Ford Focus Coupe-Cabrio: In Depth

Ford Focus Coupe-Cabrio

Focus with striking dash of Italian elegance

July 14, 2006 7:46 PM
Filed Under: American, Ford

Press Release

Page 1: Overview
Page 2: Driving Dynamics / Powertrain
Page 3: Exterior Design / Package
Page 4: Interior Design / Equipment / Body
Page 5: Safety
Page 6: Specifications

Overview

"Defining the development target was easy: To position Ford's first power-operated hardtop model as a best selling four-seat coupé-cabriolet. To do this, we needed to combine a unique body design, a retractable hardtop and everyday practicality with the acclaimed driving quality of the Ford Focus. It has also been a challenge to combine two different company cultures, but I think the multi-cultural team has delivered, and the solution we have found has resulted in a very exciting vehicle." Gunnar Herrmann, Vehicle Line Director, Ford Focus

The new Ford Focus Coupé-Cabriolet supplements the extensive Focus line-up with a striking dash of Italian elegance. This four-seater Coupé-Cabriolet, which has been developed in partnership with design and engineering teams from Pininfarina S.p.A., combines unique open-air emotion with acclaimed Ford PrecisionDrive characteristics already appreciated on other Ford Focus models.

The new Focus Coupé-Cabriolet is Ford of Europe's first power-operated hardtop model. Its two-piece, fully retractable hardtop not only guarantees comfort, stability, durability, and a high degree of year-round, everyday practicality but it also lends the vehicle two exciting and bespoke personalities. Together with sporty Ford Focus ST , the all-new Coupé-Cabriolet sits at the very top of the Focus family.

Creating a true four-seater that combines a high emotional appeal with "must have" means for everyday use was a top priority for Ford designers and engineers. With the roof closed, new Focus Coupé-Cabriolet offers a best-in-class luggage capacity of 534 litres. Even with the retractable hardtop stowed in the boot, the new Ford still provides 248 litres of luggage space under the folded roof. No direct competitor in this market segment offers more.

The new Focus Coupé-Cabriolet is based on the Ford Focus Vignale Concept, which first appeared at the 2004 Paris Motor Show. Prompted by the positive reaction that followed from both customers and media, Ford quickly gave the project the green-light for volume production in November 2004.

Since then, the vehicle has been taken from design concept to production model in a joint development programme between Ford of Europe and Italy 's Pininfarina S.p.A., which enjoys a reputation for design and production of some of the most desirable vehicles in the world. In just 20 months, this cooperation delivered its target - a striking Coupé-Cabriolet, which retains the definite and pronounced lines of the original concept car.

This stylish Coupé, which is also the first Ford of Europe production vehicle to carry the unique "Pininfarina" design badge, reveals its second personality in just 29 seconds. At the touch of a button, it transforms quietly and quickly into a dynamic Cabriolet thanks to easy-to-use and reliable technology.

Because of its construction, the two-piece retractable hardtop delivers excellent customer advantages in terms of durability, rigidity, and sealing capability. Yet it also provides the vehicle with seamless, flowing and elegant lines.

In this respect, the slender profile of the rear roof pillars is of particular significance for the vehicle's body design. They flow elegantly into the boot lid, which gently arches towards the rear of the car. This lends new Focus Coupé-Cabriolet an unusually elegant yet dynamic stance - with the roof open or closed.

The highly individual rear design is dominated by distinctive tail lights linked by a chrome strip with an embossed "FOCUS" logo, giving the car a premium, tailored feel reminiscent of Italian tourers from famous carrozzerias . This appeal is further enhanced by a unique front bumper shape, bold wheel arches and an elegant profile.

"New Ford Focus Coupé-Cabriolet is more of a classic Grand Tourer than a sports roadster" says Jon Wellsman, Ford of Europe's Brand Manager for Focus. "With this vehicle we're responding to what customers have asked for ever since we showed the original Focus Vignale Concept.

"Also, it marks an entry point for Ford of Europe into a growing segment of the market - between 2000 and 2004 the number of retractable hardtop cars has multiplied by five, and this number is still increasing. We want to participate in that growth", adds Wellsman.

Another Bodystyle for the Ford Focus

The addition of the new Coupé-Cabriolet model extends the Ford Focus range, offering customers a superb choice.

Focus now offers three-door and five-door hatchbacks, a four-door sedan and a five-door wagon, plus the new Coupé-Cabriolet and the Ford Focus C-MAX multi-activity vehicle. The range offers a vehicle for every driver need, including, with the recently launched Focus ST , those looking for high performance.

The Ford Focus is one of the most successful model ranges in Europe with more than 4 million units built, plus 370,000 Focus C-MAX models built since its launch in 2003. The Focus, which boasts European sales of 442, 000 units in 2005, is produced at European assembly plants in Saarlouis in Germany , Valencia in Spain and St Petersburg in Russia .

But the Focus story isn't confined to Ford of Europe. Production sites for the Ford Focus outside of Europe include the US , China , Taiwan , Philippines and South Africa . More than five million Focus cars have been sold worldwide, with major sales highlights in 2000 and 2001, when the Focus achieved the status of being the best-selling car in the world. The previous Focus model was also the first vehicle in automotive history to win the 'Car of the Year' title both Europe and America.

