Ford's Game-Changing Hybrid

If Ford Motor Co. can keep churning out vehicles such as the '10 Fusion Hybrid sedan, it will go a long way toward silencing critics of the Detroit auto makers.

The Fusion Hybrid is more than just timely. It's also a useful public-relations tool, as evidenced by the media coverage Ford received when the car earned an Environmental Protection Agency fuel-economy rating of 41 mpg (5.7 L/100 km) in the city and 36 mpg (6.5 L/100 km) on the highway. That translates to 38.5 mpg (6.1 L/100 km) combined.

Those numbers demonstrate Detroit indeed can build viable products for today's fuel-conscious environment.

But they also proved challenging to duplicate during a recent test drive. The best we squeeze out of the Fusion Hybrid is a combined 33 mpg (7.1 L/100 km).

In fairness, our drive came during a brutal Michigan winter cold snap. Running the heater on high most of the time siphons battery power, causing the car to rely more on its gasoline engine.

The weather also seems to limit the speeds at which we are able to drive in all-electric mode. Ford says the Fusion Hybrid can travel up to 47 mph (76 km/h) on juice alone, significantly higher than most hybrids.

But we can only achieve about 30 mph (48 km/h) in all-electric mode. And that requires a feather-light touch on the accelerator. Pressing the pedal too hard immediately kick-starts the gas engine.

We blame the heater again.

Still, the Fusion Hybrid delivers pleasant surprises, such as Ford's nifty new display dubbed “SmartGauge with EcoGuide,” which provides real-time powertrain information to help drivers maximize fuel efficiency.

The new instrument cluster features an analog speedometer, flanked by two full-color liquid-crystal screens.

The screens can be reconfigured to display different levels of information, including fuel level, battery-charge status and average mpg. The screen on the right displays a graphic of leaves and vines, which grow, or shrink, depending on how economically the vehicle is driven.

Although it may seem gimmicky, the graphic is a clever way to enjoyably eke out better performance. It is difficult not to glance at the graphic, because it serves as an instantaneous report card. You can't imagine the disappointment that sets in when the leaves fall off the vine.

For Fusion Hybrid and its sibling, the Mercury Milan Hybrid, Ford improves on the powertrain used in the Escape and Mercury Mariner hybrid cross/utility vehicles. The Escape Hybrid won a Ward's 10 Best Engines award for 2009.

The Fusion utilizes new nickel-metal-hydride “traction” battery cells in its packs. These are lighter and slimmer and generate 20% more power than the pack used in the Escape and Mariner.

The Fusion battery packs stow behind the rear seat, leaving the trunk slightly compromised: 11.8 cu.-ft. (0.3 cu.-m) for the hybrid model vs. the 16.5 cu.-ft. (0.5 cu.-m) in the gas-powered Fusion.

The pack placement has benefits: Having extra weight in the middle of the car helps it “swivel” around corners, unlike hybrids with rear-mounted batteries that cause the back end to swing out too easily.

The battery powers a 275-volt, permanent-magnet AC synchronous motor that produces 106 hp. The instant torque affords an exhilarating experience in the Fusion Hybrid, as the rush of speed from a full stop comes with an eerie silence from the ultra-quiet electric motor.

The Fusion's gas engine also receives an upgrade over previous iterations. The new 2.5L inline 4-cyl. produces 155 hp and 136 lb.-ft. (184 Nm) of peak torque and is mated to an electronically controlled continuously variable transmission.

The transition between gas and electric mode is surprisingly seamless.

The cabin is extremely quiet due to an acoustic windshield, thicker front-door glass than in the previous-generation Fusion, new hood insulators and new interior headliner material.

For '10, Ford spruces up the exterior of the Fusion, giving it a much sportier appearance than the outgoing model. A new “Powerdome” hood complements a lowered front end, as well as new headlamps, grille and larger fog lamps.

Our tester stickers at $29,590. That's a lot of money, but about middle-of-the-pack for a hybrid. Add in the $3,400 available government tax credit, and Fusion Hybrid looks more reasonable.

The Fusion Hybrid competes with, and often surpasses, other hybrids in the market. But its largest contribution may well be as a game-changer for Ford.

Next-Gen Ford Hybrids Optimized to Lessen Battery Drain
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'10 Ford Fusion Hybrid

Vehicle type: Front-engine, front-wheel drive, 5-passenger sedan

Engine: 2.5L DOHC inline 4-cyl.

Power (SAE net): 156 hp @ 6,000 rpm

Torque: 136 lb.-ft (184 Nm) @ 2,250 rpm

Electric motor: 79 kW (106 hp) @ 6,500 rpm, 275-volt NiMH battery

Transmission: Continuously variable

Wheelbase: 107.4 ins. (273 cm)

Overall length: 190.6 ins. (484 cm)

Curb weight: 3,720 lbs. (1,687 kg)

Base price: $27,270

Fuel economy: 41/36 mpg (5.7/6.5 L/100 km)

Competition: Toyota Camry Hybrid, Toyota Prius, Honda Civic Hybrid, Nissan Altima Hybrid