoid overloading the backup structures, the rail is engineered to bend and counter-bend, while still offering very stiff resistance to further intrusion,” Liesenfelder explains. “We call this the ‘crush-bend-bend-bend’ strategy.”
New Fiesta’s underfloor structural beams – so-called ‘sled runners’ – also are formed from dual-phase steel, as are lateral floor reinforcements, which help the structure manage side impact forces.
Such extensive use of dual-phase steel inspired the Ford body engineering team to develop new engineering techniques. Because dual-phase steels acquire greater strength after stamping, the team worked to quantify how much this added strength contributed to the overall body structure. Defining the ultimate strength of the assembly would help Ford’s sophisticated crash simulation computers model crash performance with a very high degree of accuracy.
The new Fiesta team created a new computer map of the strength of the body structure taking into account the components’ ‘forming history’.
“Mapping the strength of the structure improves our understanding of the benefits of these dual-phase steels and increases our ability to predict structural behaviour accurately,” Liesenfelder says. “It’s this kind of attention to detail that has gone into defining new Fiesta and its safety performance.”
Reinforcements in the roof, doors and floors of the vehicle are made from other gauges of high-strength steel, including a Boron steel door beam on three-door models.
To support extensive use of high-strength steels, further manufacturing investment was required for new robotic welding heads equipped for mid-frequency welding to deliver optimal weld quality with the new materials, and replacing heads calibrated for normal 50 Hz welding used with milder steel grades.
Knee Airbag for Fiesta
New Fiesta introduces a new knee airbag into its Intelligent Protection System (IPS), the first application of a knee airbag in a Ford small car.
The IPS links new Fiesta’s restraints and passive safety technologies to perform as a single system designed to protect occupants in the event of a collision. The new knee airbag is aimed at protecting the driver from lower leg injuries in a frontal impact.
The 14.8-litre knee airbag deploys from the lower instrument panel. It joins a suite of other restraints technologies in new Fiesta’s IPS, including:
• Dual front airbags for driver and passenger
• New head and thorax side airbags for the driver and front-seat passenger
• New inflatable curtain airbags to protect outboard occupants of the front and rear seat rows
• Three-point safety belts with dual-stage digressive load-limiting pretensioners for the front seat occupants
• Three-point safety belts for all three rear seat occupant positions
• Anti-submarining front seat design
• Whiplash-optimised front seats
• Beltminder safety belt reminder system for front seat occupants
“The addition of the knee airbag to IPS means we can tailor the response of other elements of the system more finely,” says Gisbert Gaeb, Ford of Europe’s manager for Safety Body Engineering.
Safety with Customer Choice
New Fiesta offers its customers the opportunity to choose the configuration of the Fiesta IPS, based on their individual needs.
“The majority of Fiesta customers drive alone,” explains Gaeb. “We’ve oriented new Fiesta’s IPS towards the driver and front passenger areas, but also developed additional safety options.”
Head and thorax side airbags are standard in most European markets, but Ford also offers the option of a new inflatable side curtain, which deploys from the headliner to offer additional side-impact protection for outboard occupants both front and rear.
Head and thorax side airbags are designed to protect the head and upper body of front-seat occupants from side impact forces. The airbags deploy from the seat side bolsters, featuring a tuck-seam design that was developed by Ford safety engineers to deploy the bag’s upper shape quickly and accurately position it between the occupant’s head and structural elements of the vehicle side.
New Fiesta IPS technologies benefit from extensive airbag sensor calibration testing. This detailed engineering work was conducted to ensure appropriate and timely deployment of airbags under most conditions, for example in angled impacts where front or side airbags could deploy additionally to provide even better protection.
New Fiesta is equipped with three-point safety belts for all five occupant positions, retractor pretensioner safety belts for the front seating positions and anti-submarining front seats.
The retractors pull the safety belts tightly to position the occupant ideally for airbag effectiveness, with a ‘dual-stage digressive load limiting’ feature that allows a slight reduction in belt tension to reduce risk of chest injury.
Ford Beltminder, a reminder system to encourage occupants to use their safety belts, is standard on new Fiesta.
More Safety than Meets the Eye
New Fiesta’s safety features extended beyond those you can see from the cabin.
A new front seatback design has been developed to give excellent whiplash protection. The design exceeded crash test requirements without requiring the use of active head-restraint technology.
New Fiesta also has an additional safety feature located under the carpet in the front driver’s footwell. This is a special carpet underlay – called a ‘crash pad’ – situated between the floor panel and carpet, to minimise loading to the lower leg during an impact.
