There’s a common misperception that U.S. automakers are behind some imports in technology and fuel efficiency. That may have been true some years ago, but it could not be further from the truth today. Both Ford and GM have become quality and fuel economy leaders in the last few years, especially from the highly competitive mid-size segment up. Chrysler still trails in both but is working hard and fast to catch up. Don’t believe us? Check the numbers.

And while it is true that Japanese automakers Honda and Toyota saw the potential of gasoline-electric "hybrid" technology earlier, invested heavily in it sooner and brought it to market first, it is also true that the top two U.S. makers have assumed hybrid fuel-efficiency leadership as of 2009 with their own state-of-the art technology. While GM is offering fairly affordable mild hybrid sedans and more expensive, high tech 2-Mode hybrid SUVs and trucks, Ford has redesigned its already excellent parallel hybrid system— and is expanding its availability to the substantially upgraded 2010 Ford Fusion and Mercury Milan midsize hybrid sedans.

The EPA estimates for these ultra-fine new Fusion and Milan Hybrids are an impressive 41 mpg city and 36 highway, which beats Toyota’s ’09 mid-size Camry Hybrid by eight and two mpg, respectively. They are, Ford says, the most fuel-efficient midsize sedans in America.

Design and Features
The conventional Fusion and Milan, nicely restyled and much improved for 2010, offer the mid-size segment’s best gasoline four-cylinder fuel economy, more powerful available V-6s, class-exclusive technologies—including blind spot detection and warning with cross traffic alert and Ford SYNC®—and more total passenger and luggage capacity than the Camry. The Fusion’s new look is sportier, more upscale and aerodynamically slicker. The new front end sports large, wrap-around headlamps, a refined three-bar grille over an aggressive lower air intake, a power-dome hood, and new aerodynamic underbody shields to further boost its fuel economy. Around back, more integrated tail lamps contribute to a smoother, more appealing look.

The interior design is more technical and contemporary, with new metallic trim finishes on the instrument panel, center console, doors and steering wheel. A new instrument panel offers soft upper and lower skins—less hard plastic than typical Japanese sedans—and cool ice-blue lighting. The gauges have daytime backlighting and 3-D elements simulating the high tech, jewel-like look of a fine watch. And we love the new leather-wrapped steering wheel, with form-fitting "palm swells," and the very comfy new seats, with improved contours, more side support, smoother side bolsters and either textural or leather inserts with contrasting stitching.

All-New Hybrid
But the most exciting news is this all-new Fusion Hybrid. Together with its Mercury Milan Hybrid counterpart, it joins the Ford Escape and Mercury Mariner (compact SUV) Hybrids to double both the size and volume of Ford Motor Co.’s hybrid lineup. The Ford Hybrid team has developed a powertrain system that combines the best attributes of the gasoline engine and electric battery-driven motors," Ford engineers assert, "to deliver optimal driving performance and fuel economy," Driving a Fusion Hybrid on city streets and in urban freeway traffic near Ford’s Dearborn, MI Product Development Center on a bitter cold winter afternoon, we were impressed by its efficiency "coaching" system, which Ford calls SmartGauge™ with EcoGuide, and by how seamlessly and transparently it transitioned from gas to electric power, and back. We achieved an average of 38.4 mpg driving normally with traffic and 48.6 mpg very slowly, feather-footing our way along while ignoring irritated drivers behind.

Among this next-generation system’s key features are an ultra-efficient new 2.5-liter four-cylinder "Atkinson cycle" engine good for 155 hp and 136 lb.-ft. of torque mated to an electronically-controlled continuously variable transmission, or "e-CVT." Intake Variable Cam Timing (iVCT), enable seamless transitions from gas to electric and vice-versa, while both spark and cam timing are varied according to engine load to optimize efficiency and emissions. Enhanced electronic throttle control reduces airflow on shutdowns, which reduces fuel need on restarts, and a "wide-band lambda sensor" analyzes air-fuel ratios and adjusts the lean/rich mixture to keep the system in balance and minimize emissions.

The new 275-volt nickel-metal hydride (NiMH) battery is smaller, lighter and optimized to produce 20 percent more power. Cooled by cabin air, its improved chemistry allows it to run at higher temperatures, and an added variable voltage converter boosts voltage to the battery to operate the motor and generator more efficiently. A "smarter" climate control system with an electric air-conditioning compressor minimizes engine usage by running it only as needed for heating and cooling.

The brake system delivers full regenerative braking (when the drive motor becomes a generator), backed up by friction braking as needed, to capture nearly 94 percent of the energy normally lost through friction in braking and send it back to the battery. And, as we noticed during our drive, it delivers much better brake pedal feel compared to the previous system.

The hybrid system also allows the Fusion and Milan Hybrids to operate longer at higher speeds in electric mode than competitive systems. They can run up to 47 mph in pure electric mode, approximately double the speed of some competitors. "Because our hybrid can run at a much higher speed in electric mode, you can do so much more in city-driving situations," says Ford Hybrid Applications Manager Gil Portalatin. "Under the right conditions, you can drive in your neighborhood or in mall parking lots without using a drop of gasoline.' With the 41 city and 36 hwy ratings, Fusion and Milan Hybrids can achieve a driving range of over 700 miles on a single tank of gas.

The bottom line of all this advanced technology is a very "normal" driving experience requiring little sacrifice in exchange for superior fuel efficiency vs. Toyota’s Synergy Drive or anyone else’s similar system. And then there’s Ford’s SmartGauge™ with EcoGuide, which cleverly coaches drivers on how to optimize their hybrid’s efficiency performance.

It uses two high-resolution, full-color liquid crystal display (LCD) screens flanking the speedometer that can be configured to show different levels of information. The approach is multi-layered: A tutorial mode helps drivers learn about the system and its instruments, while tech enthusiasts will enjoy detailed gauges that help them become more efficient. The system even "grows" leaves and vines on-screen to reward efficient driving.

Drivers can choose one of four data screens: The basic "Inform" screen displays fuel level and battery charge status; "Enlighten" adds an electric vehicle mode indicator and a tachometer; "Engage" adds engine output power and battery output power; and "Empower" adds power to wheels, EV power threshold and accessory power consumption. All levels can show instant fuel economy, fuel economy history, odometer, engine coolant temperature, transmission gear and trip data—trip fuel economy, time elapsed fuel economy and miles to empty. There’s even an engine coolant temperature indicator that turns green when the engine is warm enough to allow engine shut-off and restart for full EV operation.

The 2010 Fusion Hybrid is differentiated from conventional models by "road and leaf" hybrid badging on the sides and rear, eco-friendly seat fabric made from post-industrial 85-percent recycled materials, a standard 110-volt power outlet and unique 17-inch, 15-spoke wheels. Anyone considering investing in a mid-size hybrid sedan should give this one a serious look and an extended drive. It should arrive in Ford dealer showrooms by spring 2009.