Page 1: Overview
Page 2: Driving Dynamics / Powertrain
Page 3: Exterior Design / Package
Page 4: Interior Design / Equipment / Body
Page 5: Safety
Page 6: Specifications

Driving Dynamics

"Transferring Ford's driving agility to a Coupé-Cabriolet requires some expertise. For example, you have to consider the differences in weight distribution and the higher overall weight. That's why we were lucky to be able to use the strong basis from Ford Focus plus a very rigid body structure." Andreas Woehler, Manager Vehicle Dynamics

New Ford Focus Coupé-Cabriolet reflects Ford's acclaimed driving quality philosophy in the same way its core Focus range siblings do. The model's suspension has been engineered with proven Focus components as a basis, but with specific tuning that takes into account a completely new body structure with different weight factors.

"Simply adopting a 'plug and play" solution was not feasible for this project. Ford has an excellent reputation for driving quality, and we want to do justice to this with every new model", says Woehler.

The chassis includes reliable core Focus components like the front axle with MacPherson strut suspension, Ford's Control Blade independent rear suspension, and a low friction steering system. Wolfgang Helbert, team leader in Woehler's group, was also responsible for fine-tuning the sporty Ford Focus ST : "This experience was of great help because in some areas I could work with ST settings without letting go of the Coupé-Cabriolet's individual characteristics."

For additional stiffness, Ford Focus Coupé-Cabriolet uses an extra cross-member across the bulkhead between the MacPherson struts and bushings taken from the ST rack. To match the vehicle's perfectly balanced weight (front 53%: rear 47%), the rear suspension was also derived from the Focus ST design, but is tuned towards a more comfortable setting.

For the front gas-filled dampers, a new piston valve has been adopted while the rear axle uses compact mono tube dampers. Drivers will appreciate minimised noise levels and enhanced body control.

By comparison with the Focus sedan, both front and rear dampers have been stiffened by 30 percent. Front and rear stabilisers were aligned in accordance to the springs, and have been stiffened by 8 percent at the front and 33 percent at the rear. Additional ST-proven spring aids, strut mounts, and new 16- and 17-inch wheels with 205x55 and 205x50 tyres respectively add to the Focus Coupé-Cabriolet's agility signature.

Electro-hydraulic power-assisted steering is available with both the 2.0-litre Duratec and Duratorq TDCi engines. The proven EHPAS system offers speed-related steering effort and reduced fuel consumption. New software specially written for use in Focus Coupé-Cabriolet provides more direct steering feedback.

In addition to this essential suspension tuning, a new sport suspension has been developed. This comes as standard with the Sport Pack and is optionally available for Titanium models. It features more highly tuned springs, dampers and anti-roll bar to provide more sportiness. When specified, the Focus open air cruiser is 10mm lower at the front and 8mm at the rear axle, yet still comfortable enough for relaxed cruising.

Powertrain

"Before choosing engines for the new Ford Focus Coupé-Cabriolet, we listened to the wishes and needs of this subsegment's customers. With our acclaimed TDCi power units available, we believed it was crucial that we offered them access to this efficient technology for our stylish grand tourer." Norbert Steffens, Manager C-Segment Powertrain

Up to three proven Ford powertrains from the Focus range are offered in the new Coupe-Cabriolet model – two Duratec petrol engines, and one Duratorq TDCi diesel.

Ford offered diesel open-top motoring once before, however. In 1995, the Escort TD Cabriolet was launched, and customers were surprised to find that diesel engine torque reserves were well suited for relaxed Cabrio cruising. The new Ford Focus Coupé-Cabriolet's TDCi engine takes this relationship to the next level.

136 PS, 2.0-litre Duratorq TDCi

Developed as part of Ford Motor Company's diesel engine co-operation with PSA Peugeot Citroën , this robust engine features a peak torque of 320 Nm at 2,000 rpm and a maximum power output of 100 kW (136 PS). In combination with Ford's Durashift 6-speed manual transmission, which will be delivered with refined shifting character, Focus Coupé-Cabriolet reaches a top speed of 205 kph (128 mph) and accelerates from zero to 100kph (62 mph) in just 10.3 seconds. Targeted fuel consumption in combined ECE mode is a remarkably low 5.9 litres for 100 kilometres.

The 2.0-litre Duratorq TDCi engine employs latest generation common-rail injection technologies simultaneously to balance and refine the engine's combustion acoustics, emissions and fuel consumption. Up to 1,600 bar of injection pressure, Piezo injection valves, a Garrett turbocharger with variable turbine geometry and intercooling smooth out the process for a more progressive and complete combustion.

Thus equipped, the engine would meet and surpass the strict Euro 4 emissions regulations even without the standard DPF system (Diesel Particulate Filter).

A dual-mass flywheel helps to balance idle speed and reduces the rattles and vibration, while the noise-attenuating properties of the cast-iron engine block further improve NVH behaviour.

Being quiet and cultivated, powerful and relaxed, economical and clean, Ford's 2.0-litre Duratorq TDCi engine is a perfect touring companion for the new Focus Coupé-Cabriolet.

145 PS, 2.0-litre Duratec HE

Ford's acclaimed 2.0-litre Duratec HE petrol engine is a lively alternative to the torquey Duratorq TDCi. It offers 145 PS (107 kW) at 6,000 rpm and peak torque of 185 Nm at 4,500 rpm. Ninety percent of maximum torque is permanently available between 2,200 and 6,000 rpm.

Equipped with this engine, Focus Coupé-Cabriolet reaches a top speed of 208kph (130 mph) and accelerates from zero to 100kph (0-62mph) in 10.3 seconds. In combined ECE mode, target fuel consumption is a reasonable 7.5 litres.