New Fiesta also offers ISOFIX child restraint anchors for outboard rear seating positions.
Looking Out for Pedestrians
The attractive face of new Fiesta is about more than just kinetic design-inspired styling. Also, it incorporates an array of features designed to protect pedestrians.
From major design elements – like its distinctive clamshell bonnet and sporty windscreen rake – to small details like the breakaway spindles of its new aero windscreen wiper blades or the finely shaped headlamps, new Fiesta has been thoughtfully crafted around pedestrian protection.
New Fiesta’s clamshell bonnet helps protect pedestrians from impacting hard surfaces and sharp edges. Its rear corners are a particular pedestrian safety improvement, while its unique four-bar hinge – which allows the bonnet to open outward and upward – also plays a role in distancing the bonnet from the engine underneath.
The clamshell’s interior structure is as important as its curvy exterior. The pedestrian protection design target was to minimise an underlying structure with hard points that could cause head injuries. The bonnet therefore incorporates an innovative ‘hexagenous’ architecture – a term coined by Ford engineers to describe the reinforcement that comprises joined-up hexagon shapes which create space between the bonnet and engine.
Hard elements like the windscreen wiper motor have also been relocated to the outboard side of the engine compartment to remove other potential hard points of contact.
The front bumper design is another pedestrian-friendly design element. Its shape, known as a ‘tri-plane curvature’, comprises three curves, or planes, rather than being a continuous curve. This limits the exposure of a pedestrian to the most damaging perpendicular impacts with the bumper.
The bumper also includes an integrated energy-absorbing grille insert which acts as another key pedestrian safety element. It has been engineered with specific deformation properties to avoid causing pedestrian lower leg injuries.
New Fiesta also incorporates a lower leg stiffener behind the fascia in the area of the lower spoiler. Its function is to ensure the pedestrian’s lower leg remains vertical and is not allowed to rotate below the vehicle.
Safety engineers and designers worked hand in hand to shape the fine detail of new Fiesta’s distinctive headlamps to protect pedestrians, particularly children. The location and dimensions of the headlamps – a key design element of the front end – were carefully designed to minimise exposure for direct contact with the head in an impact. This is matched to the steeply raked ‘pedestrian-friendly’ windscreen.
“New Fiesta is a clear example that making a safe car doesn’t mean making a large car, or a heavy car. There is no need to compromise between safety and good design or driving character,” concludes Liesenfelder.
The new Ford Fiesta has been developed around a philosophy of bringing ‘big car’ premium features to the small car segment, for the comfort and convenience of driver and passengers.
High-quality finishes, appealing, contemporary materials and user interfaces inspired by mobile phones communicate immediately that new Fiesta is no ordinary small car.
“Elements like these are crucial in extending the traditionally rational appeal of Fiesta into something more emotionally appealing,” says Giovanni De Pasca. “Today’s small car buyers are concerned about more than cost and functionality. This new generation is very discerning about style, both the big picture and the small details. We’re confident that this new-generation Fiesta will be highly appealing to them.”
New Fiesta is designed to deliver a ‘cockpit’ feel, with major functions oriented towards the driver, ensuring core controls are within easy reach, including the new In-Car Entertainment (ICE) system in the centre console.
This ‘cockpit’ character is accentuated by a 30 mm lower seating position, a higher instrument panel and a 20 mm higher gearshift placement versus the previous-generation Fiesta. This characteristic is enhanced in new Fiesta Sport with the addition of bolstered sports seats. New Fiesta also introduces steering wheel-mounted controls for key audio and vehicle systems – another ‘big car’ feature already found on Mondeo, S-MAX and Galaxy.
Extensive, detailed work was undertaken to create a driver’s seat that was comfortable, yet offered sporty styling and wide-ranging adjustment. Significant back and thigh support has been engineered into the seat, to complement new Fiesta’s driving character, without compromising comfort.
The driver’s seat now adjusts up and down by 55 mm to accommodate different driver’s needs, which is a first for Fiesta. A 286 mm fore and aft adjustment also offers a significant improvement.
This combination of lower seat mounting and greater adjustment also ensures headroom is not compromised even for the tallest drivers, despite new Fiesta’s lower, sportier exterior profile.
The driving position has also been improved in its angle to the steering column, which is now four-way adjustable for reach and height and located at a more vertical angle to the driver, for greater comfort and enhanced ‘cockpit’ experience.
