Engine range. A powerful new twin sequential turbocharged 2.0-liter TDCi engine will in 2015 offer 210 PS (154 kW) and 450 N·m of torque—delivered from 2000 rpm—with significantly reduced CO₂ compared to the outgoing 200 PS (147 kW) 2.2-liter TDCi engine.

The new high-powered TDCi diesel engine follows the downsizing trend we’ve led with our EcoBoost petrol technology. Smaller engines deliver better fuel efficiency and emissions, and we claim the power back with advanced technology. Twin sequential turbocharging delivers the seamless performance consumers want every day in all conditions, and makes turbo-lag a distant memory.

—Andrew Brumley, chief engineer, Ford Engine Programs

Electronically-controlled twin sequential turbocharging enables faster engine response. A small, low-inertia turbine is used to respond quickly to initial boost demand, and a larger high-inertia turbo is able to sustain greater boost pressure for peak performance.

The variable geometry turbochargers are supported by both charged air-cooling and water air-cooling for a more efficient feed of air into the engine; an Active Thermal Management System that improves warm-up times by supplying cooling to specific components on-demand to reach peak efficiency faster; and a variable oil pump that reduces parasitic losses by increasing oil pressure on-demand.

A revised 2.0-liter TDCi diesel engine with single variable geometry turbocharger technology delivers 150 PS (110 kW) and 180 PS (132 kW). All three 2.0-liter TDCi variants feature a revised engine block, and new cylinder-head and fuel injection designs, and Ford’s lean NO_x trap exhaust after-treatment system.

The 150 PS and 180 PS diesel engines will be available with Ford’s Intelligent All-Wheel Drive system, which offers a seamless transition between front-wheel drive and all-wheel-drive performance to automatically enhance traction and road-holding when needed. The system continually measures how the car’s wheels are gripping the road surface every 16 milliseconds, and can adjust power delivery to individual wheels in 100 milliseconds.

All-new Mondeo also will be the first vehicle in its segment equipped with a 1.0-liter gasoline engine. Ford’s 1.0-liter EcoBoost engine was in 2014 named International Engine of the Year for a third time in a row, and will join the Mondeo engine line-up in early 2015 with 125 PS (92 kW) and CO₂ emissions of 119 g/km. The engine calibration has been refined to deliver optimized performance for a larger vehicle.

Ford’s new 1.5-liter EcoBoost engine also will be available in Mondeo for the first time with 160 PS (118 kW) and delivering 134 g/km CO₂ emissions, while the 2.0-liter EcoBoost is available with 203 PS (149 kW) and 240 PS (177 kW).

An ECOnetic Technology model will be available, powered by a 1.6-liter diesel engine with anticipated class-leading diesel CO₂ emissions of 94 g/km.

First Mondeo Hybrid. The all-new Mondeo Hybrid will be the first Ford Hybrid Electric Vehicle to be manufactured in Europe alongside the gasoline- and diesel-engine Mondeo range at Ford’s facility in Valencia, Spain. It will deliver 99 g/km CO₂ from a specially-developed 2.0-liter gasoline engine combined with two electric motors—one to drive the wheels and another to supply regenerative charging—and a 1.4 kWh lithium-ion battery with an anticipated life-span of 10 years and 240,000 km (150,000 miles).

The Mondeo Hybrid represents the third generation of Ford global hybrid technology, and utilizes in-house battery, control software and continuously variable transmission technology. It also is the first generation of Ford hybrid globally to operate without engine accessory drives for significantly reduced drag.

Fuel efficiency and emissions are further reduced across the range by aerodynamics that cut drag by up to 10%; Active Grille Shutter; smart regenerative charging; and Electronic Power Assisted Steering and Auto-Start-Stop with all powertrains.

Pedestrian detection. Ford’s new Pre-Collision Assist with Pedestrian Detection can detect people in the road ahead, or who could cross the vehicle’s path, and automatically applies the brakes if the driver does not respond to warnings. The system processes information collected from a windshield-mounted camera and radar located in the bumper, and checks it against a database of “pedestrian shapes” to distinguish people from typical roadside scenery and objects.