This engine has already proved itself in the Ford Focus, Mondeo, and as a slightly modified version in the Fiesta ST . It is light - a fact that contributes to optimised weight balance and also serves to improve fuel economy.

Combined with the 2.0-litre Duratec HE engine, Durashift MTX-75, Ford's robust and responsive 5-speed manual transmission, provides new Focus Coupé-Cabriolet with effortless and refined shifting character. A Durashift Automatic transmission is also planned for introduction with this engine option in the near future.

100 PS 1.6-litre Duratec

Ford's best- selling Focus engine in Europe forms the entry point for the Focus Coupé-Cabriolet's engine range. It offers 74 kW (100 PS) at 6,000 rpm and a peak torque of 150 Nm at 4,000 rpm.

This extremely successful and efficient engine works together with Ford's Durashift IB5 5-speed manual transmission in a combination capable of a top speed of 182 kph (114mph), with acceleration from zero to 100 kph (62mph) in 13.6 seconds. Target combined fuel consumption is 7.1 litres per 100 kilometres.

Ford's 1.6-litre Duratec offers a perfect balance of rev and torque performance. Combined with its smooth operation and good fuel economy, this engine is an ideal and cost effective partner for relaxed wind-in-the-hair motoring.

Page 1: Overview
Page 2: Driving Dynamics / Powertrain
Page 3: Exterior Design / Package
Page 4: Interior Design / Equipment / Body
Page 5: Safety
Page 6: Specifications

Design

EXTERIOR DESIGN

"Our first thoughts were very clear: The starting point had to be a beautiful and dynamic Coupé. One with an elegantly arched roof that seamlessly integrates with the side profile. We were pretty sure about what we didn't want - a cabriolet that looks like it's wearing a cap when the roof is closed. I think the final design of the new Ford Focus Coupé-Cabriolet shows at first glance that we have achieved our objectives, and we have done this together with our design colleagues at Pininfarina. Together we have created a Ford Focus with an Italian tailored suit, and I am very proud of the fact that we were able to transfer the Concept's expressive design language into a volume production model." Chris Bird, Director Design, European Product Development

When Ford of Europe and Pininfarina designers set out to dress the new Focus Coupé-Cabriolet, they began with a bundle of ideas that described the new vehicle's characteristics quite precisely: It had to be a true and recognisable Ford Focus, yet with an Italian-style and tailor-made body "suit". It also had to exude elegance, harmony, and dynamism from every angle, regardless of whether the hardtop is closed or stowed in the boot.

Guy Colborne, Ford of Europe's Design Manager, describes the development process: "It was very organic, driven by a team consisting of Ford and Pininfarina designers and with both groups contributing ideas and strengths from their respective companies." Working alongside the Ford design team on the programme were Pininfarina Design Director Ken Okuyama, and Design Coordinator Filippo Capadona. They brought in the Italian company's wealth of experience on Coupé design to the fore on the new Focus model.

The most exciting phase of design development came when both parts of the team delivered their first drafts. A 1:1-scale solid epo-wood model was built which was divided lengthwise, one side was the Ford design and the other represented the Pininfarina proposal. This unusual approach turned out to be very inspiring, bringing both groups together into a single team which then developed the vehicle passionately into one consistent and exciting piece. In a very natural way therefore, an elegant and harmonic design language evolved that in its final execution incorporates design ideas from both companies.

The combined design team quickly agreed that a two-piece roof had undeniable advantages. Colborne says: "Of course this decision was made in consultation with our engineering departments, but from a design point of view a two-piece retractable hardtop gave us the chance to draw the roof line without unwanted visual breaks. Every gap is an unnecessary distraction for the eye."

But the two-piece design also involved creating longer roof panels that would require storage in the boot area. To execute this design was particularly challenging, but together the team incorporated the space required for the folding roof into a shape that is both elegant and dynamic, yet still very functional.

Results from a series of so-called "product clinics" revealed that the designers had accomplished their task successfully. When presented to customers anonymously, many thought the prototype Focus Coupé-Cabriolet was simply a stylish Coupé. The transformation into four-seat cabriolet came as a surprise and a bonus.

The pivotal point of the Focus Coupé-Cabriolet design is the body shape around C-pillar. Here the gently rising lines of the bootlid and the rear window meet to form a solid, tapered shoulder. Its no-frills design forms the base for the gently arched roof line. This design feature helps to create a more integrated and flowing feel to the exterior. A chrome strip runs from A-pillar to bootlid and underlines the tapered shoulder line, lending an additional, three-dimensional aspect to the vehicle's profile.

These clearly-defined and smooth lines also give the Focus Coupé-Cabriolet a distinctive profile when the hardtop is stowed in the boot.

"The gently rising window lines give rear passengers a feeling of safety and enclosure. This feeling is justified as the rear headrests and the covers of the Rollover Protection Device are seamlessly integrated in the flowing body profile", says Guy Colborne.

New Focus Coupé-Cabriolet is very well-proportioned because the cabin sits centrally between the axles. The tapered body form lends the car a stretched and elegant look and ends with a distinctive tail shape which houses the retractable hardtop and provides best-in-class luggage space.

The large tail lamps are designed to reflect the shape of the front lamps, and both add substantially to the vehicle's stance and character. The tail lamps' wrap-round design shows as triangles on the vehicle's side, which accentuate dynamism. Compared with the core Focus range, this more radical treatment of the tail lamps and the chrome strip with the embossed "Focus" logo are unique identifiers for the new Coupé-Cabriolet.

Premium flair is achieved by various chrome elements, including the strip running from the fast A-pillar to C-pillar as well as fittings for the front grille and fog lamps.