“It was important for us to create a driver’s seat that both looks the business and does the business,” says Giovanni De Pasca.
Virtual Interior for Better Visibility
In optimising new Fiesta’s interior package, engineers made extensive use of the Computer Aided Virtual Engineering (CAVE) system, first used on the new Mondeo.
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. This system proved invaluable to designers and package engineers when shaping new Fiesta’s interior.
The driver’s rearward view was also optimised using the virtual-reality CAVE system. Detailed work was undertaken among design, package and ergonomics experts to shape the rear glass of the new Fiesta for ample visibility within its kinetic design shape.
As a final touch of comfort, new Fiesta features a full footrest for the driver, the first Fiesta to offer this on both left- and right-hand drive models.
Mobile Phone Inspired Convenience
The striking centre stack on new Fiesta’s instrument panel is the heart of new Fiesta’s ICE. As such, it needed to be instantly intuitive to all types of customer, as well as a creative and attractive piece of interior design.
The new Fiesta team sought inspiration away from traditional automotive switchgear and studied the use and architecture of mobile phones to determine the most intuitive interactive platform.
The Human Machine Interface (HMI) strategy for new Fiesta focused around three pillars that were also used in developing the system for the latest Mondeo:
• Simplicity and integration
• Usefulness and personalisation
• Controllability and automation
In new Fiesta, the result is a HMI that separates the traditional entertainment system elements – screen, controls and electronics – into a mobile phone-inspired user interface.
Dr. Stefan Becker, Supervisor, HMI Development, explains: “Mobile phones have internationally recognised interfaces and orientations, with the goals of being stylish, yet simple to understand and operate. We wanted to use this core understanding that customers now share across the world to move away from a traditional automotive approach.”
The design was heavily researched and tested by the ergonomics and HMI teams – both in laboratory conditions and with real customers – to prove its safety and simplicity. The driver is able to operate easily the ICE unit with minimal distraction while driving.
Internationally recognised symbols, as seen on a mobile phone, are pictured both on each button and on the screen for easy control and coordination, while the control buttons are purposely slanted to give a stylish look and to highlight the red illumination in the button dividers.
During development, a major focus on details made for significant ergonomic improvements. For example, the centrally-located ‘OK’ directional button is a toggle button, with an added option of voice control to operate ICE functions.
Also, on the finished design, each button slants inwards for the finger to slip into so other buttons are not pressed by mistake. Angled controls and buttons make operation easy and relaxed and an outward dimple is placed on the centre button, just like a mobile phone, acting as a clear centre-point reference. Many functions can now also be controlled via intuitive steering wheel-mounted toggle switches, minimising the need for the driver to take their eyes from the road.
Ergonomics development even extended to the size of each button. The team increased the size of keys for the finished design, to the point that it now meets the requirements of about 95 per cent of male sized hands.
These subtle but important developments ensure the driver can operate the various functions easily, and refer quickly to a clear, high-mounted, 89 mm (3.5 inch) screen, thus minimising distraction time when focusing on the road ahead.
“The new Fiesta HMI system needed to be readily understood, intuitive to operate and easy to control, for people of all shapes and sizes. In creating it, we also made new Fiesta the first small car with a screen of this size plus multi-media functionality”, says Becker.
Ford EasyFuel Heads Big Car Features List
New Fiesta brings to the small-car arena an array of features normally found on big cars. Leading this list is the innovative Ford EasyFuel system. EasyFuel means never having to wrestle with a fuel filler cap again.
EasyFuel, first introduced by Ford on the new Mondeo, is more than a convenience feature. It represents a tangible difference for the customer, because it incorporates a special fuel inhibitor that is designed to prevent the vehicle from being filled with the wrong type of fuel.
More than 200,000 people misfuel their car each year in Britain and Germany alone. This error can lead to major engine damage, higher insurance premiums and an expensive repair bill. New Fiesta brings this key technology to the Ford small-car customer for the first time, preventing misfuelling and the associated damage, inconvenience and expense.
Insurance providers also rate Ford EasyFuel highly because it significantly reduces the chance of potentially large insurance claims from misfuelling.
Ford EasyFuel is simple and easy to use. The lack of a conventional cap, which would need to be removed prior to fuelling the car, reduces the danger of fingers becoming tainted with fuel.
The system’s special fuel inhibitor, designed into the fuel filler neck aperture, is engineered to accept only the correct nozzle for the powertrain fitted. This protects against both petrol and diesel misfuelling.