The Pedestrian Detection system is part of the Pre-Collision Assist package that also introduces Active Braking, which can autonomously apply braking to help mitigate rear-end collisions, right up to the vehicle’s maximum speed.

Pedestrian Detection identifies people and reduces the severity of collisions at speeds of up to 80 km/h (50 mph).

If a pedestrian is detected in front of the car, and a collision becomes imminent, the driver will first receive an audible and visual warning. Should the driver not respond, the system then shortens the time required to apply the brakes by reducing the gap between brake pads and discs. If there is still no response from the driver the brakes are applied autonomously and the vehicle speed is reduced.

Engineers tested the system on closed circuits using rigs fitted with life-size dummies. They also spent months testing and refining the system on roads around the world to prove system reliability under real world conditions.

The real world testing was crucial. Pedestrians come in all shapes and sizes, and adopt an infinite number of postures. We covered more than 500,000 kilometers to make sure that we tested Pedestrian Detection against the widest range of people and situations possible.

—Gregor Allexi, active safety engineer, Ford of Europe

The all-new Mondeo also will apply automatic braking to mitigate or avoid a collision with a vehicle ahead. Active City Stop operates at speeds of up to 40 km/h (25 mph). At higher speeds new Pre-Collision Assist uses radar and camera technology to scan up to 200 meters (656 feet) ahead, and can autonomously apply up to full braking force to help the driver mitigate or avoid many types of rear-end collision.

Radar technology further enables the new Distance Indication feature and Adaptive Cruise Control technology. Distance Indication provides an intuitive visual interface to inform the driver of the time gap to the vehicle ahead. Adaptive Cruise Control automatically maintains a chosen distance from the vehicle ahead.

In addition, the forward-facing camera supports Lane Keeping Aid, which applies steering torque to guide the all-new Mondeo back in to lane if unintended drifting towards the lane marking is detected; and Traffic Sign Recognition, which provides the driver with the latest detected speed limit, cancellation signs and overtaking regulations via the instrument cluster display.

Mondeo drivers will be able to see more clearly with the introduction of Ford’s adaptive LED headlamp technology to Europe. The sophisticated technology combines full-LED headlamps offering daylight-mimicking light clarity with Ford’s Adaptive Front Lighting System that adjusts the headlight beam angle and intensity to match driving environment. It can choose one of seven settings according to vehicle speed, ambient light conditions, steering angle, distance to the vehicle in front and windscreen wiper activation.

Mondeo also is designed to help drivers in and out of parking spaces. An advanced version of Active Park Assist featuring Perpendicular Parking enables drivers to detect suitably-sized spaces and reverse hands-free into those parallel to the road or side-to-side with other cars.

This advanced parking feature will be supported by both Park-Out Assist, which helps drivers to exit parallel parking spaces; and Side Parking Aid, which delivers an on-screen visual representation and audible warning of obstacles to the sides of the vehicles, as well as to the front and rear.

Materials. An industry-first application of hydro-formed high strength steel is used to produce the A-pillars, B-pillars, and roof rails. A new magnesium inner tailgate structure for the four- and five-door models weighs approximately half as much as a traditional steel equivalent. Also helping save up to 115 kg for the 1.5-liter EcoBoost model for re-investment elsewhere is a recycled Front Energy Absorber, Ford’s first design to meet pedestrian protection requirements in both the US and Europe.

The weight saved during development has been carefully re-invested into fuel-saving features such as aero-shields and Auto-Start-Stop technology; comfort and convenience features; and a stronger and safer body structure. We’ve improved the strength of safety relevant areas by 40 per cent, and verified the performance with thousands of computer simulations and more than 180 real-world crash tests.

—Ulrich Koesters, vehicle line director, Ford of Europe

Hydro-forming uses high pressure hydraulic fluid to press metal into more complex shapes than is possible using traditional stamping methods for better strength-to-weight-ratios and bending stiffness.