Ford and Pininfarina designers paid special attention to the front. The target was to give it a more substantial look and to match this with the rear end design. While the smaller openings of the lower grille with their integrated fog lamps closely resemble the concept shown in Paris 2004, the large chrome-framed upper and lower grilles highlight the vehicle's dynamic qualities and distinguish it from its sporty brother, the Focus ST .

The design team have opted for a palette of exclusive body colours for the Focus Coupe-Cabriolet. Customers can choose from fresh "Acqua Blue", close to the colour of the Ford Vignale Concept shown in Paris 2004, or the elegant and rich "Luna", as seen on the Geneva 2006 show car. These and other, darker paint colours like" Pitch Black", "Blue di Cine" or "Iris" provide for an attractive contrast with the bright chrome applications. Also available are an intensive red metallic, "Grenadine", a new silver called "Argento", and "Red Hot", a solid red.

"We are proud of the results of our cooperation with Pininfarina," concludes Chris Bird. "We believe we achieved our Italian tailor-made suit objective, and that it fits the Focus perfectly. Above all, the team delivered a desirable car to be seen in - roof open or closed!"

PACKAGE

"We wanted the Focus Coupé-Cabriolet to be a true four-seater with a retractable hardtop and the biggest luggage space in its class, both in Coupé and Cabriolet modes. That's why we focussed on everyday practicality within compact measurements. Despite this rather rational approach we haven't neglected one absolutely important factor: The integrity of the vehicle's design." Giovanni De Pasca, Manager Package

Defining the interior dimensions and creating new Ford Focus Coupé-Cabriolet's package was also a challenge because of various competing issues. Ralph Gesang, who supervised the development process, explains: "You have to consider carefully the vehicle's length in order to make it as compact as our customers expect, any specific requirements for everyday use and, of course, the attractiveness and balance of the overall body design."

Design and Body Engineering departments were responsible as a team for defining the vehicle's exterior dimensions. They mutually agreed to use the underbody structure and front section of the four-door Ford Focus sedan as the basis for this vehicle, and make it not much longer than 4.5 metres. Also, the measurements of the two-piece retractable hardtop design would be fundamental in defining the boot dimensions.

This complex development process met all set objectives: New Ford Focus Coupé-Cabriolet is exactly 4,509mm long and offers the largest luggage volume among C-segment vehicles with retractable hardtops. As a Coupé, the new model has an impressive maximum capacity of 534 litres. With the roof stowed in the boot, the remaining 248 litres of available space under and around the stowed roof panels still represent a best in class figure, irrespective of how many roof partitions competitors use for their vehicles.

Compared with core Focus models, the seat height was lowered 20mm closer to the center of gravity. This provides passengers with sufficient headroom when the roof is closed and enhances the open air experience with the roof open. Also, a higher beltline and instrument panel add to a feeling of confidence and protection as well as better integration into the vehicle.

With sport seats, the balanced ergonomics of all driving controls, and a shifter placed relatively high in the centre console, any driver should be able to find a perfect fit.

Inside, Focus Coupé-Cabriolet offers 1,216mm of shoulder room for the rear passengers, more than any competitor. The rear seats offer comfortable accommodation for adults even in Coupé mode. This level of comfort is possible because of the hardtop's efficient and reliable folding mechanism, which doesn't use the rear side panels for stowage.

"The task of meeting all our objectives was demanding. But we came up with feasible solutions because the departments involved worked together so closely. We're very satisfied with what we have achieved!" summarises Gesang.

Page 1: Overview
Page 2: Driving Dynamics / Powertrain
Page 3: Exterior Design / Package
Page 4: Interior Design / Equipment / Body
Page 5: Safety
Page 6: Specifications

INTERIOR DESIGN

"In order to create a consistent look, we wanted to translate obvious exterior elegance into the interior design - to evoke the feeling that you are sitting in a very special car. Our objective was to create a high quality experience and an impression of Italian elegance." Ulrike Dahm, Senior Colour & Materials Designer

As with a vehicle's exterior, the interior is also subject to an intensive process of creativity and harmonisation. Not only is the form of interior elements important for the overall impression the vehicle creates, but in order to make an emotional connection with a new car, the choice of matching colours, textures and materials is crucial.

New Focus Coupé-Cabriolet shares its dashboard layout with the core Focus models. However, to distinguish it, a new colour scheme was developed, designed to match the vehicle's overall elegance.

Dahm explains: "We paid great attention to the choice of exterior body colours when we created the vehicle design. We selected a set of exclusively developed paint colours, which beautifully underline the car's elegance, and we wanted to match these to some appropriate interior treatments".

Two fundamentally different colour schemes were chosen: Dark and sporty Ebony/Flint and the warm and elegant Iris/Camel. If customers choose the latter, the dashboard's soft-feel upper section is dominated by "Iris", a dark violet tone, while "Camel" forms a bright contrast for its lower part and the remaining interior surfaces.

High quality materials enhance this colour concept. Specially developed, attractive seat fabrics offer high levels of comfort and air circulation. Leather seats are available for the higher "Titanium" series while aluminium applications throughout emphasise the vehicle's premium appeal.

The aim of the interior design was to get a more sporting feel for the front occupants and a feeling of enclosure and safety for the rear passengers particularly when the roof is down.

The front seat and front header have been lowered to give a sportier Coupé feel to the driver and front passenger. The rear seats were designed for two occupants, which gave the design team the opportunity to design a unique seat that wraps around the two rear passengers and flows into the rear quarter panels giving a more sporting, tailored fit and feel to the interior. This is integrated visually with the front instrument panel, centre console and door trim panels.