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 ensure the system is as secure as a properly fitted conventional filler cap. EasyFuel has been tested to rigorous internal Ford safety standards, including an 80 km/h barrier crash test, to verify its robustness against fuel leakage.
Keyless is Effortless
For the first time on a small Ford, new Fiesta offers customers the option of keyless entry and start.
Removing the need for a conventional key and allowing quick and easy cabin entry and luggage area access, the keyless entry system uses a radio signal to communicate with the key when the driver touches a door sensor.
When the driver pulls the door handle, the sensor checks instantly that the correct key fob is nearby and unlocks the car automatically. New Fiesta also shares other Ford models ‘auto re-lock’ function – if the car is unlocked but no door opened, new Fiesta will automatically re-lock itself.
When leaving the car, it can be locked securely by pressing the sensor buttons on either of the front door handles. In an additional feature, drivers will be able to check if the vehicle is locked by pulling a door handle, as this will only unlock the doors after the door sensor has been pressed again.
The system uses the same stylish key fob as new Mondeo, with a removable blade key that can be used to unlock the doors in an emergency. The keyless entry option is combined with the keyless start ‘Ford Power’ button.
Power to the People
The ‘Ford Power’ keyless start button is an option on new Fiesta, following its successful introduction on recent Ford models, including the new Focus and Kuga.
To start the engine, the driver keeps the keyless entry fob about their person and simply presses the clutch pedal on cars with manual transmission – or the brake pedal on cars fitted with automatic transmission (with the gear selector in P or N) – then pushes the button to start the engine.
New Fiesta communicates instantly with a micro-chip in the key fob to activate the ignition system. A further push of the button switches the engine and ignition off, with a safeguard to prevent it being operated while the car is in motion. The entertainment systems can be activated without starting the engine by pushing the button alone.
Smarter Screens, Brighter Lights
Through new Fiesta, Ford is introducing another ‘big car’ feature to the small car segment – automatic heated screens, making Ford’s renowned ‘Quickclear’ heated front windscreen even smarter.
New Fiesta will automatically activate its heated screens (front, if fitted and rear) if started when the ambient temperature is below six degrees Celsius.
Night-time driving will also be made more comfortable by new Fiesta’s adoption of high-intensity, projector beam headlamps, fitted as standard to Ghia, Sport and Titanium models and optional elsewhere.
Cruise control is another feature that has migrated from larger Ford cars into the new Fiesta.
Beyond the convenience and driving ease cruise control represents, it can also assist new Fiesta’s fuel economy. Cruise control helps keep the vehicle at the desired speed more accurately and efficiently than the driver can, especially over long distances, making highway cruising more fuel-efficient.
New Fiesta’s cruise control features steering-wheel mounted controls for driver convenience.
New Fiesta will also continue to feature such convenient driver aids as automatic headlights and rain-sensitive windscreen wipers.
Other ‘big car’ features available for new Fiesta include:
• ‘One-shot up’ power driver’s window
• Rear power windows on Ghia and Titanium five-door models
• Power mirrors, even on entry-level models, finished in body colour for Trend upwards, with integrated side indicators and featuring ‘radius’ glass to improve the scope of rearward vision in both mirrors. Power folding mirrors feature on Ghia and Titanium models.
• Reach-and-rake steering wheel adjustments to help drivers optimise driving position. This combines with Fiesta’s improved seat-height adjustment capability for ergonomic flexibility
• Flexible ‘aero’ wiper blades, with improved sweep ability and sound refinement. The system features asymmetrical blades – 600 mm long on the driver’s side, 425 mm on the passenger side, for a wide sweep arc
Space and Storage Zones
From the outset, Ford designers and ergonomists worked together to create an interior that is as intuitive as it is attractive. New Fiesta was created to accommodate the broadest possible range of individuals – from the 2.5 percentile female, to the 97.5 percentile male – and the broadest possible requirements.
As a small car that was designed to stay small, the challenge for new Fiesta’s development team was to improve the interior space and stowage for driver and passengers, without increasing the overall dimensions of the car.
Ergonomists divided new Fiesta interior into zones for each occupant, to ensure storage areas, switches and controls were all within comfortable reach. At the same time, Package teams were working on ingenious new storage options for new Fiesta. The combined result is space and storage zones that are convenient for all occupants.
Sitting in new Fiesta, the space is immediately obvious. Front legroom has increased by 11 mm over the previous-generation Fiesta and is best in class at 1069 mm. Generous front shoulder room of 1350 mm and headroom of 991 mm combine to create a comfortable environment for any length of journey.