The Mondeo’s hydro-formed roof rails are assembled from fewer sections and laser welded; removing joints that can act as weak-spots while saving 2.5 kg (5.5 lbs) in weight on each side. The B pillar design reduces side impact intrusion by 64 mm while saving 6 kg (13 lbs) in weight.

The Mondeo body structure features 61% high strength steel. Bake-hardened steel is used in the roof structure to reduce weight by a further 0.5 kg (1.1 lb).

Further structural developments include:

• An anti-roll bar uniquely designed to limit transmission travel in a frontal impact, minimizing steering rack movement;

• Sill rocker panels made of martensitic boron steel for improved side impact protection;

• Bumper crash cans optimized for energy absorption and harmonised with chassis rail characteristics;

• A flanged front cowl design that allows for flex under impact to increase energy absorption; and

• An integrated rear underbody wheel-arch-to-rail connector that increases torsional stiffness by up to 25% compared with a traditional design.

Ford also uses a pioneering technique to transform discarded plastic water bottles into front bumper components. Recycled plastic is used to produce the Xenoy material that accounts for 38% of the all-new Mondeo Front Energy Absorber. The component sits behind the front bumper and is designed to help mitigate severity of collisions with pedestrians.

Ford’s industry-first Inflatable Rear Seatbelt technology will make its European debut on the all-new Mondeo. It will be the first vehicle in its segment to feature belts that, in the event of an accident, rapidly expand in 40 milliseconds to disperse crash forces across a body area five times greater than that achieved by a conventional seatbelt.

Inflatable Rear Seatbelts are joined by nine further airbags including a driver-knee bolster airbag, a driver airbag optimized for chest protection, and deeper side airbags shaped to more effectively protect the occupant and direct them away from the impact area.

Dynamics. The first model for Europe to be built on Ford’s new global CD-segment platform, the all-new Mondeo will debut Ford’s new integral link rear suspension configuration for improved refinement and more dynamic performance.

The new suspension design delivers the compliance required for greater comfort, while retaining lateral stiffness for enhanced steering and handling. It also allows the wheel to move rearwards on impact with bumps. This delivers improved impact absorption for a smoother ride and reduced noise levels.

The all-new platform and body structure combination delivers 10% more torsional stiffness than the outgoing model for the most responsive and versatile Mondeo driving experience yet. The chassis is enhanced with active systems including Torque Vectoring Control, Pull-Drift Compensation, Active Nibble Compensation, Continuous Control Damping and Torque Steer Compensation.

The introduction of Electric Power Assisted Steering to Mondeo for the first time also enables steering weight to adapt and match the “comfort,” “normal” and “sport” chassis settings of Ford’s Continuous Control Damping. Drivers will notice a greater difference between the chassis characteristics delivered by the three settings.

An optimized anti-lock braking system helps reduce stopping distances by more than 1 meter from 100 km/h (62 mph).

Refinement. Road noise reductions of around 3 decibels in the rear and 2 decibels in the front have been achieved with integral link rear suspension and additional sound deadening material within the underbody shields, wheel arch liners and front and rear doors to block tire noise. The number of holes within the body shell also has been reduced to minimise noise transfer.

Wind noise is reduced to levels previously only experienced in the premium segment through optimized window pillar and door mirror shape, enhanced door and window seals, and improved interior noise absorption. The thickness of the rear window glass is increased by 0.4 millimeters, helping reduce passing traffic noise for rear seat passengers.

More seals have been added between the hood and front wings, and the engine bay sound insulation changed from fiberglass to foam, saving 1.5 kg in weight while contributing to a reduction of between 1.5 and 2 decibels for powertrain noise transmitted to the cabin.

In addition, all-new Mondeo features a humidity sensor that enables pre-emptive measures against flash-fogging of window interiors, and delivers best-in-class cooling from 55 ˚C to 18 ˚C (131 ˚F to 64 ˚F) in 15 minutes.

Mondeo will enhance comfort and convenience for drivers with features including first-in-class power-adjustable, memory-equipped steering column; power tailgate; heated steering wheel; and heated and cooled multi-contour seats with unique Active Motion massage function.