Once again, Pininfarinas's extensive experience in Coupé design was invaluable to the interior design team, ensuring that rear passenger headroom is optimised without adversely affecting the exterior design of the roofline and rear screen.

EQUIPMENT

A two-series line-up for new Ford Focus Coupé-Cabriolet reflects the vehicle's exclusivity and individual style.

The well-appointed Trend series offers body-coloured side mirrors with integrated direction indicators and chrome applications for the upper front grille, the lower side window frames, and the rear of the car. Standard and stylish 16" alloy wheels are an additional visual highlight.

Upmarket features bring a high level of comfort to the interior. Trend models get air conditioning, a CD audio system, a trip computer, heated front seats and a centre console. Front one-shot power windows support the functionality of the electro-hydraulic hardtop.

An optional "Plus Pack" includes a four-spoke leather steering wheel with integrated cruise control, and a cabrio windbreak.

The Trend model is available with a choice of three engines: Ford's 1.6-litre Duratec petrol unit with 100PS (74 kW), the 2.0-litre Duratec HE with 145PS (107 kW) and the acclaimed 2.0-litre Duratorq TDCi diesel with 136PS (100 kW).

A dynamic 'Sport Pack' will be available as an option for the Trend series and offers sports suspension, 17-inch Anthracite coloured alloy wheels with 205x55 tyres, a three-spoke leather steering wheel, and darker front lamp background

At the top of the range is the Titanium model. This offers even more elegance and comfort with chrome applications for the fog lamps and the lower front grille, and exclusive 17-inch silver alloy wheels round off the distinct exterior.

Inside, the Titanium model offers a premium appearance with standard leather seats available in three different colours: Camel, Saddle, and Ebony. Fully adjustable and heated front seats with two-way power functionality for the driver, a four-spoke leather steering wheel with integrated cruise control, and a number of aluminium details. Dual zone climate control with special mode for open air cruising plus a Sony CD/MP3 audio system, rain sensing wipers, an auto-light function, an auto-dimming rear view mirror, and a glove box with cooling function add to the list of luxurious features.

Both the 2.0-litre Duratec HE and Duratoq TDCi engines are available for Ford Focus Coupé-Cabriolet Titanium.

A significant number of options and dedicated accessories will also be offered to allow customers the opportunity to further personalise their Focus Coupe-Cabriolet. For even more comfortable cruising with the roof down, an effective wind deflector is available. Additions designed to enhance the vehicle's appearance include 18" accessory alloy wheels with unique design, a range of interior chrome fittings and aluminium applications, and colour-keyed floor mats. Practical items include load nets, reversible mats, and tow bars.

Please note: Equipment data may vary according to market specifications.

RETRACTABLE HARDTOP

"Choosing a two-piece retractable metal hardtop was a fundamental decision. This construction features very stable kinematics and a high structural integrity, which significantly increases the body's torsional rigidity." Andreas Stichweh, Manager Body Engineering Ford Focus Range

The key unique feature of the all-new Ford Focus Coupé-Cabriolet is, of course, the folding roof. It provides the vehicle with its harmonious and elegant profile, yet is also essential for functionality, durability, and rigidity.

"Our intention was to make the highly acclaimed Ford Focus product quality equally tangible in the new Coupé-Cabriolet, with an emphasis on Ford PrecisionDrive dynamics. A prerequisite to achieve this was an very rigid body structure with the retractable hardtop playing an important role. In addition, we didn't want to have a complicated roof construction in order to provide a robust, reliable and highly functional system to the customers," .explains Susan Love, Manager of Body Engineering for Ford Focus Coupé-Cabriolet.

Focus Coupé-Cabriolet's retractable metal roof uses five hydraulic cylinders, three electric motors, and eleven sensors. Working together, they perform the opening or closing of the roof in just 29 seconds. The complexity of the procedure is barely noticed by the vehicle occupants, and the only thing the driver has to do is push a small button on the centre console.

The roof is light when compared with other, more complex roof constructions, providing a kerb weight benefit of about 30 kg. The weight of moving parts is only 68 kg - this is an important fact, because the change in axle load from open to closed roof is just 17kg.

When the driver pushes the button with ignition activated to open the roof, the sequence begins:

All parts that do mechanical work are executed durably and lock precisely into their respective positions. When the hardtop is closed, an additional safety pin ensures the firm connection of both roof sections. These meticulous engineering details provide a significant increase in torsional body rigidity over open-top mode, a clear benefit for driving quality.

To keep the whole open/close procedure firmly under the driver's control, the activating button has to be pushed continuously until either operation is fully executed. This enables the operator to interrupt the procedure if necessary.

For increased safety and durability, the hardtop can only be operated when the vehicle is standing still, while ignition is switched on. This system works with or without the engine running, and features an electronic interlock.

The compactness of the roof provides segment-best luggage space of 248 litres in open-top mode. There is more than enough space for weekend luggage, and the loading space opening under the folded roof has a height of 26cm, a fact that makes stowing hard cases and luggage items relatively easy.

Closing the bootlid is made easier as an electric motor gently and safely pulls it shut until it latches. With this comfort feature, there is no need to slam the bootlid.

In order to ensure a tight seal and easy operation when opening the doors while the hardtop is up, the front windows automatically move down by approximately one centimetre and then up again after closing.