Rear seat passengers are not forgotten either. Despite its sweeping exterior profile and high belt line, new Fiesta still offers 953 mm headroom for rear seat passengers, together with 1297 mm shoulder room and rear legroom of 823 mm.
In five-seat mode, new Fiesta has the largest luggage space of any Fiesta yet, with 295 litres – up from 284 litres in the previous model. This rises to a cavernous 979 litres in two-seat mode. Rear seats offer single-motion folding capability for stowage of larger items – an action which does not require lifting the rear seat cushion or removing the headrests.
A low boot lip (702 mm from the ground) and broad opening to the rear hatch (606 mm high, 996 mm wide) make loading and unloading easy and practical.
Useful and ingenious storage spaces abound throughout new Fiesta’s cabin, and are convenient for all occupants. Chief amongst these is the eight-litre glovebox on the front passenger side, capable of storing items of different sizes from CDs to drinks cans and bottles. Other storage areas include:
• Best-in-class sized front door bins, capable of storing 1.5-litre bottles or a sizeable road atlas
• Central storage pocket in the centre console stack
• Open storage bin in front of the gearshift, with non-slip surface, for keys or wallet
• Open storage space in front of handbrake with USB socket and 12-volt power connector for MP3 player or mobile phone
• Two 0.4-litre cup holders alongside an offset parking brake
• Storage bin at the rear of the centre console, large enough for a handbag/CDs and easily accessible for rear passengers
Clear Fiesta Choice
New Fiesta has been designed and engineered to meet a range of customer requirements, with performance from feisty to frugal, interior choices from ultra-modern to traditional and a comprehensive list of standard features at all levels.
Choosing a new Fiesta to meet individual needs is made simple with a straightforward series line up. From the affordable and well equipped Ambiente and the popular Trend, customers can choose a path based on their preferences, while benefiting from similar specifications and prices. Ghia matches a luxury feel with a classic style and subtle interior colours, while Sport and Titanium introduce technological style and materials, for those customers seeking a contemporary, hi-tech look.
The core new Fiesta range comprises:
Ambiente – Expected to be approximately six per cent of European new Fiesta sales, Ambiente is an affordable and well-equipped entry to the new Fiesta range, offering body coloured bumpers, Intelligent Protection System, reach and rake-adjustable steering and power mirrors as standard.
Engine choice varies by market, but includes both 60 PS and 80 PS versions of the 1.25-litre Duratec and 68 PS 1.4-litre Duratorq TDCi.
Trend – Enhancing new Fiesta’s inherent style, Trend features a choice of four interior environments, with a generous specification level that adds body coloured, powered and heated door mirrors, electric front windows and remote central locking. A bright headlamp finish completes its stylish exterior.
Anticipated to account for 63 per cent of new Fiesta European sales, Trend offers a wide choice of engines including 1.25 and 1-4-litre Duratec petrol, 1.4 and 1.6-litre Duratorq TDCi in most markets, all with a choice of power outputs.
Sport – The visually striking new Fiesta Sport shows its promise through subtle sports styling additions, including five-spoke, 16-inch alloy wheels, projector headlamps, front fog lamps, sports spoiler and bumper skirts. This theme is continued on the inside with a leather steering wheel unique sports gear knob and sports seats creating a focused driving environment. Standard equipment adds a trip computer, side airbags and air conditioning.
New Fiesta Sport introduces the 1.6-litre, 120 PS Duratec Ti-VCT petrol engine, but will also be available with the 1.6-litre 90 PS TDCi.
Ghia and Titanium – Both top of the range new Fiestas create a premium look and feel, with chrome surround to the grille and side windows, front fog lamps, leather steering wheel and air conditioning.
Both models offer a broad spectrum of engines, varied by market, with Duratec petrols available in 1.25, 1.4 and 1.6-litre and Duratorq TDCi diesels in either 1.4 or 1.6-litre, most with a choice of power outputs.
Beyond this, customers can choose the new Fiesta style to suit their preference. Ghia adds a traditional luxury feel with chrome and soft leather, finished with 15-inch alloy wheels, rain-sensing wipers and automatic, projector headlamps and automatic climate control in most markets, while Titanium brings a contemporary look to this equipment level with higher contrast materials, such as dark gloss surfaces and bright metal accents.