"Meeting all of our objectives like stability, durability, functionality, and the design for an electro-hydraulic Coupé-Cabriolet hardtop was quite a challenge. But together with our colleagues from Pininfarina and roof-specialist Webasto, we believe we have found the right balance," says Love.

BODY CONSTRUCTION

"The challenge was to create a body structure with a high torsional rigidity as a basis for exceptional driving quality and low NVH levels. It is also necessary for supporting the retractable hardtop's functionality. Above all, the goal was to retain as much of the original Focus Vignale Concept design as possible." Andreas Stichweh, Manager Body Engineering Ford Focus Range

The Focus Vignale Concept was a valuable exercise for Ford's body engineers as it helped determine fundamental parameters, which in turn formed the base structure of new production model. The combined cornerstones, a four-seater Coupé-Cabriolet with a fully retractable hardtop, generous cabin and luggage space dimensions for everyday practicality, and renowned Ford driving quality, meant that an existing Focus underbody structure had to be used, and that of the four-door sedan was the ideal choice.

In developing the body structure, torsional rigidity was a key factor. This forms the basic parameter for the highly acclaimed driving character of Ford vehicle like the Focus, and an attribute that is now represented to customers as Ford PrecisionDrive. Torsional rigidity also makes a major contribution to vehicle NVH behaviour (Noise, Vibration, and Harshness). In a conventional sedan roof structure, the roof acts as a stabiliser, so removing it and retaining this rigid body structure is no easy task: Removing the roof from a sedan body can reduce torsional rigidity to just ten percent of the original figure.

Using the Focus four-door sedan underbody and its front section body structure was a great help to Ford's body engineers because these parts also contribute to high torsional rigidity.

Most of the new body parts specially developed for the all new Coupé-Cabriolet consist of high strength steel to HSS1 and HSS 2 levels of quality. This also applies the rockers, which are 35mm higher than on the Focus sedan. They connect with additional transverse reinforcements placed under the bottom of the rear seat and, together with HSS 2 panel reinforcements and the rear bulkhead, form an incredibly strong structure giving high torsional rigidity and a solid cabin construction.

The A-pillars also play a vital role in the cabin structure. They are reinforced by HSS 2 material and steel bars made of Ultra HSS, which stiffen the A-pillars' overall length significantly.

These reinforcements are very effective, so the amount of stiffening underbody transverse ribs could be reduced to just two, which in turn led to a significant weight reduction and improved ground clearance. The transverse ribs connect the rockers' rear ends with the underbody structure just above the rear axle, where they add to overall rigidity and improve driving dynamics.

The overall result is impressive. The all-new Ford Focus Coupé-Cabriolet offers a torsional rigidity of 678 kNm/rad with the hardtop stowed away, a figure one would normally expect from much more expensive Cabriolets. Torsional rigidity increases to 1169 kNm/rad with the roof closed. Andreas Stichweh believes that this results in "figures some three-door sedans could be proud of!"

Another benefit of an ultra-stiff body shell is an optimised NVH behaviour. Paths that transport vibrations, powertrain noise, and driving noise can be clearly defined and then influenced positively when the body structure shows high rigidity.

Page 1: Overview
Page 2: Driving Dynamics / Powertrain
Page 3: Exterior Design / Package
Page 4: Interior Design / Equipment / Body
Page 5: Safety
Page 6: Specifications

Safety

"Our top priority was to give Focus Coupé-Cabriolet as much active safety competence as possible. At the same time, the car's passive safety elements had to be as effective as with any other vehicle." Gisbert Gäb, Manager Vehicle Safety

Active Safety

Precise suspension tuning is the active and solid base for the new Focus Coupé-Cabriolet's safety package. As a part of Ford PrecisionDrive, it helps drivers intuitively to rely on their Ford car in any driving situation.

For stopping confidence, the 2.0 litre versions feature ventilated front disc brakes with a diameter of 300mm. At the rear, the large disc brakes have a diameter of 280mm. For the 1.6 litre version, the discs measure 278mm at the front and 265mm at the rear. Depending on individual market specifications, the standard ABS is also available with ESP and EBA. In addition, the team paid special attention to brake responsiveness.

Passive Safety

At Ford, passive safety starts with an ultra stiff body shell and a rigid passenger safety cell. When developing the passive safety concept for Focus Coupé-Cabriolet, engineers benefited from the existing structure developed for the Focus 4-door model.

In this model, crash energy at the front end is absorbed and distributed via the rockers, the roof and the doors' stiff outer waistline. Thanks to the decoupling chassis subframe, crash energy transfer into the underbody structure is minimised which results in less deformation of the front passenger's footwell.

Without a regular sedan roof structure however, front crash load paths for the Focus Coupé-Cabriolet had to be redistributed behind the A-pillars into the door structure. As a result, these load paths were significantly reinforced by using high strength HSS 2 steel and increasing the rocker height by 35mm. The load path through the door structure can carry loads up to seven tons – comparable with the cumulated load capability of a Focus 4-door at the roof and door structures.

Despite high levels of impact energy passing through the door structure, the load path results in no mechanical pressure to the door lock. Crash energy is distributed via the upper door reinforcement structure and into the rear side panel. Door structure shut faces have a profile narrowing by seven degrees, which avoids canting after a crash and supports easy opening.

These highly effective stiffening measures yield tangible results. During standard side-impact crash tests at 50kph, deformation of the passenger cabin's side structure measured at the B-pillar was around half of what a comparable sedan delivers. Injuries related to head rotation are mitigated due to the complete lack of an upper B-pillar.

Crash tests with the optimised rear body structure have been carried out to Ford's standard rear impact speed of 80kph. The structure performs well even with the car in Cabriolet mode. When folded away, the hardtop segments act as additional elements that can deform in the event of an impact, while the highly rigid rear bulkhead together with the lowered RPD (Rollover Protection Device) bars form an effective anti-intrusion guard for the passenger cabin area.

Rollover Protection Device (RPD)

In addition to standard front and side airbags, Ford's new RPD system plays a vital role in increasing Focus Coupé-Cabriolet's passive safety performance.

RPD is designed to help protect passengers in the unlikely event that the vehicle rolls over. Electronic sensors and a gyroscope are at the heart of the system, and can detect an impending rollover. When this happens, two ultra-strong safety roll bars "fire" into position within a tenth of a second. A pyrotechnic device unlocks the system, then extremely strong springs force the roll bars upwards to their deployed position where they lock safely. The bars move up by approximately 20 centimetres to provide an ideally positioned safety strut. When the car has its roof up in Coupé mode, they can also deploy. Combined with the reinforced A-pillars and the highly rigid front window frame, RPD is a reassuring device that provides valuable extra protection for occupants.

While it was important to calibrate the RPD system settings so that the safety roll bars deploy quickly and before a potential rollover, it was equally important to eliminate the possibility of unwanted ignition.

Dirk van Oirschot, Project Manager for Safety, says: "The calibration setup was developed "virtually", using detailed calculation models on powerful computer system models. Subsequently, however, we tested and evaluated the system calibration meticulously and in a wide range of test conditions, reflecting almost any potential real life situation."

Three-point safety belts for all seats with pretensioners and load-limiters for both front seats, the well-proven Ford horizontally stroking steering column, and safety pedals all combine with RPD to maximise occupant restraint and protection.

Page 1: Overview
Page 2: Driving Dynamics / Powertrain
Page 3: Exterior Design / Package
Page 4: Interior Design / Equipment / Body
Page 5: Safety
Page 6: Specifications

Features

See tables below






































Vehicle Type

Modern C-segment 2-door Coupé-Cabriolet with electro-hydraulically operated retractable hardtop.

Structure

Computer-optimised, high-efficiency, unitary-welded steel body incorporating rigid occupant protection cell and front and rear energy-absorbing crumple zones. Special reinforcements to raise torsional stiffness. Direct-glazed windshield.

Safety features

Dual front air bags, thorax side air bags, active Rollover Protection Device (RPD), pyrotechnic pretensioner and load-limiting retractor for driver and front passenger, safety belts, collapsible pedals, ABS with optimised brake assist and optional ESP (standard in Germany, Austria, Switzerland, France and all Scandinavian markets). Rigid occupant protection cell and energy-absorbing crumple zones.

Bumper system

Damage-resistant, full-depth moulded reinforced polypropylene.

Anti-corrosion

Multi-stage paint and body protection process, including extensive pre-coating of zinc on steel panels, optimized phosphate spray coat, electrocoat primer, primer/surfacer, basecoat/clearcoat topcoat system, comprehensive wax injection of cavities, PVC underbody coating plus stone chip protection. Particular attention paid to sealing flanges with rust-inhibiting adhesive and thick PVC sealing beads. Front plastic wheelarch liners, rear textile wheelarch liners, plastic anti-scuff panels on rear load sill.

Suspension

Front – Independent MacPherson struts with offset coil spring over gas filled damper units and lower L-arms with optimized front rubber bush and rear hydrobush mounted on separate reinforced cross-member.

Rear – Independent Short-Long Arm (SLA) Control Blade multi-link system mounted on reinforced subframe, anti-roll bar and gas-filled dampers.

Sports suspension (optional for Titanium series) with unique anti-roll bars, springs and dampers, reduced ride height (10mm front, 8mm rear).

Steering

Type – Rack and pinion

Hydraulic Power Assisted Steering (HPAS) on 1.6L petrol engine

Turning circle (m) – 10.4 m (curb-to-curb); 10.9 (wall-to-wall)*

Turns lock-to-lock – 2.9

Brakes

Type – Dual circuit, diagonally split, hydraulically operated disc front with drum or disk rear brakes dependent upon engine/series rear. Vacuum servo assisted with electronically controlled four-channel brake distribution ABS and optimised brake assist optional. ESP optional (standard in Germany , Austria , Switzerland , France and all Scandinavian markets).

Front – 300 mm diameter x 25 mm thick ventilated discs (with 2.0L petrol and 2.0L TDCi) or 278 mm x 25 mm ventilated discs

Rear – 280mm diameter x 11 mm wide discs (with 2.0L petrol and 2.0L TDCi) or 265 mm x 11 mm discs

Wheels and tyres (fitment varies by series and market)

Wheel type

Pressed Steel

Alloy

Alloy

Alloy
(Dealer option)

Wheel size

6.5 x 16 inch

6.5 x 16 inch

6.5 x 17 inch

7.5 x 18 inch

Tyre size

205/55

205/55

205/50

225/40

Engine Data

1.6L Duratec 16V – 100 PS / 74 kW

Displacement (cc)

1596

Bore (mm)

79

Stroke (mm)

81,4

Fuel type, grade

Unleaded petrol, 95 (RON)

Max power (ISO kW/PS)

74 / 100

At engine speed (rpm)

5500

Max torque (ISO Nm)

150

Max BMEP (bar)

11,8

At engine speed (rpm)