“When we consider all of the comfort and convenience features in the new Fiesta range, we think of it not as our new small car, but our smallest large car,” concludes Giovanni De Pasca.
Across the model range, new Fiesta combines an enhanced and efficient powertrain line-up with weight reductions to deliver better fuel economy and reduced CO2 emissions.
The New Fiesta range – with four 16-valve Duratec petrol and two Duratorq TDCi diesel engine choices – offers a projected range-wide CO2 average of 132 g/km, a 1.3 per cent improvement over the already efficient previous Fiesta. This incremental advance represents a potential saving of over 11,000 tonnes of CO2 across Europe, assuming annual European sales comparable with the previous Fiesta and an average distance of 15,000 kilometres per year.
However, this is just the beginning of the story; new Fiesta also introduces the latest in Ford’s ECOnetic range of low-CO2 models. The new Fiesta ECOnetic offers the impressive torque of the 1.6-litre Ford Duratorq TDCi engine with target CO2 emissions of just 99 grams per kilometre (g/km).
“It’s here that all the hard, uncompromising work by the Fiesta team really pays off for the customer,” says Joerg Beyer, Chief Carline Engineer for new Fiesta. “Reducing fuel consumption and CO2 emissions was absolutely central to our powertrain development strategy for new Fiesta. It’s important to customers; it’s important to Ford and it’s important to governments. We believe the results of our efforts make new Fiesta truly a compelling choice for environmentally aware drivers.”
New Fiesta is approximately 40 kilogrammes lighter than its predecessor and is also among best in class for its small, 2.08 square metre frontal area and drag coefficient of 0.33. Similarly, while many competitors have grown taller with each new generation, new Fiesta has reduced in height by 36 mm, versus the previous model.
“We kept a razor-sharp focus on avoiding gains in size and weight,” Beyer says. “When you combine that with new powertrain technologies, aerodynamic efficiency and careful engine calibrations, the fuel economy and emissions benefits really start adding up.”
New Fiesta’s Electric Power Assist Steering (EPAS) system also plays its part. Compared with traditional hydraulic power-steering pumps which operate constantly, EPAS only operates when steering assistance is required. Ford powertrain and vehicle dynamics engineers carefully calibrated the system for optimal steering precision and feel for the driver, as a primary driving quality objective for the car.
All powertrains fitted to new Fiesta achieve Euro Stage IV emissions standards.
New Fiesta ECOnetic
New Fiesta completes the initial trilogy of Ford ECOnetic models promised across the core of the company’s European vehicle range. It brings class-leading, low CO2 emissions performance of just 99 g/km to the small car segment.
With the debut of Fiesta ECOnetic, Ford has achieved its mission of delivering a sub-140 g/km Ford Mondeo, a sub-120 g/km Ford Focus and a sub-100 g/km Ford Fiesta. These models are designed to provide a compelling choice for consumers who are increasingly concerned about CO2 emissions.
New Fiesta ECOnetic also demonstrates that very favourable fuel consumption levels and significantly reduced CO2 emissions can be achieved using conventional technology coupled with a clever combination of individual fuel-saving measures.
New Fiesta ECOnetic is powered by a specially calibrated version of the 1.6-litre, 90 PS (66kW/89 bhp) Duratorq TDCi engine. It features a longer final-drive-ratio of 3.055:1.
These actions, combined with a suite of additional detail engineering actions, give new Fiesta ECOnetic an impressive projected fuel economy of 3.7 litres per 100 kilometres (76.3 miles per gallon) in the official combined European driving cycle. Its target 99 g/km CO2 emissions level is 10 per cent below the already impressive emissions level of the mainstream Duratorq TDCi Fiesta engine range.
A no-maintenance, coated Diesel Particulate Filter (c-DPF) is fitted to new Fiesta ECOnetic and all 1.6-litre Duratorq TDCi models. It is designed to regenerate automatically during normal driving conditions.
Beyond the EPAS system shared with all new Fiestas, other features contributing to Fiesta ECOnetic’s sub-100 CO2 emissions include:
• Lower ride height – Fiesta ECOnetic borrows the Fiesta Sport’s lower suspension, which improves aerodynamic efficiency
• Aerodynamic improvements – Wheel deflectors and aerodynamic wheel covers provide incremental aerodynamic enhancements
• Fuel-saving tyres – Fiesta ECOnetic features low-rolling-resistance tyres in economical 175/65R14 profile
“Basing the ECOnetic model on the 1.6-litre Duratorq TDCi engine means it will still offer the responsive feel of low-end torque,” says King. “This really makes Fiesta ECOnetic a no-sacrifice approach from the customer’s point of view.”