4000

Compression ratio

11.0:1

Cylinders

4, in line

Cylinder head

Aluminium alloy

Cylinder block

Aluminium alloy

Crankshaft

Nodular cast iron with 8 counterweights

Valves per cylinder

4

Valve gear

DOHC 16V

Included angle between valves

42 degrees

Valve Sizes (mm)

Intake: 30.1 Exhaust: 24.1

Camshaft drive

Belt

Pistons

Aluminium alloy with low friction piston skirt coating

Connecting rods

Sinter-forged steel with fracture-split big ends

Engine management

Siemens integrated PCS

Fuel injection

Sequential electronic multipoint

Ignition

Electronic distributorless

Emission controls

Closed-loop three-way catalyst

Emission level

Euro Stage IV

2.0L Duratec 16V – 145 PS / 107 kW

Displacement (cc)

1999

Bore (mm)

87,5

Stroke (mm)

83,1

Fuel type, grade

Unleaded petrol, 95 (RON)

Max power (ISO kW/PS)

107 / 145

At engine speed (rpm)

6000

Max torque (ISO Nm)

185

Max BMEP (bar)

11,63

At engine speed (rpm)

4500

Compression ratio

10.8:1

Cylinders

4, in line

Cylinder head

Low pressure, aluminium alloy casting

Cylinder block

Aluminium alloy with deep skirt and bearing beam

Crankshaft

Nodular cast iron with 4 counterweights

Valves per cylinder

4

Valve gear

DOHC 16V direct acting, mechanical, shimless tappets

Included angle between valves

39 degrees

Valve Sizes (mm)

Intake: 35.0 Exhaust: 30.0

Camshaft drive

Silent, inverted-tooth chain with hydraulic tensioner

Pistons

Short skirt silicon-aluminium alloy with graphite coating

Connecting rods

Sinter-forged steel with fracture-split big ends

Engine management

Visteon EMS 7

Fuel injection

Sequential electronic multipoint

Ignition

Electronic distributorless

Emission controls

Closed loop, three-way catalyst with oxygen sensor

Emission level

Euro Stage IV

2.0L Duratorq TDCi – 136 PS / 100 kW

Displacement (cc)

1997

Bore (mm)

85

Stroke (mm)

88

Fuel type, grade

Diesel

Max power (ISO kW/PS)

100 / 136

At engine speed (rpm)

4000

Max torque (ISO Nm)

320

Max BMEP (ISO Bar)

20,1

At engine speed (rpm)

2000

Compression ratio

18:1

Cylinders

4, in line

Cylinder head

Aluminium alloy

Cylinder block

Cast iron

Crankshaft

Forged steel

Valves per cylinder

4

Valve gear

DOHC, 16V

Valve Sizes (mm)

Intake: 28.2 Exhaust: 23.16

Camshaft drive

Belt/Chain

Pistons

Aluminium alloy

Connecting rods

Forged steel with fracture-split big ends

Engine management

Bosch integrated PCS

Fuel injection

2nd generation common-rail direct injection with turbocharger

Emission controls

Oxidation catalyst and closed-loop EGR and DPF

Emission level

Euro Stage IV + DPF

Exterior and Interior Dimensions

Exterior (mm)

Overall length

4509

Overall width without mirrors

1834

Overall width with mirrors

1991

Overall height

1456

Overall height during roof operation

1839

Wheelbase

2640

Front tread

1535

Rear tread

1531

Front overhang

875

Rear overhang

994

Rear overhang during roof operation

1186

Interior (mm)

Front (mm)

Headroom

965

Effective leg room

1067

Shoulder room

1412

Rear (mm)

Headroom

925

Effective leg room

805

Shoulder room

1216

Luggage area (mm)

Maximum cargo height

563

Width between wheel arches

953

Length at floor

915

Luggage volume (litre)

Coupé mode with roof up

534*

Cabriolet mode with roof down

248*

? Measured using the VDA method. Dimensions may vary dependent on the model and equipment fitted. *With tyre repair kit.

Weights

Minimum kerbweight (kg)

Maximum kerbweight (kg)

Gross Vehicle Mass (kg)

Max. towable mass (kg)

1.6 Duratec

1413

1492

1870

1000

2.0 Duratec

1465

1544

1950

1350

2.0 Duratorq TDCi,
Durashift 6-speed manual
(Stage IV + DPF)

1548

1631

2045

1450

# Represents the lightest kerbweight assuming the driver at 75 kg, full fluid levels and fuel levels, subject to manufacturing tolerances and options, etc., fitted.

Note All vehicles are 5-speed manual. All petrol engines are equipped with a catalytic converter.

DPF = Diesel Particulate Filter.

Towing limits quoted represent the maximum towing ability of the vehicle at its Gross Vehicle Mass to restart on a 12 per cent gradient at sea level.

The performance and economy of all models will be reduced when used for towing.

Nose weight limit is a maximum of 75 kg on all models.

Transmission Table

1.6L Duratec 16V 100 PS

2.0L Duratec 16V 145 PS

2.0L Duratorq TDCi 136 PS

Transmission type

Durashift 5-Speed

Durashift 5-Speed

Durashift 6-Speed

Clutch type (Diameter)

220

228

240

6 th gear

-

-

0.711

5 th gear

0.878

0,805

0.886

4 th gear

1.108

1.028

0.842

3 rd gear

1.414

1.448

1.241

2 nd gear

2.038

2.136

1.864

1 st gear

3.583

3.667

3.231

Rev gear

3.615

3.727

1.360

Final drive

4,059

4.067

4.071 (gear 1,2,3,4); 2.850 (gear 5,6,rev.)