Duratorq TDCi – Better Than Ever
Two popular Duratorq TDCi engines, with state-of-the-art common-rail injection, are available for new Fiesta, featuring new technologies, enhanced fuel economy, lower CO2 emissions and improved performance.
New Fiesta customers can choose from the popular 1.4-litre, 68 PS or the 1.6-litre, 90 PS TDCi, both offering improved fuel economy over the corresponding previous Fiesta model.
In new Fiesta, both are rated identically for combined fuel consumption, at just 4.2 litres per 100 kilometres (67.3 mpg), and CO2 emissions, at just 110 g/km – an improvement over the previous Fiesta of 6.7 per cent for the 1.4-litre and 4.6 per cent for the 1.6-litre. In real terms, this improvement equates to saving approximately 45 litres of fuel over an average year’s driving (15,000 kilometres) for the 1.4-litre TDCi – or an extra tankful for each customer.
In other conditions, the 1.4-litre TDCi achieves 5.3 litres per 100 kilometres (53.3 mpg) on the urban cycle and 3.5 litres per 100 kilometres (80.7 mpg) on the extra urban cycle. The 1.6-litre TDCi is rated at 5.2 litres per 100 kilometres (54.3 mpg) urban and 3.6 litres per 100 kilometres (78.5 mpg) extra urban.
All Ford Duratorq TDCi diesel engines come with state-of-the-art common rail injection technology for high efficiency, high pulling power and low fuel consumption. In addition, under full acceleration, the engine calibration allows the maximum nominal torque to be briefly topped by ‘transient overboost’ when the driver needs it for overtaking or similar situations.
Twin pilot injection technology is featured for the 1.4-litre TDCi for smooth operation and significant improvement in noise, vibration and harshness (NVH) performance. Pilot injections are small doses of fuel prior to the main injection of fuel, precisely timed by the engine electronic controls and delivered through its common rail system at pressures of up to 1,500 bar.
The 1.4-litre TDCi uses Siemens Piezo injectors and control strategy with capability for multiple pilot injections. Twin pilot is used as extensively across the speed and load range as possible. At idle and low speed, this gives a significant noise improvement by softening the combustion process, achieved by spreading it over a larger crank angle.
The 1.6-litre TDCi also incorporates significant calibration enhancements. It uses a Bosch control system with peak fuel pressure of 1,600 bar. Detailed attention has been devoted to tuning the system’s interactions with exhaust gas recirculation, rail pressure and injection timing. This provides for more refinement, especially at low speed and load levels.
“New Fiesta takes an enormous step forward in terms of combustion noise,” King says. “It’s another pleasant surprise for the diesel customer.”
Part of the improved refinement of the latest Duratorq engines is achieved through careful calibrations of their speed at idle. With the target of achieving a smooth, constant idle speed, Ford powertrain engineers devoted extensive attention to fuelling and timing calibrations. Rigorous testing was conducted even with low-quality fuels to ensure that the engines would maintain smooth idle operation, simulating worst-case conditions.
New Fiesta diesels also feature load-dependent idle speed. The engine control system senses high load factors, such as air-conditioning, and changes the idle speed accordingly. This system features intelligent controls to ensure that idle speed is kept as low as possible to minimise fuel consumption.
Both TDCi engines are constructed of aluminium alloy. This reduces the weight of the engine, contributing to responsive performance and good fuel economy.
New Duratec Ti-VCT Engine
New Fiesta provides even more powertrain choice for the customer with the introduction of a more powerful, 1.6-litre Duratec Twin Independent Variable Cam Timing (Ti-VCT) petrol engine to the range.
The new, 120 PS Duratec Ti-VCT is offered exclusively in the new Fiesta Sport model. It accelerates Fiesta Sport from zero to 100 km/h (0-62 mph) in 9.9 seconds and sits at the top of the new Fiesta petrol engine range, joining the acclaimed 1.25-litre and 1.4-litre petrol engines.
Despite its feisty character and its 20 extra horsepower, the new Duratec Ti-VCT is still more fuel efficient than the 100 PS, 1.6-litre engine in the previous Fiesta. New Fiesta Sport still returns a combined fuel economy of 5.9 litres per 100 kilometres (47.9 mpg) and CO2 emissions of 139 g/km.
The responsive new Duratec Ti-VCT engine delivers strong torque output across the mid-rev range, peaking at 152 Nm at 4,050 rev/min, and it uses twin independent variable cam timing to provide the optimal balance of performance and fuel economy.
This high-tech engine features map-controlled fully independent variable camshaft timing on intake and exhaust camshaft. Featured in the second-generation Ford Focus and the latest Mondeo, it offers very good fuel economy in combination with high performance.
The Duratec Ti-VCT also features an aluminium cylinder head and block, which contribute to the new Fiesta’s weight-control strategy.
More Duratec Options and Automatic Transmission
Three other 16-valve Duratec petrol engines are offered in the new Fiesta powertrain range, which will also feature an automatic transmission option:
A 60 PS (44 kW/59 bhp) 1.25-litre model, delivering 5.4 litres per 100 kilometres (52.3 mpg) combined and CO2 emissions of 128 g/km. This engine features peak torque output of 109 Nm at 3,600 rev/min, 0-100 km/h (0-62 mph) acceleration of 16.9 seconds and a top speed of 152 km/h (94mph)
An 82 PS (60 kW/80 bhp) 1.25-litre, with combined fuel economy of 5.7 litres per 100 kilometres (49.6 mpg) and CO2 emissions of 133 g/km. Higher performance means peak torque of 114 Nm at 4,200 rev/min, 0-100 km/h (0-62 mph) acceleration of 13.3 seconds and a top speed of 168 km/h
A 96 PS (71 kW/95 bhp) 1.4-litre, with a choice of the Durashift 5-speed manual transmission, or Durashift 4-speed automatic. The 1.4-litre manual achieves a fuel economy of 5.7 litres per 100 kilometres (49.6 mpg) and CO2 emissions of 147 grams per kilometre. This popular engine accelerates new Fiesta to 100 km/h (0-62 mph) in 12.2 seconds on the way to a top speed of 178 km/h (111mph)
Performance Still Key
Beyond fuel economy and emissions, the new model is set to extend Fiesta’s reputation as a sporty driver’s car with enhancements to its trademark performance feel and driveability.
“Sportiness has been a core part of the Fiesta personality,” Joerg Beyer says. “It was important that we didn’t sacrifice that important attribute while making those fuel-economy gains. Performance feel is even better in the new Fiesta and we’ve made some key driveability improvements, too.”
Even with the smallest engine in the range, the proven Duratec 1.25-litre petrol engine, new Fiesta achieves a 22 per cent improvement in 0-100 km/h (0-62 mph) acceleration and 14 per cent better in-gear acceleration in passing manoeuvres, thanks to its reduced weight and improved powertrain calibration.
New Fiesta also features carefully mapped accelerator pedal response calibration. The electronic throttle has been tuned to respond differently depending on how much and how sharply the throttle is applied. Aggressive throttle inputs generate a sharper, sportier response, while gentle throttle inputs deliver a smoother, progressive feel.
“Accelerator pedal response mapping is the result of attention to the smallest of details to enhance the driving experience,” Beyer explains. “Our general philosophy in calibrating the Fiesta engine range was to flatter the novice driver and reward the expert.”
Cars like new Fiesta are often the choice of new drivers. New Fiesta’s stall prevention system is one way in which Fiesta makes it easier for beginners and drivers faced with stop-start traffic or challenging parking manoeuvres.
Stall prevention is a unique engine mapping profile to reduce the potential for the vehicle to stall when moving away from stationary. The system anticipates when the driver is going to pull away. When the clutch is engaged, the engine’s ignition profile is altered to increase the amount of available torque. Tuned for each powertrain derivative, it was developed based on typical car parking manoeuvres.
The anti-stall technology is absolutely seamless to the driver – whether novice or experienced – and makes new Fiesta easier to drive in city traffic, easier to manoeuvre into tight parking spaces and more pleasurable for all drivers.
Packaging Power Efficiently
New Fiesta’s design reflects the careful packaging of powertrain components in the engine compartment. This was a key area of co-operation between Ford and Mazda in developing the shared technologies of the new generation of Ford Motor Company small car products. Extensive computer-aided-design work was conducted to package the engine and its ancillary components, such as hoses, cables and hard components into a tight space while protecting them from heat, movement and harmful vibrations and ensuring optimal crashworthiness.
Concludes Joerg Beyer: “Thanks to its mix of careful calibration and latest powertrain technology, new Fiesta is a tailored driving experience, carefully and precisely tuned to respond to all drivers and driving styles.”